ignition ISUZU KB P190 2007 Workshop Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 3960 of 6020
Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–47
14 Reconnect the fuel and EVAP pipes three brackets and clips, refer to 6C Fuel System – V6.
15 Reinstall the following components:
a Starter motor, refer to 6D1-2 Starting System.
b Transmission support, refer to 3.7 Transmission Support and Mount.
c Front and centre exhaust assemblies, refer to 6F Exhaust System.
d Rear propeller shaft and for 4WD front propeller shaft, refer to 4A Propeller Shaft.
16 Reconnect the harness connectors to the following: a Vehicle speed sensor, refer to 3.5 Vehicle Speed Sensor.
b Neutral start and back-up switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
c For the following on 4W D vehicles, refer to 7D Transfer Case and Adaptor Housing:
• neutral switch,
• 2WD – 4WD shift actuator switch,
• speed sensor.
17 Reinstall the selector cable to the transmission external manual shaft linkage, secure the selector cable to the bracket and attach the heat shield to the neutral start and back-up lamp switch, refer to 3.3 Selector Cable
Assembly.
18 Perform a reverse flush of the cooler lines and a flow rate test, refer to 2.2 Reverse Flush and Flow Rate, if either of the following applies:
• the transmission fluid is contaminated,
• the transmission has been replaced,
• the torque converter has been replaced, or
• the transmission oil pump has been replaced.
19 Lower the vehicle to the ground.
20 If required, top up the transmission fluid level (cold).
21 Reconnect the battery ground lead.
22 Start the engine and check for any fluid leaking at the fittings. If a leak is found, stop the engine and rectify the leak.
23 Road test until the transmission has reached operating temperature. Re-check the fluid level and for any fluid leaks, refer to 2.1 Transmission Fluid.
3.19 Transmission Control Module
Remove
1 Ensure the ignition switch is in the OFF position.
2 Disconnect the connector (1) from the transmission control module (TCM) (2) as follows, refer to Figure 7C4 – 63: a remove the securing pin (3),
b press the locking tab and swing the lever (4) to free the connector,
c remove the connector.
3 Remove the four bolts (5) and nuts (6), then the TCM from the mounting bracket (7).
4 If required, remove the two nuts (8) and the mounting bracket from the firewall.
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Page 3961 of 6020
Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–48
Figure 7C4 – 63
Reinstall
Reinstallation of the transmission control module (TCM) is the reverse of the removal procedure, noting the following:
1 If a new TCM is installed it must be programmed, refer to TCM Programming Procedure in this Section.
2 If required, install the mounting bracket to the firewall and tighten the nuts to the correct torque specification.
TCM bracket attaching
nut torque specification ........................................7.0 Nm
3 Install the TCM onto the bracket and tighten the bolts and nuts to the correct torque specification. TCM attaching bolt and nut
torque specification ..............................................7.0 Nm
4 Lock the connector securely to the TCM by with the locking lever and the securing pin.
5 Using Tech 2, clear any TCM diagnostic trouble code (DTC) that may have set during the removal procedure, refer to 0C Tech 2.
TCM Programming Procedure
1 The transmission control module (TCM) must be programmed with the correct software/calibration. Ensure the following conditions exist before starting the TCM programming procedure:
a The battery is fully charged.
b The Tech 2 cable connection at the data link connector (DLC) is secure.
c The ignition switch is in the ON position.
2 Program the TCM using the latest software for the vehicle, refer to the following: a Current release of TIS for the latest software and
b 0C Tech 2 for TCM service programming.
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Page 3978 of 6020
7A2-12 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
Control and Functions
Item Description
Shift and lock-up control Shift and lock-up points can be controlled in accordance with output of S1, S2, and SL solenoids based on "Shift-map" made up of vehicle speed and the opening.
Overdrive off cut control W hen the select lever is operated from D to 3, if the vehicle speed is more than 142km/h (89mph), TCM enables to remain overdrive in order to prevent over rev.
Lock-up cut control Lock-up is inhibited with following condition in order to improve the shift feeling.
• 1st gear
• Idling
• Operating brake switch
• L position
• During shift change
Driveng mode select control
• The TCM selects a suitable driving mode from the ten kinds for the variety
driving condition.
1) Normal mode
2) Power mode
3) 3rd start mode
4) HOT mode
5) L4 mode
6) Up slope1 mode
7) Up slope2 mode
8) Down slope mode
9) Auto cruise mode
10) W arm up mode • The priority of driving mode
Normal < Power < Up slope1 < Up slope2 < Down slope < L4 < W arm up < Auto
cruise < 3rd start < HOT
Oil temperature compensation
control If the ATF temperature exceeds 130
°C (266 °F), the TCM selects the HOT mode
shift pattern for lock-up, thus preventing the oil temperature from rising. (The HOT
mode is released, if the ATF temperature is less than 115 °C /239 °F.)
