Daewoo CIELO EURO III Manual Download

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1B – 6 SOHC ENGINE MECHANICAL

DAEWOO T-154 BL2,3

SPECIAL TOOLS TABLE (Cont’d)

A102B152

-26

-B

Engine Assembly

Support Fixture

A102B153

KM-427

Piston Pin Service Set

A102B154

MKM-571-B

Gauge

A102B155

KM-253

Valve Guide Reamer

A102B155

KM-254

Valve Guide Reamer

A102B155

KM-255

Valve Guide Reamer

A102B156

KM-340-0

Cutter Set

Includes:

KM-340-7

Includes:

KM-340-13

Includes:

KM-340-26

A102B157

KM-348

Valve Spring

Compressor

Summary of Contents for CIELO EURO III

Page 1: ...into each spark plug port 2 Insert the engine compression gauge into each spark plug port 3 Crank test each cylinder with four to five compression strokes using the starter motor 4 The lowest reading...

Page 2: ...o to Step 9 Go to Step 10 9 Install a new oil pressure gauge Is the repair complete Go to Step 1 10 Inspect the engine oil Is the engine oil in the crankcase diluted or of the improper viscosity Go to...

Page 3: ...t is engine oil automatic transmission fluid power steering fluid etc 2 Identify where the fluid is leaking from 2 1 After running the vehicle at normal operating temperature park the vehicle over a l...

Page 4: ...DIAGNOSIS Definition for Knock Engine knock refers to various types of engine noise Heavy knock is usually very loud and the result of broken or excessively worn internal engine components Light knoc...

Page 5: ...ed Go to Step 7 Go to Step 8 7 Replace and or tension the belts to specifications as necessary Is the repair complete Go to Step 1 8 Inspect the exhaust system Is the system grounded Go to Step 9 Go t...

Page 6: ...rt up but last only a few seconds Go to Step 2 System OK 2 Check the engine oil Is the proper viscosity oil used in the crankcase Go to Step 4 Go to Step 3 3 Install oil of the proper viscosity for th...

Page 7: ...r viscosity for the expected seasonal temperatures Is the repair complete Go to Step 1 10 Inspect the piston pin clearance Is the clearance more than the specified value 0 020 mm 0 0008 in Go to Step...

Page 8: ...t Procedure Go to Step 6 6 Inspect the crankshaft pulley Is the crankshaft pulley loose Go to Crankshaft Replacement Procedure System OK Connecting Rod Bearing Noise Symptom Step Action Value s Yes No...

Page 9: ...ect the piston pin and the bushing Is the piston pin or the bushing worn or loose Go to Pistons and Rods Replacement Procedure Go to Step 3 3 Inspect the piston Is the piston broken or cracked Go to P...

Page 10: ...the valve lifters dirty stuck or worn Go to Cylinder Head and Valve Train Components Replacement Procedure Go to Step 5 5 Inspect the camshaft lobes Are the camshaft lobes damaged or improperly machi...

Page 11: ...should be kept in order They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is perfor...

Page 12: ...DAEWOO T 154 BL2 3 BLANK...

Page 13: ...1B 8 Lower End 1B 10 Maintenance and Repair 1B 12 On Vehicle Service 1B 12 Valve Cover 1B 12 Cylinder Head and Gasket 1B 13 Camshaft 1B 27 Timing Belt Check and Adjust 1B 31 Timing Belt 1B 36 Oil Pum...

Page 14: ...65 mm 0 00025 in Piston Diameter 76 470 mm 3 01 in Clearance to Bore 0 030 mm 0 0012 in Piston Rings Ring End Gap Ring End Gap Top Compression 0 3 mm 0 019 in 2nd Compression 0 3 mm 0 019 in Groove Cl...

Page 15: ...0007 0 0027 in Rod Side Clearance 0 070 0 242 mm 0 0027 0 009 in Valve System Valve Lash Compensators Hydraulic Face Angle All 46 Seat Angle All 46 Seat Runout Maximum All 0 03 mm 0 019 in Face Runou...

Page 16: ...0 45 15 37 45 15 Crankshaft Pulley Bolt 95 30 15 70 30 15 Crankshaft Position Sensor Retaining Bolt 10 89 Cylinder Head Bolts Camshaft Support Housing Cylinder Head Mounting Bolts 25 70 70 30 18 70 70...

Page 17: ...Relief Valve Bolt 30 22 Oil Pump Rear Cover Bolts 6 53 Power Steering Pump Mounting Bolts 25 18 Power Steering Pump Pulley Bolts 25 18 Rear Timing Belt Cover Bolts 10 89 Right Transaxle Brace Bolts 6...

Page 18: ...upport Fixture A102B153 KM 427 Piston Pin Service Set A102B154 MKM 571 B Gauge A102B155 KM 253 Valve Guide Reamer A102B155 KM 254 Valve Guide Reamer A102B155 KM 255 Valve Guide Reamer A102B156 KM 340...

Page 19: ...d A102B158 KM 419 Distance Gauge A102B160 KM 635 Crankshaft Rear Oil Seal Installer A102B159 MKM 412 Engine Overhaul Stand A202B005 KM 498 B Pressure Gauge A102B161 KM 470 B Angular Torque Gauge A102...

Page 20: ...1B 8 SOHC ENGINE MECHANICAL DAEWOO T 154 BL2 3 COMPONENT LOCATOR UPPER END A402B001...

Page 21: ...sure Plate 27 Bolt 28 Bolt Stud 29 Intake Manifold Gasket 30 Bolt Stud 31 Valve Thrust Piece 32 Valve Key 33 Valve Spring Plate 34 Valve Spring 35 Valve Stem Seal 36 Exhaust Valve Spring Seat 37 Valve...

Page 22: ...1B 10 SOHC ENGINE MECHANICAL DAEWOO T 154 BL2 3 LOWER END A202B006...

Page 23: ...25 Crankshaft Gear 26 Pressure Relief Valve Plunger 27 Spring 28 Oil Pump Seal Ring 29 Bolt Plug 30 Crankshaft Bearing Set 31 Crankshaft 32 Shaft Seal Ring 33 Flywheel Manual Transaxle 34 Bolt Manual...

Page 24: ...e from the valve cover A402B003 3 Remove the eight bolts from the valve cover 4 Remove the valve cover 5 Remove the valve cover gasket 6 Clean the sealing surfaces of the valve cover and the camshaft...

Page 25: ...mp fuse 2 Start the engine After it stalls crank the engine for 10 seconds to rid the fuel system of fuel pressure 3 Disconnect the negative battery cable 4 Disconnect the engine control module ECM gr...

Page 26: ...jector harness connectors A102B016 12 Disconnect the idle air control IAC valve connec tor 13 Disconnect the throttle position TP sensor connec tor 14 Disconnect the engine coolant temperature ECT sen...

Page 27: ...emove the upper timing belt cover A102B004 21 Align the camshaft gear timing mark to the notch in the rear timing belt cover A102B006 22 Remove the right front wheel Refer to Section 2E Tires and Whee...

Page 28: ...if equipped 27 Remove the power steering pump pulley if equipped A402B009 28 Disconnect the fuel return line at the fuel pressure regulator 29 Disconnect the fuel feed line at the fuel rail A102B118 3...

Page 29: ...ering pump if equipped Re fer to Section 6B Power Steering Pump 39 Install the engine mount bracket to engine mount retaining bolts and tighten the bolts to secure the en gine if the power steering pu...

Page 30: ...and the valve cover gasket Notice Take care to prevent any scratches nicks or damage to the camshaft 48 While holding the camshaft firmly in place remove the camshaft gear bolt 49 Remove the camshaft...

Page 31: ...yt ic converter at the exhaust manifold flange A102B119 56 Disconnect the heater inlet hose at the coolant dis tributor 57 Disconnect the surge tank coolant hose at the throttle body A402B005 58 Remov...

Page 32: ...gasket A102B122 Cleaning Procedure 1 Clean the gasket surfaces of the cylinder head and the engine block 2 Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and...

Page 33: ...ft using a torque wrench Use the angular torque gauge KM 470 B to tighten the cylinder head bolts another 70 degrees plus 70 degrees plus 30 degrees A102B029 6 Connect the throttle cable at the throt...

Page 34: ...en Tighten the auxiliary catalytic converter to exhaust manifold nuts to 40 N m 30 lb ft A102B046 11 Connect the ignition wires at the spark plugs 12 Install the rear timing belt cover 13 Install the...

Page 35: ...mshaft firmly in place install the camshaft gear bolt Tighten Tighten the camshaft gear bolt to 45 N m 33 lb ft A402B004 18 Install the valve cover and the valve cover gasket 19 Install the valve cove...

Page 36: ...if equipped Refer to Section 6B Power Steering Pump 28 Install the engine mount bracket to engine mount re taining bolts if the power steering pump was installed Tighten Tighten the engine mount brac...

Page 37: ...thermostat housing A102B118 36 Install the alternator adjusting bracket 37 Install the alternator adjusting bracket retaining bolt Tighten Tighten the alternator adjusting bracket retaining bolt to 2...

Page 38: ...nstall the air filter housing bolts Tighten Tighten the air filter housing bolts to 8 N m 71 lb in 49 Connect the air intake tube to the throttle body 50 Connect the breather tube to the valve cover 5...

Page 39: ...emove the valve cover bolts 4 Remove the valve cover 5 Remove the valve cover gasket A102B074 6 Install the valve spring compressor KM 565 A Notice Take extreme care to prevent any scratches nicks or...

Page 40: ...the electronic ignition EI system igni tion coil connector 13 Disconnect the EI system ignition wires at the igni tion coil 14 Remove the EI system ignition coil mounting bolts 15 Remove the EI syste...

Page 41: ...ft end play should be 0 04 to 0 16 mm 016 to 0 64 inch 5 Install the EI system ignition coil mounting plate 6 Install the EI system ignition coil mounting plate bolts Tighten Tighten the EI system ign...

Page 42: ...Notice Take extreme care to prevent any scratches nicks or damage to the camshaft Such damage can im pair vehicle operation 13 Install the camshaft gear 14 While holding the camshaft firmly in place i...

Page 43: ...TIMING BELT CHECK AND ADJUST Tools Required J 42492 Timing Belt Adjuster KM 470 B Angular Torque Gauge Adjustment Procedure 1 Disconnect the negative battery cable 2 Disconnect the intake air temperat...

Page 44: ...bolts if equipped 12 Remove the power steering pump pulley if equipped 13 Remove the power steering pump mounting bolts if equipped 14 Remove the upper timing belt cover bolts 15 Remove the upper tim...

Page 45: ...nkshaft gear to the notch at the bottom of the rear timing belt cover A102B004 23 Align the camshaft gear timing mark to the notch at the top of the rear timing belt cover A102B040 24 Slightly loosen...

Page 46: ...he crankshaft pulley bolt 31 Remove the driver from the timing belt automatic tensioner 32 Loosen the coolant pump retaining bolts A102B041 33 Rotate the coolant pump until the adjust arm pointer of t...

Page 47: ...pump mounting bolts if equipped Tighten Tighten the power steering pump mounting bolts to 25 N m 18 lb ft 43 Install the power steering pump pulley if equipped 44 Install the power steering pump pulle...

Page 48: ...iming Belt Adjuster KM 470 B Angular Torque Gauge Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the intake air temperature IAT sensor connector 3 Disconnect the air intake tub...

Page 49: ...er timing belt cover bolts 13 Remove the upper timing belt cover A102B008 14 Remove the crankshaft pulley bolt 15 Remove the crankshaft pulley 16 Remove the lower timing belt cover bolts 17 Remove the...

Page 50: ...the timing belt A102B042 Installation Procedure 1 Align the mark on the crankshaft gear to the notch on the bottom of the rear timing belt cover 2 Align the mark on the camshaft gear to the notch on...

Page 51: ...st arm hole and the tensioner bracket hole A102B030 8 Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt 9 Align the mark on the crankshaft gear to the notch at the bottom...

Page 52: ...aining bolts to 10 N m 89 lb in A102B008 15 Remove the crankshaft pulley bolt 16 Install the lower timing belt cover 17 Install the lower timing belt cover bolts Tighten Tighten the lower timing belt...

Page 53: ...e power steering pump if equipped Refer to Section 6B Power Steering Pump 23 Install the alternator drive belt 24 Install the A C compressor drive belt if equipped A102B002 25 Install the right front...

Page 54: ...dapter Engine Oil Pressure Inspection Procedure 1 Remove the right hand wheel well splash shield 2 Remove the oil pressure switch connector A202B003 3 Install the adapter KM 135 in place of the oil pr...

Page 55: ...connect the negative battery cable 2 Remove the power steering pump if equipped Re fer to Section 6A Power Steering System 3 Remove the timing belt Refer to Timing Belt in this section 4 Remove the re...

Page 56: ...the engine block and the oil pan 13 Remove the oil pump A202B002 Inspection Procedure 1 Clean the oil pump and the engine block gasket mat ing surfaces 2 Remove the safety relief valve bolt 3 Remove t...

Page 57: ...the engine 11 Install the oil pump rear cover and the bolts Tighten Tighten the oil pump rear cover bolts to 6 N m 53 lb in 12 Install the safety relief valve the spring the washer and the bolt Tight...

Page 58: ...and the support bracket bolts to 10 N m 89 lb in A102B019 9 Install the oil pan Refer to Oil Pan in this section 10 Install the CKP sensor and the bolt Tighten Tighten the crankshaft position sensor...

Page 59: ...heated oxygen O2 sensor 4 Remove the auxiliary catalytic converter upper flange nuts from the exhaust manifold and the bolts from the bracket B102G003 5 Remove the nuts from the front muffler pipe to...

Page 60: ...k sealing surface 3 Clean the oil pan retaining bolts 4 Clean the oil pan retaining bolt holes in the engine block A102B043 Installation Procedure 1 Install the oil pan gasket to the oil pan 2 Install...

Page 61: ...0 N m 89 lb in TAA1F480 6 Install the catalytic converters Tighten Tighten the auxiliary catalytic converter to exhaust manifold nuts and bracket bolts to 40 N m 30 lb ft B102G003 Tighten Tighten the...

Page 62: ...Assembly Support Fixture Removal Procedure 1 Disconnect the negative battery cable 2 Support the engine assembly using the engine as sembly support fixture KM 263 B A102B020 3 Remove the engine mount...

