engine ISUZU KB P190 2007 Workshop Repair Manual

TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-133
Except Euro 3 specification engine
Final gear ratio & tire size 41/11 (3.727) & 215/70R15
43/10 (4.300) & 245/70R16
Gear Accel.
pedal
position
(%) Normal mode
Power drive mode 4L mode
Veh ic l e speed
(km/h) Veh i cl e
speed
(MPH) Output
shaft
speed
(RPM) Veh i cl e
speed
(km/h) Veh i cl e
speed
(MPH) Output
shaft
speed
(RPM) Veh i cl e
speed
(km/h) Veh i cl e
speed
(MPH) Output
shaft
speed
(RPM)
Upshift 1-2
50 27-34 16-20 930 31-38 19-23 1054 30-37 18-22 1023
100 35-42 21-25 1178 35-42 21-25 1178 34-41 20-25 1147
2-3 50 49-57 29-34 1621 58-66 35-40 1891 55-63 33-38 1798
100 70-78 42-47 2263 70-78 42-47 2263 71-79 43-47 2294
3-4 50 87-96 52-58 2790 97-106 58-64 3099 84-93 50-56 2697
100 109-119 65-71 3471 109-119 65-71 3471 113-123 68-74 3595
Downshift 4-3
0 39-36 23-22 992 29-36 17-22 992 29-36 17-22 992
50 66-74 40-44 2139 74-82 44-49 2387 71-79 43-47 2294
100 104-113 62-68 3316 104-113 62-68 3316 98-107 59-64 3130
3-2 0 6-12 4-7 279 6-12 4-7 279 6-12 4-7 279
50 30-37 18-22 1023 47-55 28-33 1550 45-53 27-32 1488
100 65-73 39-44 2108 65-73 39-44 2108 59-67 35-40 1922
2-1 0 6-12 4-7 279 6-12 4-7 279 6-12 4-7 279
50 10-16 6-10 403 19-26 11-16 682 18-25 11-15 651
100 29-36 17-22 992 29-36 17-22 992 27-34 16-20 930

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7A2-134 TRANSMISSION CONTROL SYSTEM (JR405E)
TCM Signal Test
Inspection Tool
Use a DMM to measure voltage and circuit continuity.
Also use an oscilloscope to measure waveform. Refer
to the following table for the specified ranges or
reference waveform. Since the TCM terminals are extremely small, use
appropriate test adapter from the test adapter kit. This
will make measurement easier.
Pin No. Wire color Pin function DMM (+) DMM (-) Test condition Standard value
1 of C-94 RED/ WHT Battery voltage 1 of C-94 Ground Any time Nearly 12 volts
2 of C-94 YEL/ VIO P range switch signal 2 of C-94 Ground P range
Nearly 12 volts
Other than P range Less than 2 volts
3 of C-94 RED Brake pedal switch
signal 3 of C-94 Ground Pedal is released Less than 2 volts
Pedal is applied Nearly 12 volts
4 of C-94 PNK/ WHT 3rd start lamp control 4 of C-94
(back probe) Ground Lamp OFF Nearly 12 volts
Lamp ON Less than 2 volts
5 of C-94 VIO/ GRN Keyword serial data
communication 5 of C-94 7 of B-58 Ignition OFF
Continuity
6 of C-94 — Not used— — ——
7 of C-94 BLK/ RED Engine speed signal
input 7 of C-94
(back probe) 5 of C-95
(back
probe) Engine run at 2000
RPM Nearly 6.2 volts by
AC range or
waveform
8 of C-94 — Not used— — ——
9 of C-94 — Not used— — ——
10 of C-94 BLK/ YEL Vehicle speed signal
output (2WD) 10 of C-94
(back probe) 5 of C-95
(back
probe) Vehicle run at 20 km/h
(12 MPH) Nearly 6.5 volts by
AC range or waveform
11 of C-94 GRN/ WHT 3rd start switch signal 11 of C-94
(back probe) GroundSwitch is released Nearly 12 volts
Switch is pressed Less than 2 volts
12 of C-94 BLU/ WHT 4WD low signal output 12 of C-94
(back probe) Ground 4L mode Less than 2 volts
Other than 4L Nearly 12 volts
13 of C-94 — Not used— — ——
14 of C-94 — Not used— — ——
15 of C-94 — Not used— — ——
16 of C-94 RED/ WHT Accelerator pedal
position (APP) signal
input 16 of C-94
(back probe) 5 of C-95Pedal is released (0%) Off duty ratio 10%
Pedal is fully applied (100%) Off duty ratio 90%
17 of C-94 BLK/GRN 3 range switch signal 17 of C-94 Ground 3 range
Nearly 12 volts
Other than 3 range Less than 2 volts
18 of C-94 YEL/ BLK Diagnostic request
switch 5 of C-9411 o f B -
58 Ignition OFF
Continuity
19 of C-94 ORN/ BLU Transmission oil
temperature lamp control 19 of C-94
(back probe) Ground Lamp OFF Nearly 12 volts
Lamp ON Less than 2 volts
20 of C-94 GRY/ YEL Check trans lamp
control 20 of C-94
(back probe) Ground Lamp OFF Nearly 12 volts
Lamp ON Less than 2 volts
21 of C-94 PNK Power drive lamp
control 21 of C-94
(back probe) Ground Lamp OFF Nearly 12 volts
Lamp ON Less than 2 volts

