engine mount ISUZU KB P190 2007 Workshop Repair Manual

7A2-70 TRANSMISSION CONTROL SYSTEM (JR405E)
DTC P1120 (Flash Code 22)
Circuit Description
The accelerator pedal position (APP) sensor is
mounted on the accelerator pedal control assembly.
The analogue APP signals are converted by the engine
control module (ECM) into a pulse width modulation
(PWM) signal. This converted signal is continually sent
from the ECM to the TCM to determine appropriate
shift points depending on the accelerator pedal
pressing amount. If the TCM fails to receive a PWM
signal from the ECM, this DTC will set.
Condition for Running the DTC • The ignition switch is ON.
Condition for Setting the DTC • The TCM detects that the APP PWM signal from the ECM is not being received.
Action Taken When the DTC Sets • The TCM blinks the Check Trans lamp when the diagnostic runs and fails.
During the vehicle running; • The TCM holds the last gear position when the
diagnostic runs and fails.
• The TCM inhibits lock up control.
After the vehicle stopped;
• The TCM stops all shift solenoid valves and fixes to the 3rd gear. If a fail-safe valve problem is
detected, the shift solenoid valves are not stopped
but gear is fixed to the 3rd gear.
• The TCM stops PC solenoid valve.
Condition for Clearing the DTC • The TCM turns OFF the Check Trans lamp when the diagnostic runs and does not fail.
• A current DTC clears when the diagnostic runs and does not fail.
Diagnostic Aids • If an intermittent condition is suspected, refer to Intermittent Conditions in this section.
Circuit/ System Testing DTC P1120
Step Action Value(s)Yes No
1 Did you perform the Diagnostic System Check -
Transmission Controls? —
Go to Step 2 Go to Diagnostic
System Check - Transmission
Controls
2 1. Install a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the ENGINE DTC Information with a scan tool.
Is DTC P2621 or P2622 set? —
Go to Applicable DTC in engine
control section Go to Diagnostic
Aids

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ISUZU KB P190 2007

TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-105
B3: Engine Races Up During Starting (Slip)
B4: Large Shock When Selector Lever is Changed from N to D Range or N to R Range
Checks Action
Definition:
The engine speeds up but the vehicle speed does not increase when the accelerator pedal is stepped on at starting.
Diagnosis Hints Slipping of the clutch is suspected. Gear ratio error DTC might be set.
Transmission Fluid Checks Inspect the transmission fluid for the following conditions. If the transmission fluid is
extremely blacked, contaminated or smells burnt, slipping of clutch is suspected.
• Low quantity
• Contamination
•Smell
Line Pressure Checks Inspect the line pressure in forward ranges for a possible dropped pressure. Refer to
Line Pressure Test in Test Instruction section.
Stall Speed Checks Inspect the stall speed in forward ranges. Refer to Stall Test in Test Instruction section.
Control Valve Body Checks Inspect the valve body for the following conditions.
• Faulty operation
• Sticking spool valve
• Sticking shift solenoid valve. Perform function check. Refer to On-Vehicle Service section.
• Faulty operation of transmission fluid pressure switch. Perform function check. Refer to On-Vehicle Service section.
• Clogged hydraulic circuit
Clutch and Brake Checks Inspect any clutch for slipping.
Additional Checks • Inspect the engine for proper outputs. Refer to appropriate inspection chart in
engine section.
• Inspect the TCM grounds for being clean, tight, and in their proper locations.
• Observe the Accelerator Pedal Position (APP). APP parameter should change linearly from 0 to 99 or 100% according to the accelerator pedal operation.
Checks Action
Definition:
A large shock is felt when the selector lever is changed from N to D or N to R during idle.
Diagnosis Hints • Check the vehicle side such as exhaust mounting and engine mounting.
• With the fail-safe operation, garage shock may grow worth. If there is no DTC, faulty operation of the control valve or seized clutch might be suspected.
Transmission Range Switch &
Selector Lever Cable Checks Inspect the transmission range switch and selector lever cable for misadjusting or
disordering. Refer to On-Vehicle Service section.
Line Pressure Test Inspect the line pressure in D range or R range for a possible high or low pressure.
Refer to Line Pressure Test in Test Instruction section.
Control Valve Body Checks Inspect the valve body for the following conditions.
• Faulty operation
• Sticking spool valve
• Sticking shift solenoid valve. Perform function check. Refer to On-Vehicle Service section.
• Clogged hydraulic circuit
Clutch and Brake Checks Inspect any clutch for seizing.
Additional Checks • Inspect the transmission input signals.
• Inspect the engine for proper idle speed.
• Inspect the suspension for play.