Page 63: ...e mount attaching nuts Tighten Tighten the engine mount attaching nuts to 40 N m 30 lb ft A102B020 3 Install the engine mount bracket retaining bolts Tighten Tighten the engine mount bracket retaining...

Page 64: ...Disconnect the engine control module ECM ground terminal from the intake manifold A102B001 5 Drain the engine coolant Refer to Section 1D En gine Cooling 6 Disconnect the intake air temperature IAT s...

Page 65: ...e at the intake manifold A402B009 14 Disconnect the throttle cable from the throttle body and the intake manifold 15 Remove the two throttle cable bracket bolts and the throttle cable bracket 16 Disco...

Page 66: ...r adjusting bracket and the bolts A102B033 23 Remove the three intake manifold support bracket retaining bolts from the coolant distributor and the engine block 24 Remove the intake manifold support b...

Page 67: ...bracket bolt in the sequence shown Tighten Tighten the intake manifold retaining nuts in the se quence shown to 25 N m 18 lb ft Tighten the engine lift bracket bolt to 25 N m 18 lb ft A102B118 4 Insta...

Page 68: ...able bracket and the two throttle cable bracket bolts Tighten Tighten the throttle cable bracket bolts to 8 N m 71 lb in 13 Connect the throttle cable to the intake manifold and the throttle body A102...

Page 69: ...ng TAA1F480 EXHAUST MANIFOLD Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the ignition wires from the spark plugs 3 Disconnect the oxygen O2 sensor 4 Remove the exhaust manif...

Page 70: ...ten Tighten the auxiliary catalytic converter to exhaust manifold nuts to 50 N m 37 lb ft 5 Install the exhaust manifold heat shield 6 Install the exhaust manifold heat shield bolts Tighten Tighten th...

Page 71: ...re Notice Take extreme care to prevent any scratches nicks or damage to the camshaft Such damage can im pair vehicle operation 1 Install the camshaft gear 2 While holding the camshaft firmly in place...

Page 72: ...timing belt cover bolts 7 Remove the rear timing belt cover A102B041 Installation Procedure 1 Install the rear timing belt cover 2 Install the rear timing belt cover bolts Tighten Tighten the rear tim...

Page 73: ...of fuel pressure 3 Remove the hood Refer to Section 9R Body Front End 4 Drain the engine oil A102B013 5 Disconnect the negative battery cable 6 Disconnect and separate the battery positive cable 7 Dis...

Page 74: ...tank hose from the ra diator 22 Disconnect the power steering return hose from the power steering pump if equipped 23 Drain the power steering system if equipped 24 Disconnect the power steering pres...

Page 75: ...oolant hose at the throttle body 39 Disconnect the heater inlet hose from the coolant distributor 40 Disconnect the heater outlet hose at the coolant pipe 41 Disconnect the surge tank coolant hose fro...

Page 76: ...nverter nuts from the exhaust manifold and the bolts at the bracket B102G003 52 Remove the nuts from the front muffler pipe to the main catalytic converter 53 Remove both catalytic converters as a uni...

Page 77: ...at the oil pres sure switch 59 Disconnect the crankshaft position CKP sensor connector and the CMP sensor connector 60 Remove the CKP sensor retaining bolt 61 Remove the CKP sensor 62 Remove the righ...

Page 78: ...dure 1 Install the engine into the engine compartment 2 Align the transaxle alignment pins to the transaxle 3 Install the transaxle bell housing bolts Tighten Tighten the transaxle bell housing bolts...

Page 79: ...r 11 Install the flywheel or the flexible plate inspection cover bolts Tighten Tighten the flywheel inspection cover bolts to 12 N m 106 lb in or the flexible plate inspection cover bolts to 10 N m 89...

Page 80: ...hten the crankshaft pulley bolt another 30 degrees plus 15 degrees B102G003 18 Install the CKP sensor and the CKP sensor retaining bolt Tighten Tighten the crankshaft position sensor retaining bolt to...

Page 81: ...A C compressor mounting bolts if equipped Tighten Tighten the A C compressor mounting bolts to 27 N m 20 lb ft 27 Connect the A C compressor coil connector 28 Install the alternator drive belt 29 Ins...

Page 82: ...rter solenoid S terminal wire 40 Connect the alternator voltage regulator connector 41 Connect the CTS connector 42 Connect the ECT sensor connector and the knock sensor connector if equipped 43 Conne...

Page 83: ...ery cable to the vehicle frame 62 Connect the negative battery cable to the battery 63 Connect and assemble the battery positive cable 64 Refill the engine crankcase with engine oil 65 Refill the engi...

Page 84: ...ve the upper piston connecting rod bearing 10 Ridge ream the cylinder wall A102B080 Caution Use care when handling the piston Worn piston rings are sharp and may cause injury 11 Remove the piston 12 U...

Page 85: ...ter A102B082 7 Inspect the piston for fit to the connecting rod A102B083 8 Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge Refer to Engine Specifications in...

Page 86: ...sembly using the piston pin service set KM 427 A102B084 6 Select a set of new piston rings 7 Measure the piston ring gap using a feeler gauge Refer to Engine Specifications in this section 8 Increase...

Page 87: ...pand the piston rings beyond the expan sion necessary for installation 16 Stagger the piston oil rings the oil ring rail gaps the second compression ring and the top compression ring in relation to th...

Page 88: ...KM 470 B tighten one turn of 30 degrees A102B094 21 Install the oil pump pickup tube 22 Install the oil pump pickup tube bolts Tighten Tighten the oil pump pickup tube and support bracket bolts to 10...

Page 89: ...lve Spring Compressor KM 419 Distance Gauge Disassembly Procedure 1 Remove the cylinder head with the intake manifold and the exhaust manifold attached Refer to Cylinder Head and Gasket in this sectio...

Page 90: ...A102B050 14 Remove the thermostat housing mounting bolts 15 Remove the thermostat housing 16 Remove the thermostat and thermostat gasket A102B051 17 Using the valve spring compressor KM 348 com press...

Page 91: ...der head from sealing surface to sealing surface The cylinder head height should be 94 70 to 95 65 mm 3 728 to 3 766 inches If the cylinder head height is less than 94 70 mm 3 728 inches replace the c...

Page 92: ...valve spring 9 Inspect the valve spring seating surface of the valve rotators for wear or gouges Replace as required A102B055 Cleaning Procedure 1 Clean the cylinder head 2 Clean the valve guides 3 Cl...

Page 93: ...the valves the valve guides and the cylinder head A102B066 Valve Grind 1 Ensure that there are no crater line burns on the valve cone 2 The valve may be reground only two times Do not grind the valve...

Page 94: ...ode Size Reamer Production Code Service Code Normal K 0 075 KM 253 1 K1 0 150 KM 254 2 K2 0 250 KM 255 A 3 Ream the valve guide from the upper side of the cylin der head to the next oversize After rea...

Page 95: ...install new valves and then check the valve stem projection again Refer to Valve Grind and Valve Grind In in this section 7 If the valve stem projection is still too large despite re placing the valve...

Page 96: ...old studs 13 Install the intake manifold gasket 14 Install the intake manifold 15 Install the intake manifold retaining nuts Tighten Tighten the intake manifold retaining nuts to 25 N m 18 lb ft A102B...

Page 97: ...ust manifold attached Refer to Cylinder Head and Gasket in this section A102B095 CRANKSHAFT Tools Required MKM 412 Engine Overhaul Stand J 42492 Timing Belt Adjuster KM 470 B Angular Torque Gauge J 36...

Page 98: ...2 Slightly loosen the three coolant pump retaining bolts 13 Rotate the coolant pump using timing belt adjuster J 42492 to remove the tension from the timing belt 14 Remove the timing belt A102B111 15...

Page 99: ...timing belt cover bolts 22 Remove the rear timing belt cover 23 Remove the crankshaft timing belt gear A102B064 24 Rotate the engine on the engine overhaul stand MKM 412 25 Remove the oil pan retaini...

Page 100: ...olts 37 Remove the crankshaft bearing caps 38 Remove the crankshaft bearings from the crank shaft bearing caps 39 Remove the crankshaft 40 Remove the crankshaft bearings from the engine block 41 Clean...

Page 101: ...ings in the engine block 8 Install the crankshaft A102B091 9 Install the crankshaft bearings to the crankshaft bearing caps 10 Install the crankshaft bearing caps Notice Do not reuse the old crankshaf...

Page 102: ...he connecting rod bearing cap bolts to 25 N m 18 lb ft Using the angular torque gauge KM 470 B tighten the connecting rod bearing cap bolts another 30 degrees plus 15 degrees A102B065 16 Install the o...

Page 103: ...ng belt cover 25 Install the rear timing belt cover bolts Tighten Tighten the rear timing belt cover bolts to 10 N m 89 lb in 26 Install the timing belt automatic tensioner 27 Install the timing belt...

Page 104: ...e power steering pump mounting bolts Tighten Tighten the power steering pump mounting bolts to 25 N m 18 lb ft 38 Install the upper timing belt cover 39 Install the upper timing belt cover bolts Tight...

Page 105: ...kshaft end play Refer to Engine Specifications in this section A102B071 7 With the crankshaft mounted on the front and the rear crankshaft bearings check the middle crankshaft journal for permissible...

Page 106: ...rance ranges 14 Inspect the bearing clearances for permissible toler ance ranges Refer to Engine Specifications in this section A102B072 Inspection Procedure Connecting Rods 1 Coat the connecting rod...

Page 107: ...olts Tighten Tighten the connecting rod bearing cap bolts to 25 N m 18 lb ft Using the angular torque gauge KM 470 B tighten the crankshaft cap bolts another 30 degrees plus 15 degrees A102B073 8 Remo...

Page 108: ...he excess oil to flow through the valve and drain back to the oil pan OIL PAN The oil pan is mounted to the bottom of the cylinder block The oil pan houses the crankcase and is made of pressed sheet m...

Page 109: ...nk Cap Test 1D 3 Cooling System Diagnosis 1D 4 Component Locator 1D 5 Radiator Fan 1D 5 Coolant Pump Thermostat SOHC 1D 7 Maintenance and Repair 1D 8 On Vehicle Service 1D 8 Draining and Refilling the...

Page 110: ...Mounting Bolts 4 35 Electric Cooling Fan Assembly Main Mounting Bolts 4 35 20 15 Engine Coolant Temperature Sensor SOHC 20 15 Lower Transaxle Cooler Pipe Bolt 12 106 Negative Battery Terminal Retainer...

Page 111: ...these temperatures replace the thermo stat SURGE TANK CAP TEST SPECIAL TOOLS KM 471 Adapter The surge tank cap maintains proper pressure protects the system from high pressure by opening a pressure va...

Page 112: ...eplace any damaged radiator hoses Check for a faulty water pump Replace a faulty water pump Check for a faulty surge tank cap Replace a faulty surge tank cap Check for a cylinder head or an engine blo...

Page 113: ...Action Check to determine if the thermostat is stuck open or if it is the wrong type of thermostat Install a new thermostat of the correct type and heat range Check the coolant level to determine if...

Page 114: ...IRE CALORIFER 33 FURTUN INTRARE CALORIFER 34 COLIER 35 ROBINET CALORIFER 36 COLIER 37 FURTUN 38 FURTUN AUXILIAR 39 COLIER ANSAMBLU RADIATOR 17 GALERIA DE EVACUARE 18 COLIER 19 FURTUN INTRARE LA CORPUL...

Page 115: ...NGINE COOLING 1D 7 DAEWOO T 154 BL2 3 COOLANT PUMP THERMOSTAT SOHC A102D027 1 Thermostat Housing Bolt 2 Thermostat Housing 3 Seal Ring 4 Thermostat 5 Coolant Pump Mounting Bolts 6 Coolant Pump 7 O Rin...

Page 116: ...ge tank Refer to Surge Tank in this section 6 Plug the drain cock 7 Add the clean water to the surge tank 8 Fill the tank slowly so that the upper reservoir hose remains above the water line This allo...

Page 117: ...the thermostat housing from the head 7 Remove the thermostat from its recess in the cylin der head 8 Inspect the valve seat for foreign matter that could prevent the valve from seating properly 9 Ins...

Page 118: ...se 5 Disconnect the bypass hose from the thermostat adapter E21D004 6 Remove the mounting bolts that hold the thermostat housing to the cylinder head 7 Remove the thermostat housing from the head 8 Re...

Page 119: ...hermostat housing Refer to Draining and Refilling the Cooling System in this section 2 Remove the rear timing belt cover Refer to Section 1B SOHC Engine Mechanical or Section 1C DOHC Engine Mechanical...

Page 120: ...r Refer to Section 1B DOHC Engine Mechanical 6 Refill the engine cooling system Refer to Draining and Refilling the Cooling System in this section A102D006 ELECTRIC COOLING FAN MAIN Removal Procedure...

Page 121: ...ws Tighten Tighten the electric cooling fan main motor retaining screws to 4 N m 35 lb in A102D006 3 Install the fan to the motor with the single nut in the center of the fan hub Tighten Tighten the e...

Page 122: ...e overflow hoses from the surge tank 3 Remove the tank attaching nuts 4 Remove the tank from the vehicle 5 Clean the inside and the outside of the surge tank and the surge tank cap with soap and water...

Page 123: ...he upper radiator hose clamp 8 Disconnect the upper radiator hose from the radiator A102D011 9 Remove the hose clamp from the surge tank hose at the radiator 10 Disconnect the surge tank hose from the...

Page 124: ...old radiator 5 Set the radiator into place in the vehicle with the ra diator bottom posts in the rubber shock bumpers A102D022 6 Position the radiator retainers in place 7 Install the upper right rad...

Page 125: ...OLANT TEMPERATURE GAUGE Single Overhead Cam Engine Removal Procedure 1 Disconnect the negative battery cable 2 Drain the coolant below the coolant temperature gauge level 3 Disconnect the electrical c...

Page 126: ...e surge tank When the engine stops the engine coolant cools and contracts The displaced engine coolant is then drawn back into the radiator and the engine This keeps the ra diator filled with the cool...

Page 127: ...speed when the coolant temperature reaches 93 C 199 F and high speed at 97 C 207 F The ECM will change the cooling fan s from high speed to low speed at 94 C 201 F and turn the cooling fans off at 90...