3rd start mode control By selecting 3rd start mode, the vehicle starting can be controls smoothly on low
frictional road like a snowy or muddy.
1. Enable condition a) The gear select position is "D" only.
b) Vehicle speed is less than 11km/h (7mph).
c) Transmission oil temperature is less than 120 °C (248 °F).
d) Accelerator opening is less than 8%.
e) Except 3rd start mode.
2. Disable condition a) Turning off the 3rd start mode switch
b) Shifting select position to "3", "2", or "L"(3rd start mode is not canceled b
y
selecting "N", "R", or "P")
c) Ignition key is turned off.
d) Vehicle speed is more than 35km/h (22mph).
L4 mode control The TCM detects whether the transfer is engaged in high or low based on L4 switch
signal, and selects the "Shift-map".
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Page 3982 of 6020
7A2-16 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
CAN bus systems in automatic
transmission control (AW30-40LE)
The automatic transmission control system in AW 30-
40LE uses high speed CAN bus system .The individual
CAN bus systems are connected via two interfaces and
can exchange information and data. This allows control
modules that are connected to different CAN bus
systems to communicate.
High speed CAN bus
Transmission control module in the vehicle that require
continuous, rapid communication are connected to the
high speed CAN bus. For example, the automatic
transmission is continuously notified of the current
engine load status. Since the automatic transmission
control module has to react immediately to load status
changes, rapid communication is required between the
engine control module and the automatic transmission
control module. The high speed CAN bus in the AW 30-
40LE is designed as a two-wire CAN bus (twisted pair).
The wires are shielded and twisted. The transfer rate is
500 K baud.
RUW 37ASF000401
Diagnosis
Electronic Diagnosis
How To Diagnose The Problem
1. To avoid incorrect diagnostics, this book needs to
be followed accurately. Unless stated, do not jump
directly to a section that could contain the
solution. Some important information may be
missed.
2. The sections in CAPITALS and bold are the main
sections that can be found in the contents.
3. The go to “SECTION” means to continue to check
going to the “section”.
4. The go through “SECTION” means to go through
the “section” and then to go back to the place the go
through was written.
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory o
f
electricity. This includes the meaning of voltage,
amps, ohms, and what happens in a circuit with an
open or shorted wire. You should also be able to
read and understand wiring diagrams.
Check Trans Indicator
Find CHECK TRANS indicator and verify if it is
A. Flashing: Go to On-Board Diagnostic (OBD)
System Check.
B. Staying on: Go through “Check Trans” Check.
C. Is never “ON” when the ignition key is turned on: Go through “Check Trans” Check
D. Is “ON” during 3 seconds at ignition but “OFF” after: Normal operation. No DTC or malfunction.
RTW 77ASH000101
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TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-17
Normal
C07RY005-1
Abnormal
C07RY00042-1
On-Board Diagnostic (OBD) System Check
This test determines if the transmission or its input or
output connections or sensors are failing.
1. Connect the Tech 2: Go through Tech 2 Operating.
2. Turn on the ignition but not the engine.
3. Push “F0” on Tech 2 to see the Diagnostic Trouble Code (DTC):
4. Do you have a DTC? YES: write down all code numbers and do the DTC
CHECK
NO: the DTC can not help you find the problem.
1. Go through “Check Trans” Check
2. If it is flashing and the flash is 0.4 seconds “ON”
and 0.4 seconds “OFF”, this means that you
should have a DTC stored. Please recheck go
to On-Board Diagnostic (OBD) System Chec
k
and if you find the same problem, replace the
Transmission Control Module (TCM).
“Check Trans” Check
1. Indicator is “ON” during 3 seconds at ignition but it
is “OFF” after the engine starts. The indicator is
working normally go to On-Board Diagnostic
(OBD) System Check .
RTW 77ASH000101
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Page 3984 of 6020
7A2-18 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
Normal
C07RY005-1
2. Indicator is flashing and the flash is 0.4 seconds
“ON” and 0.4 seconds “OFF” always when ignition is
on (engine cranked or not). This means that there is
a malfunction. Go to On-Board Diagnostic (OBD)
System Check .
Abnormal
C07RY00042-1
3. Indicator is staying “ON” always when Ignition is
“ON”.
1. This means that connection between the lamp
and the indicator control unit is shorted to
ground.
2. Verify if instrument panel terminal 25 o
f
connector B–23 is shorted to ground.