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ISUZU KB P190 2007

7A2-124 TRANSMISSION CONTROL SYSTEM (JR405E)
Time Lag Test
Time Lag Test Procedure1. Fully apply the parking brake and chock all wheels.
2. Check the level of the engine oil, coolant and transmission fluid. Replenish as necessary.
3. Start the engine and warm up (allow engine coolant temperature to reach at least 70 °C
[158 °F]).
Important: Keep the brakes applied at all times in
order to prevent unexpected vehicle motion. Personal
injury may result if the vehicle moves unexpectedly.
4. Let idle and record the time lag from when the selector lever is moved from N to D or N to R range
until the shock has felt.
Standard Value
Diagnosis 1. If the time lag is out of the standard value when the selector lever is moved from N to D range.
• Forward range line pressure is low.
• Slipping of low clutch.
• Slipping of low one-way clutch. • Problem in valve body (faulty operation, sticking or
clogged hydraulic circuit).
• Faulty operation of low clutch solenoid valve.
• Shorter or faulty amount of transmission fluid.
2. If the time lag is out of the standard value when the selector lever is moved from N to R range.
• Reverse range line pressure is low
• Slipping of low & reverse brake
• Slipping of reverse clutch
• Problem in valve body (faulty operation, sticking or clogged hydraulic circuit).
• Faulty operation of low & reverse brake solenoid valve.
• Shorter or faulty amount of transmission fluid.
Selector lever position Time lag
N to D range Less than 0.7 seconds
N to R range Less than 1.2 seconds

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ISUZU KB P190 2007

7A2-152 TRANSMISSION CONTROL SYSTEM (JR405E)
Output Shaft Speed (OSS) Sensor
Legend1. OSS sensor
2. Parking gear
The output shaft speed (OSS) sensor is located on
right-hand of the transmission case near the
transmission range switch. The OSS sensor is a hall
effect element type sensor, which generates a square
wave signal pulse based on the parking gear rotational
speed that is connected to output shaft (16 pulses per a
rotation of the parking gear that is fitted with the output
shaft by spline). The TCM calculates the vehicle speed
by the OSS sensor signal, and uses it to determine
appropriate shift points and calculate gear ratio. The
2WD vehicle outputs the vehicle speed signal from the
TCM to the engine control module (ECM) and the
vehicle speed meter via output signal line.
Transmission Control System Description
Transmission Control Module (TCM) Service
Precautions
Important:
To avoid shock and possible serious injury, DO NOT
touch the terminals. When disconnecting the harness
connectors, always turn OFF the ignition switch or
disconnect the battery cable.
The transmission control module (TCM) is designed to
withstand normal current draws associated with vehicle
operation. Avoid overloading any circuit. When testing
for opens and shorts, do not ground or apply voltage to
any of the TCM circuits unless instructed to do so. In
some cases, these circuits should only be tested using
a DMM. The TCM should remain connected to the TCM
harness. The TCM is located next to brake pedal via
mounting bracket. The TCM mainly controls the
gearshift system control and on-board diagnostic for
transmission control. The TCM constantly observes the
information from various sensors. The TCM controls
the systems that affect vehicle performance. The TCM
performs the diagnostic function of the system. The
TCM can recognize operational problems, alert the
driver through the check trans lamp, and store
diagnostic trouble codes (DTCs). DTCs identify the
system faults to aid the technician in making repairs.
1
2

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ISUZU KB P190 2007

ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12 fixing bolts to the specified torque.
Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
6. Fill with the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. W hen an abnormal amount of debris is found.
2. W hen an abnormal wear or chips on gears and shafts is found while overhauling.
3. W hen there is abnormal clutch facing wear and oil contamination found.