Page 128: ...DAEWOO T 154 BL2 3 BLANK...

Page 129: ...0 Generator System Check 1E 10 Maintenance and Repair 1E 11 On Vehicle Service 1E 11 Generator 1E 11 Starter 1E 15 Battery Battery Tray 1E 16 Unit Repair 1E 19 Starter Motor 1E 19 Generator 1E 31 Gene...

Page 130: ...18_C 0_F 8 0 Below 18_C Below 0_F FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Battery Cable Nuts 4 5 40 Battery Carrier Tray Lower Bolts 20 15 Battery Carrier Tray Upper Bolts 20 15...

Page 131: ......

Page 132: ...1E 4 ENGINE ELECTRICAL DAEWOO T 154 BL2 3 A402E002 CHARGING SYSTEM...

Page 133: ...tive lead to the negative battery terminal 2 Connect the voltmeter positive lead to the engine block 3 Place the ignition in the START position Does the voltmeter indicate the value specified 0 5 v Go...

Page 134: ...ct the voltmeter positive lead to the starter S terminal 2 Connect the voltmeter negative lead to the negative battery terminal 3 Place the ignition in the START position 4 Read the voltage present at...

Page 135: ...ctor 2 Connect the voltmeter positive lead to terminal ST of the ignition switch 3 Connect the voltmeter negative lead to ground 4 Turn the ignition switch to START Does the voltmeter indicate the spe...

Page 136: ...e gauge Do not gauge in the cor ners where a misleading larger dimension may be observed If the clearance is under this minimum shimming the starter away from the flywheel is re quired 5 If the cleara...

Page 137: ...rator Refer to Generator in the On Vehicle Service section 13 With the generator operating at the maximum out put measure the voltage between the generator housing and the battery negative terminal Th...

Page 138: ...Procedure 1 Disconnect the negative battery cable 2 Disconnect the intake air temperature IAT sensor electrical connector from the air intake tube A202E002 3 Remove the breather tube clamp and all ot...

Page 139: ...ine accessory drive belt For ve hicles equipped with power steering and air condition ing refer to Section 6B Power Steering Pump A202E004 7 Remove the bolt and the retaining clamp of the har ness A10...

Page 140: ...t to generator bolt 13 Carefully remove the generator A102E234 Installation Procedure 1 Install the generator at the generator lower bracket and insert the generator bolts 2 Install the nuts and the w...

Page 141: ...Tighten the generator battery lead nut to 15 NSm 11 lb ft 7 Lubricate the injector O rings on the DOHC engine with engine oil 8 Install the fuel rail assembly Tighten Tighten the fuel rail retaining b...

Page 142: ...rical connector to the air intake tube 13 Connect the negative battery cable A102E235 STARTER Removal Procedure 1 Remove the upper and the lower starter mounting bolts A102E236 2 Remove the starter so...

Page 143: ...ts to 43 NSm 32 lb ft A102E236 3 Position the starter electrical wire on the solenoid ter minal 4 Install the starter solenoid nuts Tighten Tighten the starter solenoid nuts to 15 NSm 11 lb ft A102E24...

Page 144: ...attery carrier by fastening the carrier tray upper and lower bolts Tighten Tighten the battery carrier tray upper and lower bolts to 20 NSm 15 lb ft A102E241 2 Install the battery into the tray 3 Fast...

Page 145: ...1E 17 ENGINE ELECTRICAL DAEWOO T 154 BL2 3 A102E240 4 Connect the negative and the positive battery cables Tighten Tighten the battery cable nuts to 15 NSm 11 lb ft...

Page 146: ...t springs and the brush holders for wear and damage Replace the as sembly if necessary A102E216 Important This test should be made for each ground or insulated brush to ensure continuity through both...

Page 147: ...d brush 6 2 If the lamp is lit a grounded series coil is indi cated and must be repaired or replaced 6 3 Test for an open circuit on each insulated brush by placing one lead on the series coil termina...

Page 148: ...begin the no load test close the switch and compare the rpm the current and the voltage read ings with the specifications Refer to Starter Specifi cations in this section Make disconnections only with...

Page 149: ...rcuit open armature coils broken brush springs worn brushes high insulation between the commutator bars or other causes which would prevent good contact between the brushes and the commu tator 8 5 Low...

Page 150: ...pile across the battery 12 3 Adjust the voltage to 10 volts The amme ter reading should be 13 to 19 amperes A102E221 Important Current will decrease as the windings heat up Current draw readings that...

Page 151: ...commutator must measure at least 41 91 mm 1 650 inches after it is undercut or turned Do not turn out of round commutators 19 Inspect the points where the armature conductors join the commutator bars...

Page 152: ...cushion and the driveshaft assembly from the starter housing A102E220 24 Disassemble the driveshaft assembly by first sepa rating the needle bearing from the driveshaft 25 Remove the collar and the lo...

Page 153: ...pport from the driveshaft A102E226 28 If not done in the previous steps remove the screws that hold the solenoid assembly into the housing and remove the nut from the field coil connector A102E247 29...

Page 154: ...terminal and carefully insulate the connector 33 Connect one 12 volt battery lead to the solenoid switch terminal and the other to the starter frame 34 Flash a jumper lead momentarily from the soleno...

Page 155: ...ears with lubricant Begin at Step 7 if proceeding with just the reassembly of the solenoid 3 If full disassembly of the starter and the solenoid was performed begin reassembly by placing the gear supp...

Page 156: ...d the boot A102E224 8 Lubricate the gears with lubricant and install the dri veshaft assembly with the bushing and the washer on the gear end 9 Install the cushion and the gears A102E223 10 Lubricate...

Page 157: ...ighten the starter solenoid assembly screws to 8 NSm 71 lb in 13 Install the field coil connection to the starter termi nal Install the nut Tighten Tighten the starter field coil connector nut to 8 NS...

Page 158: ...starter through bolts 19 Install the starter Refer to Starter in this section Tighten Tighten the starter through bolts to 6 NSm 53 lb in A102E201 GENERATOR Disassembly Procedure 1 Remove the generat...

Page 159: ...s in the rectifier bridge 4 Remove the stator connections from the rectifier bridge terminals by cutting the wires A102E203 5 Remove the generator through bolts A102E251 Important The fastening torque...

Page 160: ...52 8 Test the rotor for an open circuit by using the ohmme ter with the drive end frame assembled The reading should be sufficiently high or the rotor must be re placed A102E205 9 Test the rotor for o...

Page 161: ...Remove the drive end frame from the shaft 11 For vehicles with an internal generator fan remove the drive end frame and the fan A102E207 12 Remove the rotor assembly A102E208 13 Remove the stator 14 T...

Page 162: ...or cutting the terminal between the regulator and the rectifier bridge Important If the brush can be reused reassemble the brush to the holder with the retaining pin after cleaning the brush with a so...

Page 163: ...dge diode In this case consult the manufacturer regarding the test capacity 22 Test the diodes by connecting the ohmmeter termi nals to the bridge terminal and the base plate If the reading is the sam...

Page 164: ...al 5 Apply silicone grease between the bridge and the end frame for radiation purposes 6 Fasten the screws holding the rectifier regulator brush holder assembly to the end frame 7 Punch the new baffle...

Page 165: ...outer lace and the end frame casting is 1 9 mm 0 075 inch 12 Install the generator through bolts Tighten Tighten the generator through bolts to 10 NSm 89 lb in A102E251 13 Position the fan the collar...

Page 166: ...e maintained by the battery for 30 seconds at the specified temperature while meeting a minimum voltage requirement of 7 2 volts This rating is a measure of cold cranking ca pacity The battery is not...

Page 167: ...e the battery accepts the current in excess of a few milliamperes Refer to Charging Time Required in this section which focuses on the factors affecting both the charging time required and the rough e...

Page 168: ...n the engine is running If the charge indi cator is on with the engine running a charging system defect is indicated This indicator light will glow at full brilliance for several kinds of defects as w...

Page 169: ...nt Locator SOHC 1F 23 Diagnosis 1F 25 System Diagnosis 1F 25 Diagnostic Aids 1F 25 Idle Learn Procedure 1F 25 TEC Tooth Error Correction Learn Procedure 1F 26 On Board Diagnostic EOBD System Check 1F...

Page 170: ...ff DFCO 1 5L SOHC 1F 287 DTC P0171 Fuel Trim System Too Lean 1F 189 DTC P1171 Fuel Trim System Lean During Power Enrichment 1F 193 DTC P0172 Fuel Trim System Too Rich 1F 195 DTC P0201 Injector 1 Outpu...

Page 171: ...Symptom Diagnosis 1F 364 Important Preliminary Checks 1F 364 Intermittents 1F 364 Hard Start 1F 365 Surges or Chuggles 1F 367 Lack of Power Sluggishness or Sponginess 1F 369 Detonation Spark Knock 1F...

Page 172: ...ive Crankcase Ventilation Control System Operation 1F 412 Engine Coolant Temperature Sensor 1F 412 Throttle Position Sensor 1F 412 Catalyst Monitor Oxygen Sensors 1F 413 Exhaust Gas Recirculation Valv...

Page 173: ...pen Loop Closed Loop may enter Open Loop at extended idle Rich Lean B1 S1 Rich Lean varies Lean to Rich Average mS 10 211 ms or 0 ms Rich to Lean Average mS 10 211 ms or 0 ms Engine Load Value 0 100 v...

Page 174: ...ECM and finally to the scan tool over KWP 2000 serial data Air Fuel Ratio The Air Fuel Ration indicates the air to fuel ratio based on the Oxygen Sensor O2S 1 inputs The ECM uses the fuel trims to adj...

Page 175: ...Knock Present The KS Noise Channel indicates when the ECM detects the KS signal The ECM should display NO at idle Long Term FT The Long Term Fuel Trim FT is derived from the short term fuel trim value...

Page 176: ...gramming in the ignition system It computes the desired spark advance using data such as engine temperature rpm engine load vehicle speed and operating mode Total Misfire Current Counter Indicates the...

Page 177: ...lt 20 15 Exhaust Gas Recirculation Valve Retaining Bolts 20 15 Fuel Pressure Regulator Retaining Bolt SOHC 12 106 Fuel Rail Mounting Bolts 25 18 Fuel Rail Retaining Bolts 25 18 Fuel Tank Retaining Bol...

Page 178: ...alcohol providing that there is no more than 10 per cent ethyl alcohol by volume Methanol Do not use fuels containing methanol Methanol can cor rode metal parts and cause damage to plastic and rub be...

Page 179: ...ENGINE CONTROLS 1F 11 DAEWOO T 154 BL2 3 SCHEMATIC AND ROUTING DIAGRAMS ECM WIRING DIAGRAM 1 5L SOHC 1 OF 6 TAA1F010...

Page 180: ...1F 12 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F020 ECM WIRING DIAGRAM 1 5L SOHC 2 OF 6...

Page 181: ...ENGINE CONTROLS 1F 13 DAEWOO T 154 BL2 3 ECM WIRING DIAGRAM 1 5L SOHC 3 OF 6...

Page 182: ...1F 14 ENGINE CONTROLS ECM WIRING DIAGRAM 1 5L SOHC 4 OF 6...

Page 183: ...ENGINE CONTROLS 1F 15 DAEWOO T 154 BL2 3 ECM WIRING DIAGRAM 1 5L SOHC 5 OF 6...

Page 184: ...ENGINE CONTROLS 1F 16 DAEWOO T 154 BL2 3 ECM WIRING DIAGRAM 1 5L SOHC 6 OF 6...

Page 185: ...1F 17 ENGINE CONTROLS DAEWOO T 154 BL2 3 CONNECTOR END VIEW C1F0409A Date Link Connector DLC TAA1F520 TAA1F530...

Page 186: ...ENGINE CONTROLS 1F 18 DAEWOO T 154 BL2 3 CONNECTOR END VIEW Cont d TAA1F550 A402F081 A102F074 TAA1F610 1 5L SOHC A102F076...

Page 187: ...1F 19 ENGINE CONTROLS DAEWOO T 154 BL2 3 CONNECTOR END VIEW Cont d TAA1F590 1 5L SOHC 1 2 TAA1F620 A102F089 A102F082 A102F075 A402F020...

Page 188: ...ENGINE CONTROLS 1F 20 DAEWOO T 154 BL2 3 CONNECTOR END VIEW Cont d TAA1F560 A402F022 A402F017 TAA1F570 TAA1F600 A B C...

Page 189: ...1F 21 ENGINE CONTROLS DAEWOO T 154 BL2 3 CONNECTOR END VIEW Cont d TAA1F580 1 5L SOHC A B C D E A402F028 A402F019 A102F086...

Page 190: ...ENGINE CONTROLS 1F 22 DAEWOO T 154 BL2 3 BLANK...

Page 191: ...1F 23 ENGINE CONTROLS DAEWOO T 154 BL2 3 COMPONENT LOCATOR COMPONENT LOCATOR SOHC...

Page 192: ...Variable Geometry Induction System VGIS 29 Exhaust Gas Recirculation EGR Valve Information Sensors 31 Manifold Absolute Pressure MAP Sensor 32 Pre Converter Oxygen Sensor O2S 1 33 Throttle Position T...

Page 193: ...ure contact tension Poor terminal to wire connection This requires re moving the terminal from the connector body Road Test If a visual inspection does not find the cause of the prob lem the vehicle c...

Page 194: ...n the engine starts to decelerate Once the learning procedure is com pleted engine control will be learned to the opera tor and the engine will respond to throttle position 1 Stay the gear parking or...

Page 195: ...DAEWOO T 154 BL2 3 BLANK...

Page 196: ...1F 28 ENGINE CONTROLS DAEWOO T 154 BL2 3 TTA1F250...

Page 197: ...shorted to ground 4 If the engine will not start refer to Engine Cranks But Will Not Run in this section 7 A scan tool parameter which is not within the typical range may help to isolate the area whic...

Page 198: ...uit for an open short to ground or short to voltage Also check the Data Link Connector DLC ignition feed circuit for an open or short to ground and the DLC ground circuits for an open Is a problem fou...

Page 199: ...ENGINE CONTROLS 1F 31 DAEWOO T 154 BL2 3 BLANK...

Page 200: ...r an open in the 5 volt reference circuit between the ECM and the splice will cause one or more of the follow ing DTCs to be set P0107 P0112 P0117 P0122 P1107 P1112 P1114 P1122 Check for the following...