3. Verify if the indicator control unit connector C–
95 terminal 3 is shorted to ground.
4. Verify that the instrument panel terminal 8 o
f
connector B–24 is connected to battery.
5. If a problem was solved: Go to Check Trans
Indicator .
NO: Replace Transmission Control Module
(TCM).
4. Indicator is staying “OFF” with the ignition “ON”
(engine “OFF”).
1. This means that connection between the lamp
and the indicator control unit is shorted to
battery or opened.
2. Verify if instrument panel terminal 25 o
f
connector B–23 is shorted to battery or open.
3. Verify if the indicator control unit connector C–
95 terminal 3 is shorted to battery or open.
4. Verify that the instrument panel terminal 25 o
f
connector B–23 is connected to battery. If not,
check the meter fuse and the connections
(terminal 2 of connector H–7) voltage.
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Page 3990 of 6020
7A2-24 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
TRANSMISSION DATA
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle
Operating Conditions: Engine idling/ Engine coolant temperature is between 75 to 85 °C(167 to 185 °F)/
Accelerator pedal is constant/ Neutral or Park/ Accessories OFF/ Vehicle located at sea level
Engine Coolant temperature °C/ °F 75 to 85°C (167 to 185 °F)
Engine Speed RPM 700
Vehicle Speed Km/h / MPH 0
Ignition Voltage V 13.6
Accelerator Pedal Position Signal % 0
Throttle Position % 0
Accelerator Pedal Position Signal
During Cruise Control % 0
Cruise Control
Inactive / Active Inactive
Cruise Control OD Cancel Request ON / OFF OFF
Engine W arm Up Cycle Achieved FALSE / TRUE FALSE
Transmission Shift in Progress Inactive / Active Inactive
Garage Shift Control Inactive / Active Inactive
MIL Request Command ON / OFF OFF
Transmission Check Light ON / OFF OFF
Transmission Oil Temperature Lamp ON / OFF OFF
Power Drive Lamp ON / OFF OFF
3rd Start Lamp ON / OFF OFF
Transmission Fluid Temperature
°C/ °F 70 to 80°C (158 to 176 °F)
AT Input Speed RPM 625
AT Output Speed RPM 0
Transmission Range Park / Reverse /
Neutral / Drive 4 / Drive 3 / Drive 2 / Drive 1 Park
TR Switch P
ON / OFF ON
TR Switch R ON / OFF OFF
TR Switch N ON / OFF OFF
TR Switch D ON / OFF OFF
TR Switch 3 ON / OFF OFF
TR Switch 2 ON / OFF OFF
TR Switch L ON / OFF OFF
Diagnostic Switch Open / Close Open
Brake Pedal Switch ON / OFF OFF
Power Drive Switch ON / OFF OFF
3rd Start Switch ON / OFF OFF
4 W heel Drive Low ON / OFF OFF
Shift Solenoid 1 Command ON / OFF ON
Shift Solenoid 2 Command ON / OFF OFF
TCC Solenoid Engaged / Disengaged Disengaged
Downhill Mode Inactive / Active Inactive
Active Shift Mode Normal Mode /
Power Mode /
3rd Gear Start /
Transfer 4L MODE Hot 1 / Hot 2 /
UPHILL MODE 1 /
UPHILL MODE 2 / Cruise MODE /
W arm Up MODE Normal Mode
Estimated Gear Ratio
:1 7.97 : 1
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Page 3997 of 6020
TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-31
2.Demand of Data
1. Connect Tech 2 to the vehicle. W hen activated b
y
turning on the power of Tech 2, push the "Enter"
switch.
2. Turn on the ignition switch (without starting the
engine)
3. In the main menu of Diagnostic Tester, push "F1:
Service Programming System (SPS)".
4. Push “F0: Request Info” of Tech 2.
5. W here vehicle data has been already saved in
Tech 2, the existing data come on display. In this
instance, as Tech 2 starts asking whether to keep
the data or to continue obtaining a new data from
the control unit, choose either of them.
6. If you select “continue”, you have to select “Model
Year”, “Vehicle Type”, “Controller Type (Engine)”.
7.
After that. then push button and turn Ignition switch
tuned on, off, on following Tech 2 display. Tech 2
will read information from controller after this
procedure.
8. During obtaining information, Tech 2 is receiving
information from the control unit chosen. In
replacing the control unit, please be sure to
undertake “Obtaining Information” from the ne
w
unit. W ith VIN not being programmed into the new
control unit at the time of shipment, "obtaining
information" is not complete (because the vehicle
model, engine model and model year are specified
from VIN). For the procedure get additional
information on vehicles, instruction will be provided
in dialog form, when TIS2000 is in operation.
