2003 DAEWOO MATIZ Service Repair Manual

ENGINE CONTROLS 1F–279
DAEWOO M-150 BL2
DTC P1661 – Malfunction Indicator Lamp (MIL) Low Voltage
StepActionValue(s)YesNo
1
Perform an On-Board Diagnostic (EOBD) System
Check.
Is the system check complete?
–
Go to Step 2
Go to
“On-Board
Diagnostic
System Check”
2
1. Turn the ignition switch to LOCK.
2. Disconnect the cluster wiring connector.
3. With the test light, connected to ground, probe
the ignition feed circuit, at terminal A7 in the
harness connector.
Does the resistance within the specified value?
–
Go to Step 3Go to Step 6
3
1. Turn the ignition switch to LOCK.
2. With the test light, connected to ground, probe
the ignition feed circuit, at ECM wiring connector
terminal 39.
Does the test light illuminate?
–
Go to Step 4Go to Step 5
4
1. Turn the ignition switch to LOCK.
2. Replace the cluster.
Is the replacement complete?
–
Go to Step 6
–
5
Repair a short to ground or open between the ECM
wiring connector terminal 39 and cluster wiring
connector terminal A7.
Is the repair complete?
–
Go to Step 6
–
6
1. Using the scan tool, clear the Diagnostic Trouble
Codes(DTCs)
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for
setting this DTC as specified in the supporting
text.
Does the scan tool indicate that this diagnostic has
run and passed?
–
Go to Step 7Go to Step 2
7
Check if any additional DTCs are set.
Are any DTCs displayed that that have not been
diagnosed?
–
Go to
applicable DTC
table
System OK

1F – 280 ENGINE CONTROLS
DAEWOO M-150 BL2
SYMPTOM DIAGNOSIS
IMPORTANT PRELIMINARY CHECKS
Important: Several symptom procedures call for a care-
ful visual/physical inspection. Always perform the visual/
physical test first. Visual inspections may lead tocorrecting a problem without further checks and can
save valuable time.
StepActionValue(s)YesNo
1
Perform the On-Board Diagnostic (EOBD) System
Check.
Are any Diagnostic Trouble Code(s) (DTCs) stored
in the Engine Control Module (ECM) memory?
–Go to
Appropriate
DTC Table
Go to Step 2
2
1. Inspect all of the ECM ground connections.
2. Inspect all of the vacuum hoses for splits, kinks,
and proper connections.
3. Check for air leaks at all of the mounting areas of
the intake manifold sealing surfaces.
4. Inspect the ignition wires for cracking, hardness,
proper routing, and carbon tracking.
5. Inspect the wiring for proper connections,
pinches, and cuts.
Are all checks complete?
–
Go to
Appropriate
Symptom Table
–

ENGINE CONTROLS 1F–281
DAEWOO M-150 BL2
INTERMITTENT
Definition: The problem may or may not illuminate the
Malfunction Indicator Lamp (MIL) or store a Diagnostic
Trouble Code (DTC).
Important: Do not use the Diagnostic Trouble Code
(DTC) tables for intermittent problems. A fault must bepresent in order to locate the problem. If a fault is inter-
mittent, use of Diagnostic Trouble Code tables may re-
sult in the replacement of good parts.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Perform a careful inspection of any suspect
circuits.
2. Inspect for poor mating of the connector halves,
or terminals not fully seated into the connector
body.
3. Inspect for improperly formed or damaged
terminals.
4. Inspect for poor terminal-to-wire connections.
This requires removing the terminal from the
connector body to inspect it.
Are any problems present?
–
Go to Step 3Go to Step 4
3Repair the electrical connections as needed.
Is the repair complete?–System OK–
4
Road test the vehicle with a voltmeter connected to
a suspected circuit or a scan tool connected to the
Data Link Connector (DLC).
Did the voltmeter or the scan tool indicate an
abnormal voltage or scan reading?
–
Go to Step 5Go to Step 6
5
Replace the sensor in the affected circuit, if a
Diagnostic Trouble Code (DTC) was stored for this
circuit (except for the DTCs P0171 and P0172).
Is the repair complete?
–
System OK
–
6Does an intermittent Malfunction Indicator Lamp
(MIL) or DTC occur?–Go to Step 7Go to Step 8
7
1. Check for a faulty relay, Engine Control Module
(ECM) driven solenoid, or switch.
2. Check for improper installation of electrical
devices, such as lights, two-way radios, electric
motors, etc.
3. Inspect the ignition control wires for proper
routing (away from ignition wires, ignition system
components, and the generator).
4. Check for a short-to-ground in the MIL circuit or
the DLC “test” terminal.
5. Inspect the ECM ground connections.
6. Correct or repair the affected circuits as needed.
Is the repair complete?
–
System OK
–
8
1. Check for a loss of DTC memory.
2. Disconnect the throttle position (TP) sensor.
3. Run the engine at idle until the MIL comes on.
4. Turn the ignition OFF.
Is DTC P0122 stored in memory?
–
Go to Step 10Go to Step 9