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7A2-136 TRANSMISSION CONTROL SYSTEM (JR405E)
Reference Wave form
Engine speed signal
• Measurement terminal: 7 of C-94 (+) & 5 of C-95 (- )
• Measurement scale: 5 volts/div & 10 ms/div
• Measurement condition: Engine run at 2000 RPM Vehicle speed signal
• Measurement terminal: 10 of C-94 (+) & 5 of C-95 (-)
• Measurement scale: 5 volts/div & 50 ms/div
• Measurement condition: Vehicle run at 20 km/h (12 MPH)
19 of C-95 RED/ YEL R range switch signal 19 of C-95 Ground R range
Nearly 12 volts
Other than R range Less than 2 volts
20 of C-95 WHT/ BLK High clutch TFP switch
signal 20 of C-95
(back probe) Ground3rd or 4th gear Less than 2 volts
Other than 3rd to 4th gear Nearly 12 volts
21 of C-95 PNK/ BLU L range switch signal 21 of C-95 Ground L range
Nearly 12 volts
Other than L range Less than 2 volts
22 of C-95 GRY/ RED Ground return 22 of C-95 Ground Ignition OFF Continuity
23 of C-95 VIO PC solenoid control 23 of C-95
(back probe) 5 of C-95
(back
probe) P or N rage Nearly 12 volts
D range Less than 2 volts
24 of C-95 WHT Ignition voltage 24 of C-95 Ground Ignition switch ON Nearly 12 volts Pin No. Wire color Pin function DMM (+) DMM (-) Test condition Standard value

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TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-139
Repair Instructions
Transmission Controls Module (TCM) Replacement
Description
The following A - C steps provide an overview
procedure to replace and reprogram a TCM. Each A -C
steps is explained further in this section.
A. Replace the old TCM with the new TCM.
B. Program the latest software and calibrations into the
new TCM using the Service Programming System
(SPS) if released. If not released, do not perform this
and skip to Step C.
C. Program the vehicle identification number (VIN) into
the TCM.
A. Removal and Installation
Removal Procedure 1. Disconnect the negative battery cable.
2. Disconnect the TCM harness connectors (1).
3. Loosen nuts (2) and remove the TCM (3) from the bracket (4).
Installation Procedure
Follow the removal steps in the reverse order. Be sure
that the connectors are securely fastened.
B. Programming Software and Calibrations
Program the latest software/ calibrations if released.
Refer to Service Programming System (SPS)
Description and SPS (Remote Procedure) or SPS
(Pass-Thru Procedure) in this section. If not released,
do not perform this and skip to Step C.
C. Programming Vehicle Identification Number
(VIN) Notice:
If you have performed SPS in the previous
step, VIN has prgrommaned already. Programming VIN
is not necessary in this step.
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle identification > AT JR405E > Programming >
Program VIN.
4. If you installed a new, skip to step 8. If you installed a reused TCM from another vehicle or incorrect
VIN is programmed before, the TCM might be
locked already. In order to get programming
approval, the on-screen displays a message to
user. Get programming approval from the TIS
2000 using the following procedure:
a. Connect a scan tool to the terminal that installed TIS 2000 with the latest software and
the hardware key is plugged into port.
b. Turn ON the scan tool and keep at title screen.
c. Launch the TIS application.
d. Select the Security Access at the main screen.
e. Highlight the “Tech 2" on the Diagnostic Tool Selection screen and click “Next”.
f. Click “Close” on the Security Access Enabled screen.
g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Install a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle identification > AT JR405E > Programming >
Program VIN.
8. Input 17 digits of correct VIN.
9. After complete the programming, turn OFF/ ON the ignition.
10. Select Diagnostics > Lock ECU.
11. Follow the on-screen instructions and turn OFF/ ON the ignition.
Service Programming System (SPS)
Description
The service programming system (SPS) allows a
technician to program a control module through the
data link connector (DLC). The information transfer
circuit that is used at the DLC is the same serial data
circuit used by the scan tool for retrieving DTCs,
displaying data, clearing DTCs etc. This procedure
offers the ability to install software/ calibrations
matched to a particular vehicle.
Most control modules have two types of memory. The
software/ calibrations reside in the flash memory. The
two types of memory are listed below:
1
3 42