9. Following instructions by Tech 2, push the “Exit”
switch of Tech 2, turn off the ignition of the vehicle
and turn off the power of Tech 2, thereby removing
from the vehicle.
3.Data Exchange
1. Connect Tech 2 to P/C, turn on the power and
click the “Next” button of P/C.
2. Check VIN of the vehicle and choose “Next”.
3. W hen a lack of data is asked from among the
following menu, enter accordingly.
Select following Menu
• Model Year
• Model
• Engine type
• Transmission type
• Destination code (vehicles for general export)*1
• Immobiliser
* 1: How to read the destination code
"Destination code can be read from ID Plate affixed on
vehicles, while on VIN plate the destination code is
described at the right-hand edge of Body Type line. In
Fig.-3, the destination code can be read as “EK4”
(Europe).
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Page 3998 of 6020
7A2-32 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
4. After choosing the data, click the “Next” button.
5. W hen all the necessary information is entered, the
“details” of software within the database that match
the entered data will appear for confirmation. Click
the “Program” switch and then download the ne
w
software onto Tech 2.
6. “Data Transfer” comes on display. The progress o
f
downloading will be displayed on the screen in the
form of bar graph.
7. Upon finishing the data transfer, turn off the powe
r
of Tech-2, removing from P/C.
4. Programming of TCM 1. Check to see if batteries are fully charged.
2. Connect Tech 2 to Vehicle Diagnostic Connectors.
3. Turn on the power of Tech 2 and the title screen
comes on display.
4. Turn on the ignition (without allowing the engine to
start)
5. On the title screen of Tech 2, push the "Enter"
button.
6. Choose “F: Service Programming System” on the
main screen and then choose “F1: Programming”.
7. W hile data is being transferred, “Downloading” will
be displayed on the Tech 2 screen.
8. Upon finishing the data transfer, Tech 2 will displa
y
“Reprogramming Successful”. Push the “Exit”
button to bring program to completion.
9. Following “Procedure 2: Demand of Data”, try ove
r
again "Information Obtaining" and check to confirm
if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition o
f
the vehicle and then turn off the power of Tech 2,
removing from the vehicle.
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Page 4001 of 6020
TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-35
Clear DTC
NOTE: If you clear the DTC (Diagnostic Trouble
Codes) you will not be able to read any codes recorded
during the last occurrence.
NOTE: To use the DTC again to identify a problem, you
will need to reproduce the fault or the problem. This
may require a new test drive or just turning the ignition
on (this depends on the nature of the fault).
1. IF you have a Tech 2:
1. Connect the Tech 2 and perform the Tech 2
Operating.
2. Push “F1: Clear DTC Information” in the
Application Menu and answer “Yes” to the
question “Do you want to clear DTC's?”
a. W hen a malfunction still exists and the Tech 2 displays “AW 30-40 CODES NOT
CLEARED”. This means that the problem is
still there or that the recovery was not done.
Please go to DTC Check.
b. W hen a malfunction has been repaired and the recovery is done the Tech 2 displays
“AW 30-40LE CODES CLEARED”.
2. W hen you have no Tech 2, the storaged trouble
codes can be cleared by shorting the terminals
No.11 and No.4 or 5 (ground) of data link connecto
r
with a lead wire for 1 ∼ 6 seconds.
DTC Check
1. Diagnostic Trouble Codes (DTC) have been
identified by Tech 2.
2. You have written the list of the DTCs. The order o
f
the malfunctions has no meanings for this TCM.
Usually only one or two malfunctions should be set
for a given problem.
3. Check directly the DTCs you identified. The DTCs
are sorted by number. Refer to Diagnostic Trouble
Code (DTC) Identification in this section.
Self-diagnosis code (Flash code) display
• The stored trouble codes can be identified by
shorting the terminal No. 11 and No. 4 or No. 5
(ground) data link connector with a lead wire.
Indication Method:
1. Terminal No. 11 and No. 4 or No. 5 (ground) data
link connector are short circuited.
2. Turn the key switch to the ON position.
3. If no trouble code exists, the normal code (12) is
indicated repeatedly.
Data Link Connector Short Circuit
Flash Code Illumination Pattern
0.4 Sec 0.4 Sec
.
ON
OFF
3.2 Sec.
1.2 Sec.
3.2 Sec.
0.4 Sec 0.4 Sec
.
ON
OFF
3.2 Sec. 1.2 Sec. 3.2 Sec.
Self-diagnosis Start
Normal Code (12)
Trouble Code (32)
4. If several trouble codes have occurred at a time,
each code is indicated three times in numerical
order.
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