Page 201: ...5 Go to Step 9 5 Measure the voltage between the Manifold Absolute Pressure MAP sensor signal circuit at the ECM harness connector and ground Does the voltage measure near the specified value 0 v Go...

Page 202: ...1 17 Locate and repair short to voltage in TFT sensor circuit Is the repair complete Go to Step 21 18 Measure the voltage between the Fuel Tank Pres sure sensor signal circuit at the ECM harness conne...

Page 203: ...ENGINE CONTROLS 1F 35 DAEWOO T 154 BL2 3 BLANK...

Page 204: ...1F 36 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F240...

Page 205: ...ENGINE CONTROLS 1F 37 DAEWOO T 154 BL2 3 TAA1F260...

Page 206: ...supplied by the ECM to operate the fuel injectors If there is no ground present during the cranking of the engine and the fuel injector wiring is OK the ECM is at fault Engine Cranks But Will Not Run...

Page 207: ...tage loss to the engine control module ECM from the igni tion switch Is the repair complete System OK 16 Check for the presence of spark from all of the igni tion wires while cranking the engine Is sp...

Page 208: ...dings near the values specified 2 5 v with ignition ON 2 6 v during cranking Go to Step 27 Go to Step 28 27 Measure the voltage at the ECM connector terminal M5 by backprobing the ECM connector Are th...

Page 209: ...tep 40 37 Check for an open in the wire from the EI system ignition coil connector terminal 1 to the ECM connector terminal M1 Is the problem found Go to Step 38 Go to Step 40 38 1 Repair the wiring a...

Page 210: ...ep 3 50 Replace the fuel pressure regulator Is the repair complete Go to Step 3 51 1 Remove the fuel pump assembly from the fuel tank 2 Inspect the fuel pump sender and the fuel coupling hoses for a r...

Page 211: ...p connector ter minal 3 Is the repair complete Go to Step 3 60 Replace the fuel pump relay Is the repair complete Go to Step 3 61 1 Check for an open in the wiring between the fuel pump relay connecto...

Page 212: ...harness connector s terminal 1 and the engine har ness X4B terminal A Is the repair complete Go to Step 3 70 1 Check for an open between the 1 fuel injector harness connector terminal 2 and the ECM c...

Page 213: ...ENGINE CONTROLS 1F 45 DAEWOO T 154 BL2 3 BLANK...

Page 214: ...1F 46 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F230...

Page 215: ...the scan tool for later reference 3 Connections that are suspected of being faulty should be thoroughly checked as described in the diagnostic aids 4 If the engine fails to start and the MIL is inoper...

Page 216: ...d the battery feed fuses Are the fuses OK Go to Step 10 Go to Step 11 8 Check for a poor connection in the battery feed ter minal K1 ignition feed terminal K18 or the MIL control circuits and repair a...

Page 217: ...minal K1 or the ignition feed terminal K18 and repair as necessary Is the repair necessary Go to Step 22 Go to Step 21 19 Repair the open in the ignition feed circuit from ter minal K18 Is the repair...

Page 218: ...1F 50 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAB1F230...

Page 219: ...ment ECM must be repro grammed Refer to the latest Techline information for reprogramming procedures Malfunction Indicator Lamp On Steady Step Action Value Yes No 1 Perform an On Board Diagnostic EOBD...

Page 220: ...ulty one way check valve in the fuel pump Caution The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pres sure...

Page 221: ...n the values specified and holding steady 284 325 kPa 41 47 psi System OK 10 With the fuel system under pressure inspect the fuel return outlet for leaking Is the problem found Go to Step 11 Go to Ste...

Page 222: ...all a fuel pressure gauge 3 Turn the ignition ON Is the fuel system pressure below the values speci fied and holding steady 284 325 kPa 41 47 psi Go to Step 19 Go to Step 18 18 1 Relieve the fuel syst...

Page 223: ...ENGINE CONTROLS 1F 55 DAEWOO T 154 BL2 3 BLANK...

Page 224: ...er the ignition switch is turned ON Diagnostic Aids An intermittent problem may be caused by a poor con nection rubbed through wire insulation or a broken wire inside the insulation Test Description T...

Page 225: ...the fuel pump relay connector terminal 30 and ground Is the test light on Go to Step 5 Go to Step 11 5 Check for an open or short to ground in the wire between the fuel pump relay connector terminal...

Page 226: ...fuel pump relay connector terminal 30 and the battery 2 Install the fuel pump relay 3 Turn the ignition OFF for 10 seconds 4 Turn the ignition ON Does the fuel pump operate for the time specified 2 s...

Page 227: ...ENGINE CONTROLS 1F 59 DAEWOO T 154 BL2 3 BLANK...

Page 228: ...olts is present at wide open throttle The MAP sensor is also used under cer tain conditions to measure barometric pressure This al lows the ECM to make adjustments for altitude changes The ECM uses th...

Page 229: ...to Step 5 2 1 Turn the ignition OFF 2 Connect a scan tool to the DLC 3 Disconnect the MAP sensor vacuum line 4 Connect a hand vacuum pump to the MAP sensor 5 Turn the ignition ON 6 Note the MAP sensor...

Page 230: ...an engine speed change If no change in engine speed occurs the valve can be removed from the throttle body and tested Connect the IAC driver to the removed IAC valve and turn the ignition ON Do not s...

Page 231: ...as the IAC valve is cycled Does the rpm change smoothly within the value spe cified with each flash of the IAC driver 700 1500 rpm Go to Step 6 Go to Step 3 6 1 Turn the ignition OFF 2 Connect the IA...

Page 232: ...the wire between the IAC connector terminal D and the ECM con nector terminal M13 Is the problem found Go to Step 15 Go to Step 14 14 Check for an open or short in the wire between the IAC connector t...

Page 233: ...ENGINE CONTROLS 1F 65 DAEWOO T 154 BL2 3 BLANK...

Page 234: ...1F 66 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F240...

Page 235: ...to view the varying voltage signals In mea suring these outputs with a voltmeter intermittent errors may occur that cannot be seen by a voltmeter 6 After confirming ECM inputs for the electronic spark...

Page 236: ...Step 9 Go to Step 11 9 1 Repair the wiring as needed 2 Connect the EI system ignition coil connector 3 Check for the presence of spark from all of the ignition wires Is spark present from all of the...

Page 237: ...ound Go to Step 19 Go to Step 11 18 Repair the wire between the CKP sensor connector terminal 1 and the ECM connector terminal M21 Is the repair complete System OK 19 Repair the wire between the CKP s...

Page 238: ...ing fan operation by internally grounding the ECM connector terminal K12 This energizes the high speed cooling fan relay bypassing the radiator fan resistor This results in high speed cooling fan oper...

Page 239: ...2 Go to On Board Diagnostic System Check 2 1 Check the I P fuse block fuse F11 2 Replace the fuse as needed Is the fuse OK Go to Step 3 Go to Diagnostic Aids 3 1 Check the engine fuse block fuse F14...

Page 240: ...terminal C13 and ground 2 Connect a test light between the cooling fan relay B connector terminal 86 and battery positive Is the test light on Go to Step 19 Go to Step 15 13 Repair the open wire betw...

Page 241: ...Go to Step 25 Go to Step 29 25 Connect a test light between the cooling fan relay A connector terminal 87 and battery positive Is the test light on Go to Step 26 Go to Step 30 26 1 Connect a fused ju...

Page 242: ...oling fans are connected in a series circuit The ECM controls the high speed cooling fan operation by internally grounding the ECM connector terminal K28 and the ECM connector terminal K12 at the same...

Page 243: ...est Description The number s below refer to step s on the diagnostic table 4 This step along with step 5 checks for the ability of the ECM to operate the cooling fans 8 This step along with step 9 che...

Page 244: ...ges 3 Start the engine 4 Turn the A C switch ON 5 The cooling fans should run at high speed when the high side A C pressure reaches 1 882 kPa 273 psi Do the cooling fans run at high speed System OK 10...

Page 245: ...g fan relay A connector terminals 30 and 87 3 Connect a fused jumper between the cooling fan control relay connector terminals 30 and 87 Do the cooling fans run at low speed Go to Step 27 Go to Step 1...

Page 246: ...Step 32 Go to Step 12 32 1 Turn the ignition OFF 2 Connect a test light between the main cooling fan connector terminal A and battery positive 3 Turn the A C switch ON 4 Start the engine Is the test...

Page 247: ...d jumper between the ECM connector terminal K12 and ground 3 Disconnect the cooling fan control relay 4 Connect a test light between the cooling fan control relay connector terminal 85 and battery pos...

Page 248: ...the repair complete System OK 46 Repair the open wire between the cooling fan control relay connector terminal 86 and the ignition switch Is the repair complete System OK 47 Repair the open wire betw...

Page 249: ...ENGINE CONTROLS 1F 81 DAEWOO T 154 BL2 3 BLANK...

Page 250: ...1F 82 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F250...

Page 251: ...e frame and failure re cords data on the scan tool if applicable This creates an electronic copy of the data taken when the malfunction occurred The information is then stored on the scan tool for lat...

Page 252: ...ete Go to Step 17 12 Repair the open or poor connection s in the DLC ground circuit s Is the repair complete Go to Step 17 13 Reinstall the scan tool Can the scan tool communicate with the ECM Go to S...

Page 253: ...ENGINE CONTROLS 1F 85 DAEWOO T 154 BL2 3 BLANK...

Page 254: ...carefully to avoid any fuel spillage 3 The fuel pump should run about 2 seconds after the ignition is turned to the ON position 4 Insert a clear tube attached to the vent valve of the fuel pressure g...

Page 255: ...ENGINE CONTROLS 1F 87 DAEWOO T 154 BL2 3 BLANK...

Page 256: ...Absolute Pressure MAP Sensor Intermittent High Voltage Cnl No P0107 Manifold Absolute Pressure MAP Sensor Low Voltage A Yes P1107 Manifold Absolute Pressure MAP Sensor Intermittent Low Voltage Cnl No...

Page 257: ...0304 Cylinder 4 Misfire B Yes P0317 Rough Road Sensor Source Not Detected 1 5L SOHC Cnl No P0325 Knock System Internal Malfunction E Yes No P0327 Knock Sensor Circuit Fault E Yes No P0336 58x Cranksha...

Page 258: ...Signal M T only E Yes P0506 Idle Speed RPM Lower Than Desired Idle Speed E Yes P0507 Idle Speed RPM Higher Than Desired Idle Speed E Yes P0532 A C Pressure Sensor Low Voltage Cnl No P0533 A C Pressure...

Page 259: ...ENGINE CONTROLS 1F 90 DAEWOO T 154 BL2 3 BLANK...

Page 260: ...the Freeze Frame and Failure Records buff ers A history DTC is stored The ECM will substitute a fixed MAP value and use TP to control the fuel delivery the scan tool will not show a defaulted value Co...

Page 261: ...Step 2 Go to On Board Diagnostic System Check 2 1 Install a scan tool 2 Turn the ignition switch ON with the engine not running 3 Compare the Barometric Pressure BARO reading with a known good vehicl...

Page 262: ...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...

Page 263: ...ENGINE CONTROLS 1F 94 DAEWOO T 154 BL2 3 BLANK...

Page 264: ...ine load factors If the ECM detects a MAP signal voltage that is intermittently above the calculated value DTC P1106 will set Conditions for Setting the DTC No TP sensor fail conditions present Engine...

Page 265: ...tage Is a problem found Go to Step 9 Go to Step 5 5 Check for an intermittent short to voltage on the 5 volt reference B1 circuit between the ECM and the MAP Sensor Is a problem found Go to Step 9 Go...

Page 266: ...HC The MAP is less than 12 0 kPa The TP sensor is greater than or equal to 0 if the rpm is less than or equal to 1500 The TP sensor is greater than 10 0 if the rpm is greater than 1500 Action Taken Wh...

Page 267: ...Pressure MAP Sensor Low Voltage Step Action Value Yes No 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 With engi...

Page 268: ...OFF 2 Replace the engine control module ECM Is the action complete Go to Step 14 12 Check the MAP sensor signal circuit for the following conditions Open Short to ground Short to sensor ground Is a pr...

Page 269: ...ENGINE CONTROLS 1F 100 DAEWOO T 154 BL2 3 BLANK...

Page 270: ...compares the MAP sensor signal to calculated MAP based on Throttle Posi tion TP and various other engine load factors If the ECM detects a MAP signal voltage that is intermit tently below the calcula...

Page 271: ...ble DTC table Go Step 3 3 Check for a poor 5 volt reference circuit or Manifold Absolute Pressure MAP signal circuit terminal con nection at the MAP sensor Is a repair necessary Go to Step 5 Go to Ste...

Page 272: ...TP sensor is less than 20 if the rpm is less than or equal to 3000 The TP sensor is less than 30 if the rpm is greater than 3000 Action Taken When the DTC Sets The Malfunction Indicator Lamp MIL will...

Page 273: ...d A C High Side will be displayed high The vehicle will also remain in Open Loop 8 The MAP sensor vacuum source should only supply vacuum to the MAP sensor Check the vacuum port for a restriction caus...

Page 274: ...the 5 volt reference circuit for a short to voltage and repair as necessary Is a action complete Go to Step 14 Go to Step 12 10 Repair the vacuum source as necessary Is the action complete Go to Step...

Page 275: ...ENGINE CONTROLS 1F 106 DAEWOO T 154 BL2 3 BLANK...

Page 276: ...Indicator Lamp MIL will not illumi nate The ECM will store conditions which were pres ent when the DTC set as Failure Records data only This information will not be stored as Freeze Frame data A hist...

Page 277: ...EOBD System Check Is the system check complete Go to Step 2 Go to On Board Diag nostic System Check 2 1 Turn the ignition ON 2 Install the scan tool Is DTC P0113 set Go to applicable DTC table Go Ste...

Page 278: ...he sensor ground circuit 2 If a problem is found repair as necessary Is the repair complete Go to Step 9 Go to Diag nostic Aids 9 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start...

Page 279: ...ENGINE CONTROLS 1F 110 DAEWOO T 154 BL2 3 BLANK...

Page 280: ...not show the defaulted value Conditions for Clearing the MIL DTC The MIL will turn off after three four 1 5L SOHC consecutive ignition cycles in which the diagnostic runs without a fault A history DTC...