1F–282 ENGINE CONTROLS
DAEWOO M-150 BL2
Intermittent (Cont’d)
StepActionValue(s)YesNo
9
1. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?
–
System OK
–
10Does the vehicle stall while driving?–Go to Step 11Go to Step 12
11
Monitor the oxygen sensor and the injector base
pulse width with the scan tool.
Does the scan tool display a steady low voltage
(about 0 millivolts) for the oxygen sensor with the
control module commanding an injector base pulse
width of the value specified?
8 msGo to Step 9Go to Step 12
12
1. Check for an open diode across the A/C clutch
and for other open diodes.
2. Repair or replace any components as needed.
Is the repair complete?
–
System OK
–

ENGINE CONTROLS 1F–283
DAEWOO M-150 BL2
HARD START
Definition: The engine cranks OK, but does not start for
a long time. The engine eventually runs or may start and
immediately die.Important: Ensure that the driver is using the correct
starting procedure. Before diagnosing, check service
bulletins for updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Connect the scan tool to the Data Link Connector
(DLC).
2. Check the Engine Coolant Temperature (ECT)
sensor and the Intake Air Temperature (IAT)
sensor using the scan tool.
3. Compare the coolant temperature and the IAT
with the ambient temperature when the engine is
cold.
Do the ECT and the IAT readings differ from the
ambient temperature by more than the value
specified?
3
C (5
F)Go to Step 3Go to Step 4
3
1. Measure the resistance of the ECT sensor and
the IAT sensor.
2. Compare the resistance value to specifications
using the Temperature Vs. Resistance tables for
DTCs P0118 and P0113.
3. If the resistance is not the same, replace the
faulty sensor.
Is the repair complete?
–
System OK
–
4
1. Check for a sticking throttle shaft or a binding
linkage that may cause a high Throttle Position
(TP) sensor voltage. Repair or replace as
needed.
2. Check the TP sensor voltage reading with the
throttle closed.
Does the voltage measure within the value
specified?
0.4–0.8 VGo to Step 5Go to Step 26
5
1. Check the Manifold Absolute Pressure (MAP)
sensor response and accuracy.
2. Replace the MAP sensor as needed.
Is the repair complete?
–
System OKGo to Step 6
6
Check the fuel pump operation.
Does the fuel pump operate for the specified time
when the ignition switch is turned ON?
2 secGo to Step 7
Go to “Fuel
Pump Relay
Circuit Check”
7Check the fuel system pressure.
Is the fuel pressure within the specifications?380 kPa
(55 psi)
Go to Step 8Go to Step 27
8Check for water contamination in the fuel.
Is fuel contaminated?–Go to Step 9Go to Step 10
9Replace the contaminated fuel.
Is the repair complete?–System OK–