Procedures
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with suitable safet
y
stands.
4. Disconnect the fluid cooler lines at the transmission case and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using solvent and compressed air.
Note:
DO NOT exceed (200 kPa/2.0 kgf/cm
2/28 psi) air
pressure, or damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (4.5 kgf·m/33 lb·ft)
8. Replenish the ATF.
9. Start the engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all the debris from the fluid cooler circuit.
Move the select lever through the various ranges and return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF must be added.
10. Connect the negative battery cable.
11. Remove the safety stands.
12. Remove the wheel blocks.

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7A3-20 ON-VEHICLE SERVICE (JR405E)
TRANSMISSION ASSEMBLY

RUW 57ALF000201
Legend
1. Shift Cable
2. Propeller Shaft
3. Engine Harness
4. ATF Level Dipstick & Filler Tube
5. Under Cover
6. Bolt

7. ATF Pipe
8. Crossmember
9. Transmission Mount
10. Starter Motor
11. Bolt
12. Automatic Transmission

Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with the suitable safety stands.




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ON-VEHICLE SERVICE (JR405E) 7A3-21
4. Remove the shift cable from the transmission.
P1010068
5. Remove the rear propeller shaft assembly.
6. Loosen (do not remove) the nuts securing the exhaust manifold and the exhaust pipe.
7. Disconnect the harness connectors from the transmission.
8. Remove the fuel pipe bracket.
P1010013

P1010014
9. Remove the ATF level dipstick and tube.
10. Remove the undercover.
11. Rotate the ring gear and remove the 6 torque
converter bolts.
P1010016
12. Remove the automatic transmission fluid cooling pipe.
P1010060
13. Place a jack beneath the engine to support it.
14. Remove the 3rd crossmember.
15. Remove the transmission mount.
16. Lower the jack beneath the engine slightly to tilt the engine and transmission. Do not allow the radiato
r
and air conditioner hoses to stretch.
17. Remove the bolts attaching the transmission to the engine.
18. Lower the transmission from beneath the vehicle. Take care not to damage the breathers.

Install or Connect
1. Install the transmission to the engine and tighten the bolts.
Bolt torque : M10 40 N·m (4.1 kgf·m/30 lb·ft)
M12 76 N·m (7.7 kgf·m/56 lb·ft)
2. Install the cable bracket to the transmission.
3. Connect the engine harness connectors.

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MSG MODEL 7B-9
Engine Lifting Hanger
1. Attach the engine lifting hanger to the front portion of the
engine.
2.
Attach the lifting wire to both ends of the engine lifting
hanger.




Starter Motor
Remove the starter motor from the engine rear plate.




Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts
1
from the transmission 2.
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber
3 from the No.3
crossmember
4.
6. Remove the gear control box from the transmission.



7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative efforts of two mechanics.
1) Remove the transmission nuts and bolts
1 from the
engine rear plate.
2) Place a transmission jack
2 beneath the transmission .
Do not raise the transmission jack.


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MANUAL TRANSMISSION 7B1-7
Transmission (4×
××
×
2)
Disassembled View



RTW 77BLF003201
Legend
(1) Gear Control Lever Knob (9) Slave Cylinder
(2) Rear Floor Console (bucket seat) (10) Nut: rear mount to Crossmember
(3) Front Floor Console (11) Transmission Crossmember
(4) Grommet Assembly (12) Nut: rear mount to transmission
(5) Gear Control Lever (13) Rear Mount Rubber
(6) Rear Propeller Shaft (14) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (15) Transmission Retaining Nut and Bolt
(8) Fuel Pipe Bracket (16) Transmission Assembly




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7B1-10 MANUAL TRANSMISSION
12. Remove slave cylinder and put it aside.
Diesel engine
220LV019
13. Support the transmission with a transmission jack.
220RS001
14. Remove engine rear mount nuts fixing on cross
member, from the transmission crossmember.
15. Remove engine rear mount nuts fixing on the
transmission.
220R300029
Legend
(1) Transmission
(2) Nut: rear mount to transmission
(3) Rear Mount Rubber
(4) Nut: rear mount to crossmember
(5) Transmission Crossmember
16. Remove the middle part of the transmission crossmember by removing four fixing bolts and nuts.
501R300008


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