Page 281: ...ensor value below the specified value 30 C 22 F Go to Step 5 Go to Step 6 5 1 Turn the ignition switch OFF 2 Replace the IAT sensor Is the action complete Go to Step 9 6 1 Turn the ignition switch OFF...

Page 282: ...llumi nate The ECM will store conditions which were pres ent when the DTC was set as Failure Records data only This information will not be stored as Freeze Frame data A history DTC is stored Conditio...

Page 283: ...nsor that may be shorted above or below a certain temperature If this is the case replace the IAT sensor DTC P1112 Intake Air Temperature IAT Sensor Intermittent Low Voltage Step Action Value Yes No 1...

Page 284: ...red in the Freeze Frame and Failure Records buff ers A history DTC is stored The ECM will substitute a default value for IAT The scan tool will not show the defaulted value Conditions for Clearing the...

Page 285: ...4 Go to Diagnostic Aids 4 1 Disconnect the IAT sensor electrical connector 2 Jumper the IAT sensor signal circuit at terminal 2 and the IAT sensor ground circuit at terminal 1 together at the IAT sens...

Page 286: ...2 1 Using the scan tool clear the 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...

Page 287: ...ENGINE CONTROLS 1F 118 DAEWOO T 154 BL2 3 BLANK...

Page 288: ...re conditions which were pres ent when the DTC set as Failure Records data only This information will not be stored as Freeze Frame data A history DTC is stored Conditions for Clearing the MIL DTC A h...

Page 289: ...Value Yes No 1 Perform an On Board Diagnostic EOBD System Check Is the system check complete Go to Step 2 Go to On Board Diag nostic System Check 2 1 Turn the Ignition ON 2 Install the scan tool Is D...

Page 290: ...tore conditions which were pres ent when the DTC was set as Failure Records data only This information will not be stored as Freeze Frame data A history DTC is stored Conditions for Clearing the MIL D...

Page 291: ...ck complete Go to Step 2 Go to On Board Diagnostic System Check 2 1 Turn the ignition ON 2 Install the scan tool Is DTC P0118 set Go to applicable DTC Table Go to Step 3 3 Check the scan tool Is DTC P...

Page 292: ...the sensor ground circuit 2 If a problem is found repair as necessary Is the repair complete Go to Step 10 Go to Diag nostic Aids 10 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Sta...

Page 293: ...ENGINE CONTROLS 1F 124 DAEWOO T 154 BL2 3 BLANK...

Page 294: ...is stored Both cooling fan turns ON The ECM will substitute a default value for ECT The scan tool may not show the defaulted value Conditions for Clearing the MIL DTC The MIL will turn off after three...

Page 295: ...p 4 Go to Diag nostic Aids 4 Disconnect the ECT sensor electrical connector Is the ECT sensor value less than the specified val ue 30 C 22 F Go to Step 6 Go to Step 5 5 Check the ECT sensor signal cir...

Page 296: ...history DTC is stored Both cooling fan turns ON The ECM will substitute a default value for ECT The scan tool may not show the defaulted value Conditions for Clearing the MIL DTC The MIL will turn of...

Page 297: ...T electrical connector Is the ECT sensor value greater than the specified value 130 C 266 F Go to Step 6 Go to Step 5 5 Jumper the ECT sensor signal circuit at terminal 2 to chassis ground Is the ECT...

Page 298: ...tart 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 diag...

Page 299: ...ENGINE CONTROLS 1F 130 DAEWOO T 154 BL2 3 BLANK...

Page 300: ...e data A history DTC is stored Conditions for Clearing the MIL DTC The history DTC will clear after 40 consecutive warm up cycles in which the diagnostic runs without a fault DTC s can be cleared by u...

Page 301: ...for a poor sensor ground terminal M64 connection at the ECM Is a problem found Go to Step 7 Go to Step 6 6 Check for an intermittent open or a faulty splice in the sensor ground circuit Is a problem f...

Page 302: ...thout a fault The DTC s can be cleared using the scan tool Diagnostic Aids If a DTC P0122 cannot be duplicated the information in cluded in the Freeze Frame data can be useful Use the scan tool DTC in...

Page 303: ...d the TP sensor signal circuit terminal C together at the TP sensor electrical connector Is the TP sensor voltage above the specified value 4 v Go to Step 10 Go to Step 5 5 Connect a test light betwee...

Page 304: ...he 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...

Page 305: ...ENGINE CONTROLS 1F 136 DAEWOO T 154 BL2 3 BLANK...

Page 306: ...Frame data A history DTC is stored Conditions for Clearing the MIL DTC The history DTC will clear after 40 consecutive warm up cycles in which the diagnostic runs without a fault DTC P1122 can be cle...

Page 307: ...ce circuit terminal M32 connection at the ECM Is a problem found Go to Step 7 Go to Step 6 6 Check for an intermittent open or a faulty splice in the 5 volt reference circuit Is a problem found Go to...

Page 308: ...scan tool Diagnostic Aids If a DTC P0123 cannot be duplicated the information in cluded in the Freeze Frame data can be useful Use the scan tool DTC information data to determine the status of the DT...

Page 309: ...4 Go to Step 12 4 Disconnect the TP sensor electrical connector Is the TP sensor voltage less than the specified val ue 0 2 v Go to Step 5 Go to Step 6 5 Probe the TP sensor ground circuit terminal B...

Page 310: ...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 diagnosti...

Page 311: ...ENGINE CONTROLS 1F 142 DAEWOO T 154 BL2 3 BLANK...

Page 312: ...The ECT has increased a minimum amount based on ECT at engine start up Conditions for Setting the DTC Engine Running DTCs P0106 P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0201 P0202 P0203 P0204...

Page 313: ...een ECT sensor signal circuit and ground circuit terminals while moving the related con nectors and the wiring harness If a fault is induced the resistance reading will change This may help to isolate...

Page 314: ...esistance Table Go to Step 4 Go to Step 11 4 1 Turn the ignition OFF 2 Disconnect the ECT sensor electrical connector 3 Turn the ignition ON engine OFF Is the ECT sensor value less than the specified...

Page 315: ...12 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 specif...

Page 316: ...and degrade the O2S 1 performance Refer to Oxygen Sensor in this section Conditions for Setting the DTC Closed loop stoichometry The Engine Coolant Temperature ECT is greater than 60 q C 140F DTCs P0...

Page 317: ...electronic copy of the data taken when the malfunction occurred The information is then stored on the scan tool for later reference 2 This step determines if DTC P0131 is the result of a hard failure...

Page 318: ...the O2S 1 electrical connector 2 Using the scan tool clear the DTCs 3 Start the engine and idle at normal operating temperature 4 Operate the vehicle within the conditions for setting this DTC as spe...

Page 319: ...ENGINE CONTROLS 1F 150 DAEWOO T 154 BL2 3 BLANK...

Page 320: ...1 performance Refer to Oxygen Sensor in this section Conditions for Setting the DTC O2 sensor voltage is greater than 0 952 volts Closed loop stoichometry The Engine Coolant Temperature ECT is greater...

Page 321: ...C P0132 is the result of a hard failure or an intermittent condition It may be necessary to operate the vehicle within the Freeze Frame conditions and Conditions for Setting the DTC in order to duplic...

Page 322: ...ol clear the DTCs 3 Start the engine and idle at normal operating temperature 4 Operate the vehicle within the conditions for setting this DTC as specified in the supporting text Does the scan tool in...

Page 323: ...ENGINE CONTROLS 1F 154 DAEWOO T 154 BL2 3 BLANK...

Page 324: ...f the air reference and degrade O2S 1 performance Conditions for Setting the DTC Closed loop stoichiometry The engine run time is greater than 60 seconds 1 5L SOHC The O2S 1 average transition time be...

Page 325: ...haust indication The ECM will then reduce the amount of fuel deliv ered to the engine causing a severe surge or drive ability problem Test Description Number s below refer to the step number s on the...

Page 326: ...Step 10 8 1 Jumper the O2S 1 signal and low circuits terminals 1 and 2 to ground Does the scan tool indicate the voltage below the specified value 200 mv Go to Step 15 Go to Step 13 9 Repair the cond...

Page 327: ...tic Trouble Codes DTCs 2 Start the engine 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 ran and...

Page 328: ...8 q F The system voltage is greater than 10 volts The purge duty cycle D C is less than 20 The rpm is between 1500 and 3000 The airflow is between 9 and 30 g sec Engine running status within certain r...

Page 329: ...driveability problem Test Description Number s below refer to the step number s on the Diagnostic Chart 1 The On Board Diagnostic EOBD System Check prompts the technician to complete some basic check...

Page 330: ...S 1 Notice Before replacing the sensor the cause of the contamination must be determined and cor rected in order to prevent further damage to the sen sor Check for the following Fuel contamination Use...

Page 331: ...circuit problem found and corrected 5 Go to Step 15 Go to Step 14 14 1 Turn the Ignition switch OFF 2 Replace the ECM Is the repair complete Go to Step 15 15 1 Using the scan tool clear the Diagnostic...

Page 332: ...er than 10 volts The engine run time is greater than 60 seconds No related malfunctions See P0131 1 5L SOHC The O2S 1 voltage is stuck in range 0 3 0 6 volt The engine coolant temperature is greater t...

Page 333: ...n tool indicate CLOSED LOOP 80 q C 176 q F 1200 rpm Go to Step 3 Go Step 4 3 1 Turn the ignition ON with the engine OFF 2 Review the Freeze Frame data and note the parameters 3 Operate the vehicle wit...

Page 334: ...repair as necessary Is a repair necessary Go to Step 12 Go to Step 10 10 1 Turn the ignition switch OFF 2 Replace the ECM Is the repair complete Go to Step 12 11 Replace the O2S1 Is the repair comple...

Page 335: ...ENGINE CONTROLS 1F 166 DAEWOO T 154 BL2 3 BLANK...

Page 336: ...is out of range 0 4395 3 8 Engine coolant temperature is greater than 70 C 158 F The purge duty cycle D C is less than 20 Engine speed is between 1500 and 3000 rpm The airflow is between 9 and 30 g s...

Page 337: ...cing the affected sensors DTC P1134 Oxygen Sensor O2S 1 Transition Ratio Step Action Value Yes No 1 Perform an On Board Diagnostic EOBD System Check Is the system check complete Go to Step 2 Go to On...

Page 338: ...r signs of Fuel contamination Improper Room Temperature Vulcanizing RTV sealant white powdery coating on sensor Engine oil coolant consumption Are signs of contamination observed Go To Step 13 Go To S...

Page 339: ...ENGINE CONTROLS 1F 170 DAEWOO T 154 BL2 3 BLANK...

Page 340: ...atalyst s ability to convert exhaust emissions effective ly If the catalyst is functioning properly the HO2S 2 sig nal will be far less active than the signal produced by the Oxygen Sensor O2S 1 If th...

Page 341: ...between the three way cat alytic converter and the flange for leaks corrosion or for loose or missing hardware and repair as neces sary Poor connection or damaged harness Ensure that the HO2S 2 pigtai...

Page 342: ...d Does the scan tool indicate the HO2S 2 voltage within the specified value 350 mv 550 mv 0 35 v 0 55 v Go to Step 7 Go to Step 5 5 1 Turn the ignition switch OFF 2 Disconnect the engine control modul...

Page 343: ...ENGINE CONTROLS 1F 174 DAEWOO T 154 BL2 3 BLANK...

Page 344: ...catalyst s ability to convert exhaust emissions effective ly If the catalyst is functioning properly the HO2S 2 sig nal will be far less active than the signal produced by the Oxygen Sensor O2S 1 If t...

Page 345: ...hite deposit on the sensor Faulty HO2S 2 If HO2S 2 is internally shorted the HO2S 2 voltage displayed on a scan tool will be over 1 volt Disconnect the HO2S 2 and jumper the sensor low circuit to engi...

Page 346: ...rcuit terminal K36 Does the DVM indicate a voltage of the specified value 0 v r 0 5 v Go to Step 5 Go to Step 6 5 1 Reconnect the ECM electrical connectors 2 Turn the ignition switch ON with the engin...

Page 347: ...ENGINE CONTROLS 1F 178 DAEWOO T 154 BL2 3 BLANK...

Page 348: ...ity to convert exhaust emissions effective ly If the catalyst is functioning properly the HO2S 2 sig nal will be far less active than the signal produced by the Oxygen Sensor O2S 1 If the HO2S 2 pigta...

Page 349: ...the exhaust Check for the following conditions Improper mating Broken locks Improperly formed Damaged terminals Poor terminal to wire connection Damaged harness Intermittent test Observe HO2S 2 on the...

Page 350: ...th the engine OFF 2 Disconnect the HO2S 2 electrical connector 3 Jumper the HO2S 2 high and low circuits terminals A and B to ground Does the scan tool indicate the HO2S voltage below the specified va...

Page 351: ...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 h...

Page 352: ...to convert exhaust emissions effective ly If the catalyst is functioning properly the HO2S 2 sig nal will be far less active than the signal produced by the Oxygen Sensor O2S 1 If the HO2S 2 pigtail w...

Page 353: ...ntacting the exhaust Check for a poor connection or a damaged harness inspect the harness connectors for the following condi tions Improper mating Broken locks Improperly formed Damaged terminals Poor...

Page 354: ...p 9 6 Check the connections at the HO2S 2 connector and repair as necessary Is a repair necessary Go to Step 13 Go to Step 10 7 Check the connections at the HO2S 2 connector and repair as necessary Is...

Page 355: ...ENGINE CONTROLS 1F 186 DAEWOO T 154 BL2 3 BLANK...

Page 356: ...te The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers A history DTC is stored Conditions For Clea...

Page 357: ...lly toggle below the specified voltage Is the O2S voltage toggle 442 mV Go to Step 4 Go to DTC P0134 Oxygen Sensor No Activity 4 Check the items in Diagnostic Aids and repair or replace component as n...

Page 358: ...n TP is less than 80 The engine speed is between 700 and 6000 rpm The Barometric Pressure BARO is greater than 72 0 kPa The coolant temperature is between 70 q C 158 q F and 105 q C 221 q F The vehicl...

Page 359: ...a lean condition may determine the cause of the DTC being set and save diagnosis time 9 A vacuum leak can change the Fuel Trim Index and set DTC P0171 This step checks the intake man ifold for vacuum...