1F–284 ENGINE CONTROLS
DAEWOO M-150 BL2
Hard Start (Cont’d)
StepActionValue(s)YesNo
10
1. Check the fuel injector driver circuit.
2. Disconnect all of the fuel injector harness
connectors at the fuel injectors.
3. Connect an injector test light between the
harness terminals of each fuel injector connector.
4. Note the test light while cranking the engine.
Does the test light blink at all connectors?
–
Go to Step 13Go to Step 11
11
Check the fuel injector driver wiring harness, the
connectors, and the connector terminals for the
proper connections.
Is the problem found?
–
Go to Step 12Go to Step 28
12
Repair the wiring harness, the connector, or the
connector terminal as needed.
Is the repair complete?
–
System OK
–
13
Measure the resistance of each fuel injector.
Is the fuel injector resistance within the value
specified at 20
C (68
F)
Note: The resistance will increase slightly at higher
temperatures)?
11.6–12.4 ΩGo to Step 15Go to Step 14
14
Replace any fuel injector with a resistance that is out
of specifications.
Is the repair complete?
–
System OK
–
15Perform an injector diagnosis.
Is the problem found?–Go to Step 16Go to Step 17
16
Replace any restricted or leaking fuel injectors as
needed.
Is the repair complete?
–
System OK
–
17
1. Check for the proper ignition voltage output for
each cylinder with a spark tester.
2. Inspect the spark plugs for cracks, wear, improper
gap, burned electrodes, or heavy deposits.
3. Inspect the ignition wires for short conditions.
4. Inspect all of the ignition grounds for loose
connections.
5. Inspect the Engine Control Module (ECM) for the
proper operation.
Is the problem found?
–
Go to Step 18Go to Step 19
18Correct or replace any faulty ignition components.
Is the repair complete?–System OK–
19Does the engine misfire or cut out under load or at
idle?–Go to “Ignition
System Check”
Go to Step 20
20Does the engine start, but then immediately stall?–Go to Step 21Go to Step 23
21
1. Remove the Crankshaft Position (CKP) sensor.
2. Inspect for faulty connections and repair as
needed.
Is the problem found?
–
Go to Step 22Go to Step 25
22Repair the faulty connections as needed.
Is the repair complete?–System OK–

ENGINE CONTROLS 1F–285
DAEWOO M-150 BL2
Hard Start (Cont’d)
StepActionValue(s)YesNo
23
1. Check for the proper valve timing.
2. Check the cylinder compression.
3. Inspect the pushrods, the rocker arms, the valve
springs, and the camshaft lobes for excessive
wear.
4. Inspect the intake manifold and the exhaust
manifold passages for casting flash.
Is the problem found?
–
Go to Step 24Go to Step 25
24Repair or replace any components as needed.
Is the repair complete?–System OK–
25
Check the idle air control valve operation. Repair or
replace components as needed.
Is the repair complete?
–
System OK
–
26
Check the throttle position sensor circuit for proper
operation. Repair or replace components as needed.
Is the repair complete?
–
System OK
–
27Repair the fuel system as needed.
Is the repair complete?–System OK–
28
1. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?
–
System OK
–

1F–286 ENGINE CONTROLS
DAEWOO M-150 BL2
SURGES OR CHUGGLES
Definition: Engine power variation under steady throttle
or cruise. Feels like the vehicle speeds up and slows
down with no change in the accelerator pedal position.Important: Make sure the driver understands A/C com-
pressor operation as described in the owner’s manual.
The speedometer reading and the speed reading on the
scan tool should be equal.
Before diagnosing the symptom, check service bulletins
for updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
Connect the scan tool to the Data Link Connector
(DLC).
Does the oxygen sensor (O2S) respond quickly to
different throttle positions?
–
Go to Step 4Go to Step 3
3
1. Check the O2S for silicone or other contaminants
from fuel or use of improper Room Temperature
Vulcanizing (RTV) sealant.
2. Replace the contaminated O2S.
Is the repair complete?
–
System OK
–
4
1. Drive the vehicle at the speed of the complaint.
2. Monitor the long term fuel trim reading using the
scan tool.
Is the long term fuel trim reading within the value
specified?
–20–25%Go to Step 7Go to Step 5
5
Is the long term fuel trim reading below the value
specified?
–20%
Go to
“Diagnostic Aids
for DTC P0172”
Go to Step 6
6
Is the long term fuel trim reading above the value
specified?
25%
Go to
“Diagnostic Aids
for DTC P0171”
–
7
Check the fuel system pressure while the condition
exists.
Is the fuel system pressure within specifications?
380 kPa
(55 psi)
Go to Step 8Go to Step 17
8Check the in-line fuel filter.
Is the filter dirty or plugged?–Go to Step 18Go to Step 9
9Perform an injector diagnosis.
Did the injector diagnosis pinpoint the problem?–Go to Step 19Go to Step 10
10
1. Check for proper ignition voltage output using a
spark tester.
2. Inspect the spark plugs for cracks, wear, improper
gap, burned electrodes, or heavy deposits.
Is the problem found?
–
Go to Step 11Go to Step 12
11
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–
12
1. Inspect the ECM grounds for being clean, tight,
and in their proper locations.
2. Inspect the vacuum lines for kinks or leaks.
Is the problem found?
–
Go to Step 13Go to Step 14