Page 360: ...below the specified value 25 Go to Step 15 Go to Step 9 7 1 Repair the malfunction found in Step 5 2 Recheck the Fuel Trim Index while operating the engine Is the Fuel Trim Index below the specified...

Page 361: ...a 35 40 psi Go to Step 14 Go to Fuel System Diag nosis 14 1 Start and idle the engine at normal operating temperature 2 The fuel pressure noted in the above step should drop by the indicated value Doe...

Page 362: ...mation will be stored in the freeze frame and failure records buffers A history DTC is stored Conditions for Clearing the MIL DTC The MIL will turn off after three four 1 5L SOHC consecutive ignition...

Page 363: ...sing the scan tool observe the Oxygen Sensor O2S 1 voltage while running the engine at the specified temperature and rpm 2 The O2S 1 voltage should vary from the specified voltage and occasionally tog...

Page 364: ...37 P0341 P0342 P0402 P0404 P0405 P0406 P0443 P0506 P0507 P1167 P1171 and P1404 are not set The Throttle Position TP is less than 80 The engine speed is between 700 and 6000 rpm The Barometric Pressure...

Page 365: ...o Diagnostic Aids for additional checks and information DTC P0172 Fuel Trim System Too Rich Step Action Value Yes No 1 Perform an On Board Diagnostic EOBD System Check Is the system check complete Go...

Page 366: ...sary Does the inspection reveal a condition requiring a repair Go to Step 21 Go to Step 13 13 1 Disconnect the vacuum hose from the fuel pressure regulator and inspect the hose for the presence of fue...

Page 367: ...nostic Aids 19 1 Check the TP sensor mounting screws 2 If they are loose or missing tighten or replace them as necessary 3 If the screws are OK replace the TP sensor Is the action complete Go to Step...

Page 368: ...1F 199 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F210...

Page 369: ...history DTC will clear after 40 consecutive warm up cycles without a fault The DTC s can be cleared by using the scan tool Diagnostic Aids An injector driver circuit that is open or shorted to volt a...

Page 370: ...FF 4 With a test light connected to ground probe the driver circuit terminal M25 Does the test light illuminate Go to Step 7 Go to Step 6 6 Repair the short to ground or open in the injector driver ci...

Page 371: ...ENGINE CONTROLS 1F 202 DAEWOO T 154 BL2 3 BLANK...

Page 372: ...1F 203 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F210...

Page 373: ...cause a DTC P0202 to set It will also cause a misfire due to an inoperative injector A misfire DTC should also be set indicating which injector is inopera tive Long term and short term fuel trims that...

Page 374: ...the injector driver circuit Is the action complete Go to Step 10 7 1 Disconnect the injector 2 wiring connection 2 With a test light connected to ground probe the driver circuit terminal 2 Does the te...

Page 375: ...ENGINE CONTROLS 1F 206 DAEWOO T 154 BL2 3 BLANK...

Page 376: ...1F 207 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F210...

Page 377: ...0203 to set It will also cause a misfire due to an inoperative injector A misfire DTC should also be set indicating which injector is inopera tive Long term and short term fuel trims that are excessiv...

Page 378: ...in the injector driver circuit Is the action complete Go to Step 10 7 1 Disconnect the injector 3 wiring connection 2 With a test light connected to ground probe the driver circuit terminal 2 Does th...

Page 379: ...ENGINE CONTROLS 1F 210 DAEWOO T 154 BL2 3 BLANK...

Page 380: ...1F 211 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F210...

Page 381: ...TC P0204 to set It will also cause a misfire due to an inoperative injector A misfire DTC should also be set indicating which injector is inopera tive Long term and short term fuel trims that are exce...

Page 382: ...in the injector driver circuit Is the action complete Go to Step 10 7 1 Disconnect the injector 4 wiring connection 2 With a test light connected to ground probe the driver circuit terminal 2 Does the...

Page 383: ...ENGINE CONTROLS 1F 214 DAEWOO T 154 BL2 3 BLANK...

Page 384: ...1F 215 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F220...

Page 385: ...etween 11 and 16 volts Coolant temperature is between 7 q C 19 4 q F and 120 q C 248 q F There is the correct ratio between Crankshaft Posi tion CKP sensor pulses and CMP sensor pulses 1 5L SOHC Engin...

Page 386: ...nd intake manifold sealing surfaces 5 When all the accumulators are relatively equal then the misfire is being caused by something that affects the entire engine When they are not then the mis fire is...

Page 387: ...tall a fuel pressure gauge 3 Observe the fuel pressure with the engine running Is the fuel pressure within the specified value 284 325 kPa 41 to 47 psi Go to Step 8 Go to Fuel System Diag nosis 8 Chec...

Page 388: ...k plug tester did not spark Is the resistance of the spark plug cable less than the specified value 30 000 Go to Step 21 Go to Step 25 21 Inspect the engine control module ECM connector and connection...

Page 389: ...ENGINE CONTROLS 1F 220 DAEWOO T 154 BL2 3 BLANK...

Page 390: ...1F 221 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F220...

Page 391: ...een 11 and 16 volts Coolant temperature is between 7 q C 19 4 q F and 120 q C 248 q F There is the correct ratio between Crankshaft Posi tion CKP sensor pulses and CMP sensor pulses 1 5L SOHC Engine r...

Page 392: ...manifold sealing surfaces 5 When all the accumulators are relatively equal then the misfire is being caused by something that affects the entire engine When they are not then the mis fire is being ca...

Page 393: ...1 Turn the engine OFF 2 Install a fuel pressure gauge 3 Observe the fuel pressure with the engine running Is the fuel pressure within the specified value 284 325 kPa 41 47 psi Go to Step 8 Go to Fuel...

Page 394: ...Is the resistance of the spark plug cable less than the specified value 30 000 Go to Step 21 Go to Step 25 21 Inspect the engine control module ECM connector and connections Are the connections OK Go...

Page 395: ...ENGINE CONTROLS 1F 224 DAEWOO T 154 BL2 3 BLANK...

Page 396: ...1F 225 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F220...

Page 397: ...een 11 and 16 volts Coolant temperature is between 7 q C 19 4 q F and 120 q C 248 q F There is the correct ratio between Crankshaft Posi tion CKP sensor pulses and CMP sensor pulses 1 5L SOHC Engine r...

Page 398: ...e manifold sealing surfaces 5 When all the accumulators are relatively equal then the misfire is being caused by something that affects the entire engine When they are not then the misfire is being ca...

Page 399: ...OFF 2 Install a fuel pressure gauge 3 Observe the fuel pressure with the engine running Is the fuel pressure within the specified value 284 325 kPa 41 47 psi Go to Step 8 Go to Fuel System Diagnosis 8...

Page 400: ...Is the resistance of the spark plug cable less than the specified value 30 000 Go to Step 21 Go to Step 25 21 Inspect the engine control module ECM connector and connections Are the connections OK Go...

Page 401: ...ENGINE CONTROLS 1F 230 DAEWOO T 154 BL2 3 BLANK...

Page 402: ...1F 231 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F220...

Page 403: ...een 11 and 16 volts Coolant temperature is between 7 q C 19 4 q F and 120 q C 248 q F There is the correct ratio between Crankshaft Posi tion CKP sensor pulses and CMP sensor pulses 1 5L SOHC Engine r...

Page 404: ...manifold sealing surfaces 5 When all the accumulators are relatively equal then the misfire is being caused by something that affects the entire engine When they are not then the mis fire is being ca...

Page 405: ...OFF 2 Install a fuel pressure gauge 3 Observe the fuel pressure with the engine running Is the fuel pressure within the specified value 284 325 kPa 41 47 psi Go to Step 8 Go to Fuel System Diagnosis 8...

Page 406: ...Is the resistance of the spark plug cable less than the specified value 30 000 Go to Step 21 Go to Step 25 21 Inspect the engine control module ECM connector and connections Are the connections OK Go...

Page 407: ...ENGINE CONTROLS 1F 237 DAEWOO T 154 BL2 3 BLANK...

Page 408: ...1F 238 ENGINE CONTROLS DAEWOO T 154 BL2 3 FAA1F220...

Page 409: ...nd 16 volts Coolant temperature is between 7 q C 19 4 q F and 120 q C 248 q F There is the correct ratio between Crankshaft Posi tion CKP sensor pulses and CMP sensor pulses 1 5L SOHC Engine run time...

Page 410: ...anifold sealing surfaces 5 When all the accumulators are relatively equal then the misfire is being caused by something that affects the entire engine When they are not then the misfire is being cause...

Page 411: ...OFF 2 Install a fuel pressure gauge 3 Observe the fuel pressure with the engine running Is the fuel pressure within the specified value 284 325 kPa 41 47 psi Go to Step 8 Go to Fuel System Diagnosis 8...

Page 412: ...Is the resistance of the spark plug cable less than the specified value 30 000 Go to Step 21 Go to Step 25 21 Inspect the engine control module ECM connector and connections Are the connections OK Go...

Page 413: ...ENGINE CONTROLS 1F 243 DAEWOO T 154 BL2 3 BLANK...

Page 414: ...Trouble Code DTC will be stored Conditions for Setting the DTC ECM cannot detect any rough road source Engine run time is greater than or equal to 10 sec onds Action Taken When the DTC Sets The Malfun...

Page 415: ...or terminal K21 and repair as necessary Is the repair complete Go to Step 11 6 1 Reconnect the ECM and G sensor connectors 2 Turn the ignition ON 3 Probe the voltage at terminal 2 of G sensor Is the v...

Page 416: ...T 154 BL2 3 DTC P0317 Rough Road Sensor Source Not Detected 1 5L SOHC Cont d Step Action Value Yes No 12 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to...

Page 417: ...ENGINE CONTROLS 1F 247 DAEWOO T 154 BL2 3 BLANK...

Page 418: ...1 5L SOHC The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buff ers A history DTC is stored Conditions...

Page 419: ...tions for Setting The DTC as noted Is DTC P0325 set Go to Step 4 Go to Step 7 4 Listen to the engine while raising and lowering the engine speed Is a knock or audible noise present Go to Step 5 Go to...

Page 420: ...The MIL will illuminate after three consecutive trip with fail 1 5L SOHC The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame a...

Page 421: ...repro grammed Refer to the latest Techline procedure for ECM reprogramming DTC P0327 Knock Sensor Circuit Fault Step Action Value Yes No 1 Perform an On Board Diagnostic EOBD System Check Is the syst...

Page 422: ...o to Step 10 10 Check the KS signal circuit for an open or a short to ground or voltage and repair as necessary Is a repair necessary Go to Step 12 Go to Step 11 11 1 Turn the ignition switch OFF 2 Re...

Page 423: ...ENGINE CONTROLS 1F 253 DAEWOO T 154 BL2 3 BLANK...

Page 424: ...s for Clearing the MIL DTC The ECM will turn the MIL off on the third fourth 1 5L SOHC consecutive trip cycle dur ing which the diagnostic has been run and the fault condition is no longer present A h...

Page 425: ...the Crankshaft Position CKP sensor 2 Check for an open or a short to ground in the 58X high circuit between the CKP sensor connector and the ECM harness connector Is a problem found Go to Step 5 Go to...

Page 426: ...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 di...

Page 427: ...ENGINE CONTROLS 1F 257 DAEWOO T 154 BL2 3 BLANK...

Page 428: ...ning procedure always set the vehicle parking brake and block the drive wheels Release the throttle immedi ately when the engine starts to decelerate Once the learn procedure is completed engine contr...

Page 429: ...iation has been learned 65 C 149 F 4000 rpm Go to Step 5 Go to Step 3 3 Attempt the CKP system variation procedure as many times as the specified value Does the scan tool indicate that the CKP system...

Page 430: ...Freeze Frame and in the Failure Records data A history DTC is stored Conditions for Clearing the MIL DTC The ECM will turn the MIL OFF on the third fourth 1 5L SOHC consecutive trip cycle during which...

Page 431: ...N with the engine OFF 4 Using a Digital Voltmeter DVM check the voltage between the CKP sensor wiring harness connector Powertrain Control Module Engine Control Module ECM side terminal 1 and ground D...

Page 432: ...10 10 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine 3 Operate the vehicle within the conditions for setting this DTC as specified in the supporting text Does the sca...

Page 433: ...ENGINE CONTROLS 1F 263 DAEWOO T 154 BL2 3 BLANK...

Page 434: ...ement When the ECM cannot use the information from the CMP sensor a Diagnostic Trouble Code DTC is set and the ECM will fuel the engine using the Al ternating Synchronous Double Fire ASDF method Condi...

Page 435: ...or connection in any of the circuits at the CMP will cause the CMP Active Counter will stop incre menting 14 The replacement ECM must be repro grammed Refer to the latest Techline Procedure for ECM re...

Page 436: ...ary Is the repair complete Go to Step 15 11 Check for a poor connection or open in the CMP ground circuit and repair as necessary Is the repair complete Go to Step 15 12 Check for a poor connection in...

Page 437: ...ENGINE CONTROLS 1F 267 DAEWOO T 154 BL2 3 BLANK...

Page 438: ...nformation from the CMP sensor a Diagnostic Trouble Code DTC is set and the ECM will fuel the engine using the Al ternating Synchronous Double Fire ASDF method Conditions for Setting the DTC Engine is...

Page 439: ...er to the latest Techline procedure for ECM reprogramming DTC P0342 Camshaft Position CMP Sensor No Signal Step Action Value s Yes No 1 Perform an On Board Diagnostic EOBD System Check Is the system c...

Page 440: ...on in the CMP signal cir cuit terminal and repair as necessary Is the repair complete Go to Step 13 Go to Step 12 11 1 Turn the ignition OFF 2 Replace the CMP Is the repair complete Go to Step 13 12 1...

Page 441: ...ENGINE CONTROLS 1F 271 DAEWOO T 154 BL2 3 BLANK...

Page 442: ...1F 272 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F240...

Page 443: ...A history DTC will clear after 40 consecutive warm up cycles have occurred without a fault DTC s can be cleared by using the scan tool Diagnostic Aids An intermittent may be caused by a poor connecti...

Page 444: ...ignition control circuit for a short to ground Is a problem found Go to Step 8 Go to Step 5 5 Check the ignition control circuit for a short to volt age Is a problem found Go to Step 8 Go to Step 6 6...

Page 445: ...ENGINE CONTROLS 1F 275 DAEWOO T 154 BL2 3 BLANK...

Page 446: ...1F 276 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F240...

Page 447: ...0 consecutive warm up cycles have occurred without a fault DTC s can be cleared by using the scan tool Diagnostic Aids An intermittent may be caused by a poor connection rubbed through wire insulation...

Page 448: ...ignition control circuit for a short to ground Is a problem found Go to Step 8 Go to Step 5 5 Check the ignition control circuit for a short to volt age Is a problem found Go to Step 8 Go to Step 6 6...

Page 449: ...ENGINE CONTROLS 1F 279 DAEWOO T 154 BL2 3 BLANK...

Page 450: ...r equal to 10 sec onds Action Taken When DTC Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were pres ent when the DTC set as Failure Records data...

Page 451: ...nditions as noted 4 Using the scan tool monitor specific Diagnostic Trouble Code DTC info for DTC P1391 Does the scan tool indicate that DTC P1391 failed Go to Step 4 Go to Step 3 3 1 Check for the fo...

Page 452: ...for a poor connection at the G sensor 2 If a problem is found repair as necessary Is a problem found Go to Step 14 Go to Step 11 11 1 Turn the ignition OFF 2 Replace the G sensor Is the repair comple...

Page 453: ...ENGINE CONTROLS 1F 283 DAEWOO T 154 BL2 3 BLANK...

Page 454: ...ut a fault D DTC s can be cleared by using the scan tool Diagnostic Aids Check for the following conditions D Poor connection at the ECM Inspect the har ness connections for backed out terminals impro...

Page 455: ...tor 3 Observe the G sensor value displayed on the scan tool Is the G sensor value near the specified value 4 95 v Go to Step 9 Go to Step 5 5 1 Turn the ignition OFF 2 Disconnect the engine control mo...

Page 456: ...ngine 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 ran...

Page 457: ...ENGINE CONTROLS 1F 287 DAEWOO T 154 BL2 3 BLANK...

Page 458: ...t D DTC s can be cleared by using the scan tool Diagnostic Aids Check for the following conditions D Poor connection at the ECM Inspect the har ness connections for backed out terminals improper matin...

Page 459: ...circuit terminal 3 with a test light to B Is the test light ON Go to Step 7 Go to Step 9 6 1 Check the G sensor signal circuit for a short to voltage or a short to the 5 volt reference circuit 2 If t...

Page 460: ...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 ra...

Page 461: ...ENGINE CONTROLS 1F 291 DAEWOO T 154 BL2 3 BLANK...

Page 462: ...out a fault D The DTC s can be cleared by using the scan tool Diagnostic Aids Check for the following conditions D Poor connection at the ECM Inspect the har ness connections for backed out terminals...

Page 463: ...1 Turn the ignition OFF 2 Disconnect the engine control module ECM and check for an open or short in the wire between ECM connector terminal M53 and Electronic Brake Control Module EBCM connector term...

Page 464: ...s can be cleared by using the scan tool Diagnostic Aids Check for the following conditions D Poor connection at the ECM Inspect the har ness connections for backed out terminals improper mating broken...

Page 465: ...the ignition OFF 2 Disconnect the engine control module ECM and check for an open or short in the wire between ECM connector terminal M53 and Electronic Brake Control Module EBCM connector terminal 24...

Page 466: ...ve pintle position is sent to the ECM This feedback signal can also be monitored on a scan tool and is the actual position of the EGR pintle The Actual EGR Position should always be near the commanded...

Page 467: ...open determines whether the EGR system is totally restricted or par tially restricted 3 Visually and physically inspect the EGR passages and valve for excessive carbon deposits or damage 4 Be sure al...

Page 468: ...value less than the specified value 10 seconds 60 mph 97 km h 20 mph 32 km h 0 mph Go to Step 3 Go to Step 6 6 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle...

Page 469: ...ENGINE CONTROLS 1F 299 DAEWOO T 154 BL2 3 BLANK...

Page 470: ...1F 300 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F290...

Page 471: ...eze Frame and Failure Records buff ers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after three four 1 5L SOHC consecutive ignition cycles in which the diagnos...

Page 472: ...en found at this point and no additional DTCs were set refer to Diagnostic Aids in this section for additional checks and infor mation DTC P0402 Exhaust Gas Recirculation EGR Excessive Flow Step Actio...

Page 473: ...tep 19 Go to Step 17 14 Check the 5 v reference circuit for a short to voltage and repair as necessary Is a repair necessary Go to Step 19 Go to Step 12 15 Check the control circuit at terminal 1 for...

Page 474: ...1F 304 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F290...

Page 475: ...ill record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buff ers D A history DTC is stored D EGR is disabled Conditions...

Page 476: ...ill not be learned 20 If no malfunctions have been found at this point and no additional DTCs were set refer to Diagnostic Aids in this section for additional checks and infor mation DTC P0404 Exhaust...

Page 477: ...air necessary Go to Step 19 Go to Step 17 14 Check the 5 volt reference circuit for a short to volt age and repair as necessary Is a repair necessary Go to Step 19 Go to Step 12 15 Check the control c...

Page 478: ...1F 308 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F290...

Page 479: ...d in the Freeze Frame and Failure Records buff ers D A history Diagnostic Trouble Code DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after three four 1 5L SOHC consecutive...

Page 480: ...e Desired EGR Position 25 50 75 100 Go to Step 13 Go to Step 3 3 Disconnect the EGR valve electrical connector Is the Actual EGR Position near the specified value 100 Go to Step 4 Go to Step 5 4 Check...

Page 481: ...to Step 11 13 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 DT...

Page 482: ...1F 312 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F290...

Page 483: ...D EGR is disabled Conditions for Clearing the MIL DTC D The MIL will turn off after three four 1 5L SOHC consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will...

Page 484: ...ecirculation EGR valve to the specified values Does the Actual EGR Position follow the Desired EGR Position 25 50 75 100 Go to Step 15 Go to Step 3 3 1 Turn the ignition switch ON with the engine OFF...

Page 485: ...rn the ignition switch OFF 2 Replace the engine control module ECM Is the action complete Go to Step 15 14 Check the affected circuit for a poor connection or proper terminal tension at the ECM and re...

Page 486: ...1F 316 ENGINE CONTROLS DAEWOO T 154 BL2 3 TAA1F290...

Page 487: ...ditions for Clearing the MIL DTC D The MIL will turn off after three four 1 5L SOHC consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecu...

Page 488: ...lation EGR valve to the specified values Does the Actual EGR Position follow the Desired EGR Position 25 50 75 100 Go to Step 14 Go to Step 3 3 1 Turn the ignition switch ON with the engine OFF 2 Disc...

Page 489: ...ECM Is the action complete Go to Step 14 13 Check the affected circuit for a poor connection or proper terminal tension at the ECM and repair as necessary Is a repair necessary Go to Step 14 Go to St...

Page 490: ...is con sidered to be bad and the Malfunction Indicator Lamp MIL will be illuminated Conditions for Setting the DTC D Oxygen storage capacity index time is less than 0 8 second D DTC s P0106 P0107 P010...

Page 491: ...able This creates an electronic copy of the data taken when the malfunction occurred The information is then stored on the scan tool for later reference 2 If any component DTCs are set diagnose those...

Page 492: ...ed Oxygen Sensor HO2S 2 Is a problem found Go to Step 4 Go to Step 5 4 Repair the exhaust system as necessary Is the action complete Go to Step 6 5 Repair the three way catalytic converter Is the acti...

Page 493: ...ENGINE CONTROLS 1F 323 DAEWOO T 154 BL2 3 BLANK...

Page 494: ...termined by mass air temperature If the ECM detects open or shorted EVAP canister control circuits DTC P0443 will set Conditions for Setting the DTC D Ignition ON D Read the fault feedback signal from...

Page 495: ...r reference 2 Listen for an audible click when the solenoid oper ates Be sure that both the ON and the OFF states are commanded Repeat the commands as neces sary 3 This check can detect a partially sh...

Page 496: ...connect the ECM connector containing the solenoid control circuit 4 Turn the ignition ON 5 With a fused jumper wire connected to ground probe the solenoid control circuit at terminal M4 in the ECM har...

Page 497: ...54 BL2 3 DTC P0443 Evaporative Emission EVAP Purge Control Circuit Fault Cont d Step Action Value Yes No 15 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go...

Page 498: ...tage into mph km h and than supplies the necessary signal to the instrument panel for speedometer odometer operation and to the cruise control module and multi function alarm module operation This Dia...

Page 499: ...conditions D Backed out terminals D Improper mating D Broken locks D Improperly formed D Damaged terminals D Poor terminal to wire connection D Physical damage to the wiring harness Ensure the VSS is...

Page 500: ...Step 12 Go to Step 4 4 1 Turn the ignition OFF 2 Disconnect the Vehicle Speed Sensor VSS connector 3 Turn the ignition ON with the engine OFF 4 Using a Digital Voltmeter DVM connected to ground measur...

Page 501: ...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 di...

Page 502: ...de This Diagnostic Trouble Code DTC determines if a low idle condition exists as defined as 100 rpm below the de sired idle rpm Conditions for Setting the DTC D Idle engine speed error is greater than...

Page 503: ...r later reference 2 A normally operating IAC system will be able to be extended and retracted by a scan tool and change the engine idle rpm Valve movement is verified by an engine rpm change 3 If the...

Page 504: ...B and C 2 Measure the resistance across the IAC terminals A and D Is the resistance across terminals B and C and ter minals A and D infinite Go to Step 15 Go to Step 13 5 1 Turn the Ignition switch ON...

Page 505: ...IAC valve Is the action complete Go to Step 15 14 1 Turn the ignition OFF 2 Replace the ECM Is the action complete Go to Step 15 15 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Star...

Page 506: ...de This Diagnostic Trouble Code DTC determines if a high idle condition exists as defined as 200 rpm above the desired idle rpm Conditions for Setting the DTC D Idle engine speed error is greater than...

Page 507: ...checked by checking the IAC valves internal resistance 5 The IAC circuits always have ground or voltage sig nals on them in pairs If the test light illuminates on more or less than 2 terminals 1 of t...

Page 508: ...ight connected to B probe the IAC electrical connector terminals Does the test light illuminate on 2 terminals Go to Step 8 Go to Step 9 7 Check for an open or short to ground in the IAC valve high an...

Page 509: ...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 t...

Page 510: ...ion Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were pres ent when the DTC set as Failure Records data only This information will not be stored as Freeze Frame data D...

Page 511: ...low the specified value 0 06 v Go to Step 3 Go Step 4 3 1 Turn the ignition switch OFF 2 Disconnect the ACP sensor electrical connector 3 Jumper the ACP signal circuit terminal 3 to the 5 volt referen...

Page 512: ...the following conditions D Open D Short to ground D Short to sensor ground Is a problem found Go to Step 13 Go to Step 11 13 Repair the ACP sensor signal circuit Is the action complete Go to Step 14...

Page 513: ...ENGINE CONTROLS 1F 343 DAEWOO T 154 BL2 3 BLANK...

Page 514: ...nction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were pres ent when the DTC set as Failure Records data only This information will not be stored as Freeze Frame dat...

Page 515: ...elow the specified value 4 9 v Go to Step 3 Go Step 4 3 1 Turn the ignition switch OFF 2 Disconnect the ACP sensor electrical connector 3 Jumper the ACP signal circuit terminal 3 to the 5 volt referen...

Page 516: ...following conditions D Short to voltage D Short to sensor 5 volt reference circuit Is a problem found Go to Step 13 Go to Step 11 13 Repair the ACP sensor signal circuit Is the action complete Go to S...

Page 517: ...ENGINE CONTROLS 1F 347 DAEWOO T 154 BL2 3 BLANK...

Page 518: ...w a calibrated value Conditions for Setting the DTC D Ignition ON D The system voltage is less than 11 volts 1 5L SOHC Action Taken When the DTC Sets D The Malfunction Indicator Lamp MIL will not illu...

Page 519: ...alfunctions have been found at this point and no additional DTCs were set refer to Diagnostic Aids in this section for additional checks and infor mation DTC P0562 System Voltage Engine Side Too Low S...

Page 520: ...ce the ECM Is the action complete Go to Step 8 8 1 Using the scan tool clear the DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the conditions for settin...

Page 521: ...ENGINE CONTROLS 1F 351 DAEWOO T 154 BL2 3 BLANK...

Page 522: ...gnition ON D The ignition voltage is greater than 16 volts Action Taken When the DTC Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were pres ent...

Page 523: ...and infor mation DTC P0563 System Voltage Engine Side Too High Step Action Value s Yes No 1 Perform an On Board Diagnostic EOBD System Check Is the system check complete Go to Step 2 Go to On Board Di...

Page 524: ...be reliable This information will be stored in the Freeze Frame and Failure Re cords buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after three four 1 5L...

Page 525: ...o specific step s on the diagnostic table 1 On Board Diagnostic EOBD System Check prompts the technician to complete some basic checks and store the freeze frame and failure re cords data on the scan...

Page 526: ...e 1 On Board Diagnostic EOBD System Check prompts the technician to complete some basic checks and store the freeze frame and failure re cords data on the scan tool if applicable This creates an elect...

Page 527: ...DAEWOO T 154 BL2 3 BLANK...

Page 528: ...Setting the DTC D Ignition ON D ECM release time window expired 1 5L SOHC D Immobilizer option auto detected D Vehicle Speed Sensor VSS is less than 318 mph 512 km h Action Taken When the DTC Sets D...

Page 529: ...2 Read the IMMO ECM CODE message Does the message ID CODES ARE SAME appear Go to Step 5 Go to Section 9T Identification ID Code Re programming 5 Check for an open serial data wire between the immobili...

Page 530: ...ns for Setting the DTC D Ignition ON D ECM release time window expired D Immobilizer option selected 1 5L SOHC D Vehicle Speed Sensor VSS is less than 318 mph 512 km h Action Taken When the DTC Sets D...

Page 531: ...nu 2 Read the IMMO ECM CODE message Does the message ID CODES ARE SAME appear Go to Step 5 Go to Section 9T Identification ID Code Re programming 5 Check for an open serial data wire between the immob...

Page 532: ...ure re cords data on the scan tool if applicable This creates an electronic copy of the data taken when the malfunction occurred The information is then stored on the scan tool for later reference 3 T...

Page 533: ...technician to complete some basic checks and store the freeze frame and failure re cords data on the scan tool if applicable This creates an electronic copy of the data taken when the malfunction occu...

Page 534: ...terminal not fully seated in the connector D Improperly formed or damaged terminal D All connector terminals in the problem circuit should be carefully checked for proper contact tension D Poor termi...

Page 535: ...alue to specifications using the Temperature Vs Resistance table for DTCs P1111 and P1114 3 If the resistance is not the same replace the faulty sensor Is the repair complete System OK 4 1 Check for a...

Page 536: ...th a resistance that is out of specifications Is the repair complete System OK 15 Perform an injector balance test Is the problem found Go to Step 16 Go to Step 17 16 Replace any restricted or leaking...

Page 537: ...e base idle setting to specifications Is the repair complete System OK 29 Repair the fuel system as needed Is the repair complete System OK 30 Replace the ECM Is the repair complete System OK SURGES O...

Page 538: ...ltage 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 11 Go to Step 12 11 Repair or replace any i...

Page 539: ...Check for a restricted fuel filter or contaminated fuel Is the problem found Go to Step 8 Go to Step 9 8 Repair or replace any components as needed Is the repair complete System OK 9 1 Check the ignit...

Page 540: ...rating of the value specified 2 Reevaluate the vehicle s performance Does the detonation problem still exist 81 95 octane Go to Step 3 System OK 3 1 Inspect for low engine coolant 2 Check for restrict...

Page 541: ...kPa 41 47 psi Go to Step 11 Go to Step 12 11 Repair or replace the fuel system components as needed Is the repair complete System OK 12 1 Inspect for carbon buildup inside the engine 2 Remove the carb...

Page 542: ...cy 2 Inspect the fuel for water contamination 3 Check the canister purge system for proper operation Is the problem found Go to Step 5 Go to Step 6 5 Repair or replace any components as needed Is the...

Page 543: ...irs complete 12 16 v System OK CUTS OUT MISSES Definition Steady pulsation or jerking that follows engine speed usually more pronounced as engine load increases The exhaust has a steady spitting sound...

Page 544: ...Note the test light while cranking the engine for each fuel injector Does the test light blink for all of the fuel injectors Go to Step 13 Go to Step 12 12 1 Repair or replace the faulty injector driv...

Page 545: ...Go to Step 2 Go to Important Preliminary Checks 2 1 Inspect the air filter for excessive contamination 2 Inspect for fuel system leaks Are all needed checks complete Go to Step 3 3 1 Inspect the spark...

Page 546: ...age that may cause incorrect Throttle Position TP sensor voltage 2 Check the TP sensor voltage reading with the throttle closed Is the TP sensor voltage within the value specified 0 4 0 8 v Go to Step...

Page 547: ...e repair complete System OK 18 Perform an injector balance test Is the problem found Go to Step 19 Go to Step 20 19 Replace any leaking or restricted fuel injectors Is the repair complete System OK 20...

Page 548: ...s complete System OK EXCESSIVE EXHAUST EMISSIONS OR ODORS Definition A vehicle fails an emission test The vehicle has an excessive rotten egg smell Excessive odors do not necessarily indicate excessiv...

Page 549: ...e throttle body and the throttle plate and inside the engine Remove with a top engine cleaner 4 Check the Exhaust Gas Recirculation EGR valve for not opening 5 Check for proper Positive Crankcase Vent...

Page 550: ...e repair complete System OK 4 1 Check the fuel system operation 2 Check the fuel injectors by performing an injector balance test Is the problem found Go to Step 5 Go to Step 6 5 Repair or replace any...

Page 551: ...cting the fuel lines 1 Relieve the fuel pressure Refer to Fuel Pump in this section 2 Disconnect the negative battery cable 3 Drain the fuel tank 4 Disconnect the parking brake cable retainer clamps a...

Page 552: ...14 Carefully lower the fuel tank 15 Remove the fuel tank 16 Transfer any parts as needed A102F068 Installation Procedure 1 Raise the fuel tank into position 2 Install the fuel tank mounting bolts Tig...

Page 553: ...l Procedures Caution The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pres sure before disconnecting the fuel...

Page 554: ...el pump assembly connector 6 Install the fuel pump outlet line 7 Install the fuel tank return line 8 Install the pump access cover 9 Connect the negative battery cable 10 Perform an operational check...

Page 555: ...uel injector O ring seals and the retaining clip 8 Remove the fuel rail with the fuel injectors attached A102F007 9 Remove the fuel injector retainer clips 10 Remove the fuel injectors by pulling them...

Page 556: ...line 8 Connect the fuel injector harness connectors Ro tate the fuel injector as required to avoid stretching the wire harness 9 Install the fuel pressure regulator Refer to Fuel Pressure Regulator SO...

Page 557: ...ENGINE CONTROLS 1F 387 DAEWOO T 154 BL2 3...

Page 558: ...g the fuel lines 1 Relieve the fuel pressure Refer to Fuel Pump in this section 2 Disconnect the negative battery cable 3 Disconnect the fuel line at the fuel pressure regulator by sliding the connect...

Page 559: ...tor into the fuel rail body 3 Install the retaining bolt Tighten Tighten the fuel pressure regulator retaining bolt to 12 NSm 106 lb in 4 Connect the vacuum hose to the fuel pressure regu lator 5 Conn...

Page 560: ...uel injection system 4 Carefully remove the ECT sensor from the cylinder head underneath the electronic ignition EI system ignition coil A102F002 Installation Procedure 1 Coat the threads on the ECT s...

Page 561: ...OO T 154 BL2 3 A102F023 THROTTLE POSITION SENSOR TYPICAL Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the throttle position TP sensor connec tor 3 Remove the TP sensor retain...

Page 562: ...bolts to 2 NSm 18 lb in 3 Connect the TP sensor connector 4 Connect the negative battery cable A102F095 THROTTLE BODY TYPICAL Removal Procedure 1 Disconnect the negative battery cable 2 Remove the air...

Page 563: ...ing dis assembly in a cold immersion type cleaner The throttle position sensor and the idle air control valve should not come in contact with any solvent or cleaner as they may be damaged 2 Clean the...

Page 564: ...permanently at tached pigtail and connector This pigtail should not be removed from the oxygen sensor Damage or removal of the pigtail or the connector could affect proper opera tion of the oxygen sen...

Page 565: ...d applied to the threads If a sensor is removed from any engine and if for any reason it is to be reinstalled the threads must have anti seize compound applied before reinstallation 1 Coat the threads...

Page 566: ...402G002 3 Remove the heated oxygen sensor HO2S 2 A402G002 Installation Procedure 1 Install the HO2S 2 Tighten Tighten the heated oxygen sensor to 41 NSm 30 lb ft A402F067 2 Connect the electrical conn...

Page 567: ...s on the worm drive 4 Remove the IAC valve 5 Clean the IAC valve O ring seal area the pintle valve seat and the air passage with a suitable fuel system cleaner Do not use methyl ethyl ketone A102F010...

Page 568: ...009 3 Install the IAC valve retaining bolts Tighten Tighten the idle air control valve retaining bolts to 3 NSm 27 lb in 4 Connect the IAC valve connector 5 Connect the negative battery cable 6 Start...

Page 569: ...sor to the mounting bracket A102F027 Installation Procedure 1 Insert the MAP sensor into the mounting bracket 2 Install the bolts through the MAP sensor and the bracket Install the retaining nuts Tigh...

Page 570: ...n EGR valve electrical connector 3 Remove the bolts and the EGR valve Installation Procedure 1 Clean the cylinder head mating surface 2 Install the new EGR valve gasket 3 Install the EGR valve with th...

Page 571: ...WOO T 154 BL2 3 C102F055 KNOCK SENSOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the intake manifold Refer to Section 1B SOHC Engine Mechanical 3 Disconnect the electrical conn...

Page 572: ...56 Installation Procedure 1 Install the knock sensor Tighten Tighten the knock sensor bolt to 20 NSm 15 lb ft C102F055 2 Connect the electrical connector at the knock sensor 3 Remove the intake manifo...

Page 573: ...electrical con nector 2 Connect the negative battery cable A102F020 EVAPORATIVE EMISSION CANISTER Removal Procedure Caution Canister and vacuum hoses contain fuel vapors Do not smoke in the area or p...

Page 574: ...TYPICAL Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the evaporative EVAP emission canister purge solenoid connector 3 Disconnect the vacuum hoses from the EVAP emis sion can...

Page 575: ...CKP sensor A102F019 Installation Procedure 1 Install the CKP sensor with the retaining bolt Tighten Tighten the crankshaft position sensor retaining bolt to 10 NSm 89 lb in 2 Connect the CKP sensor c...

Page 576: ...T 154 BL2 3 F41F001 Installation Procedure 1 Install the CMP sensor and bolts Tighten Tighten the camshaft position sensor bolts to 12 NSm 106 lb in 2 Connect the sensor electrical connector 3 Connec...

Page 577: ...ENGINE CONTROLS 1F 407 DAEWOO T 154 BL2 3...

Page 578: ...Remove the ECM retaining bolts 4 Remove the ECM from the ECM mount TAA1F450 Installation Procedure 1 Position the ECM in place 2 Install the ECM to the ECM mount and install the re taining bolts Tight...

Page 579: ...d remove the ignition wires 4 Remove the EI system ignition coil retaining bolts 5 Remove the EI system ignition coil A102F011 Installation Procedure 1 Install the EI system ignition coil into the mou...

Page 580: ...e sensor creat ing an induced voltage pulse The longer pulse of the 58th slot identifies a specific orientation of the crank shaft and allows the engine control module ECM to determine the crankshaft...

Page 581: ...ing that it is hot enough to operate properly D The ECT sensor is above a specified temperature D A specific amount of time has elapsed after starting the engine Closed Loop The specific values for th...

Page 582: ...while high tempera ture causes low resistance 70 ohms at 130_C 266_F The engine control module ECM supplies 5 volts to the coolant tempera ture sensor through a resistor in the ECM and measures the ch...

Page 583: ...rease com bustion temperature The amount of exhaust gas recir culated is controlled by variations in vacuum and exhaust back pressure If too much exhaust gas enters combustion will not take place For...

Page 584: ...ly depress the accelerator when starting until the ECM relearns idle control Engine idle speed is a function of total airflow into the engine based on the IAC valve pintle position the throttle valve...

Page 585: ...tern of finely atomized fuel at the injector tip Fuel from the tip is di rected at the intake valve causing it to become further atomized and vaporized before entering the combustion chamber A fuel in...

Page 586: ...Evaporative Emission diag nostic as well Using fuel with the wrong octane rating for your vehicle may cause driveability problems Many of the major fuel companies advertise that using premium gasoline...

Page 587: ...diag nostic executive records the following data D The diagnostic test has been completed since the last ignition cycle D The diagnostic test has passed during the current ignition cycle D The fault...

Page 588: ...st to run Each diagnostic has a specific list of conditions which must be met before the diagnostic will run Enable criteria is another way of saying conditions re quired The enable criteria for each...

Page 589: ...stem check the MIL will come on with the key ON and the engine not running When the engine is started the MIL will turn OFF D When the MIL remains ON while the engine is run ning or when a malfunction...

Page 590: ...diagnosed for the following conditions D Heater performance time to activity on cold start D Signal fixed low during steady state conditions or power enrichment hard acceleration when a rich mix ture...

Page 591: ...mits for a calibrated period of time a malfunc tion is indicated The fuel trim diagnostic compares the averages of short term fuel trim values and long term fuel trim values to rich and lean threshold...

Page 592: ...eral Description and System Operation 1G 12 Exhaust System 1G 12 Muffler 1G 12 Catalytic Converter 1G 12 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Auxiliary Catalyt...

Page 593: ...nvertor 4 Suport superior 5 urub 6 Suport inferior 7 urub 8 Piuli 9 Conduct evacuare 10 Garnitur catalizator 11 Tob fa 12 Tob 13 Garnitur tob 14 Clem cauciuc 15 Clem cauciuc 16 Scut catalizator 17 Piu...

Page 594: ...5L SOHC Removal Procedure 1 Remove the post converter heated oxygen sensor F41G003 2 Remove the front exhaust pipe nuts and the gasket from the auxiliary catalytic converter A202G003 3 Disconnect the...

Page 595: ...nger compartment A202G004 Installation Procedure 1 Install the front exhaust pipe and main catalytic con verter connecting pipe 1 5L SOHC and the gasket to the front muffler pipe flange Use the nuts t...

Page 596: ...sor Tighten Tighten the post converter heated oxygen sensor to 41 NSm 30 lb ft A402F067 AUXILIARY CATALYTIC CONVERTER Removal Procedure 1 Disconnect the post converter oxygen sensor electri cal connec...

Page 597: ...converter and the gas kets F401G003 Installation Procedure 1 Install the auxiliary catalytic converter and the gas kets Important Position the auxiliary catalytic converter onto the exhaust manifold f...

Page 598: ...e nuts Tighten Tighten the auxiliary catalytic converter to exhaust manifold nuts to 50 NSm 37 lb ft A402G004 4 Install the heat shield and the heated shield mounting bolts Tighten Tighten the exhaust...

Page 599: ...ge A202G005 2 Detach the front muffler from the rubber hanger A202G006 3 Remove the nuts and the gasket from the the rear muffler pipe flange Disconnect the front muffler from the rubber hanger 4 Remo...

Page 600: ...muffler nuts to 30 NSm 22 lb ft A202G005 2 Attach the front muffler assembly to the rubber hang er Loosely secure the front muffler assembly to the catalytic converter or the connecting pipe flange B...

Page 601: ...flange A202G007 2 Detach the rear muffler assembly from the rubber hangers on the tail pipe end 3 Remove the rear muffler assembly A202G008 4 Remove the trim ring from the rear muffler pipe 5 Check t...

Page 602: ...im ring bolt until it bottoms on the ex haust pipe Tighten an additional quarter turn 2 Secure the rear muffler assembly to the rubber hang ers on the tail pipe end A202G006 3 Secure the nuts and the...

Page 603: ...or any deterioration is dis covered upon inspection of the front muffler and pipe as sembly the complete assembly should be replaced The same procedure is applicable to the rear muffler assem bly Hea...

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