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7A2-140 TRANSMISSION CONTROL SYSTEM (JR405E)
• Electrically Erasable Programmable Read OnlyMemory (EEPROM)
This type of memory allows selected portions of
memory to be programmed while other portions
remain unchanged.
Certain learned values reside in the EEPROM,
such as:
- The vehicle identification number (VIN)
- The software/ calibrations identification numbers
- The control module security information
• Flash Read Only Memory-Flash Memory
Flash memory has increased memory storage capacity.
During programming, all information within this type of
memory is erased, and then replaced with entirely new
information.
Service Programming Methods
The two methods of programming a TCM are listed
below:
• Remote Programming
• Pass Thru Programming
For information on programming a TCM using one of
the methods listed above, refer to Service
Programming System (SPS) (Remote Procedure) or
Service Programming System (SPS) (Pass-Thru
Procedure).
Before Programming a Control Module
Important: DO NOT program an existing TCM with the
identical software/ calibration package. This procedure
is not a short cut to correct the driveability condition.
This is an ineffective repair. An TCM should only be
programmed when the following occurs:
• When a service procedure instructs you to replace the TCM.
• An updated software/ calibrations is released.
Ensure that the following conditions are met before
programming a TCM:
• The scan tool PCMCIA card is programmed with the latest software.
• The TIS 2000 is installed with the latest software.
• The hardware key is plugged into the computer port.
• Vehicle system voltage:
- There are no charging system concerns. Allcharging system concerns must be repaired
before programming the TCM.
- The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully
charged before programming the TCM.
- A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or
voltage fluctuations from a battery charger may
cause programming failure or TCM damage. - Turn OFF or disable any system that may put a
load on the vehicles battery. Turn OFF or
disable systems such as:
◊ Heating, ventilation, and air conditioning
(HVAC) systems
◊ Headlights
◊ Room lights
◊ Accessory equipment
• The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of
the ignition switch during the programming
procedure unless instructed to do so.
• All tool connections are secure:
- The RS-232 cable
- The connection at the DLC
- The voltage supply circuits
• DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or
TCM damage may occur.
• If you are performing the Pass-Thru programming procedure using a notebook computer without the
power cord, ensure that the internal battery is fully
charged.
Service Programming System (SPS)
(Remote Procedure)
Notice: Some module will not accept SPS remote
procedure using 10MB PCMCIA card. In such case,
use 32MB PCMCIA card or SPS pass-thru procedure.
The Remote SPS method is a three-step process that
involves the following procedures:
1. Connecting the scan tool to the vehicle and obtaining the information from the TCM.
2. Connecting the scan tool to the terminal and downloading a new calibration file from the
terminal into the scan tool memory.
3. Reconnecting the scan tool to the vehicle and uploading the new calibration file into the TCM.
Performing the Remote Procedure 1. Connect a scan tool to the vehicle and obtain the TCM information using the following procedure:
Notice: Ensure the TCM is installed in the vehicle and
the battery is fully charged before programming.
a. Install a scan tool.
b. Turn ON the ignition, with the engine OFF.
c. Select Service Programming System (SPS) > Request Info.

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TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-141
d. If there is already stored in the scan tool, theexisting data is displayed on the screen. The
scan tool asks user to keep existing data “Keep
Data” or “Continue” to request new vehicle
information from the TCM. If there is no data in
the scan tool, it will immediately start vehicle
identification.
e. Select the vehicle description by following the on-screen instructions based on stamped VIN
or affixed VIN plate on the vehicle.
f. During obtaining information, the scan tool is receiving information from all modules at the
same time. But only ECM information is
displayed on the screen.
g. Turn OFF all accessories and press “Okay”.
h. Verify that the correct VIN is displayed on the scan tool. If the VIN is incorrect or no VIN,
record the correct VIN.
2. Turn OFF the ignition.
3. Turn OFF the scan tool and disconnect from the vehicle.
4. Transfer the data from the terminal to the scan tool using the following procedure:
Notice: The TIS supports service programming with
the Tech 2 scan tool only.
a. Connect the scan tool to the terminal.
b. Launch the TIS application.
c. Select the Service Programming System at the main screen.
d. Highlight the following information on the Select Diagnostic Tool and Programming Process
screen, then click “Next”.
• Select Diagnostic Tool - Tech 2
• Select Programming Process - Identify whether an existing TCM is being
reprogrammed or a TCM is being replaced
with a new one
• Select ECU Location - Vehicle
e. Verify the connections on the Preparing for Communication screen, then click “Next”.
f. Verify the VIN on the Validate Vehicle Identification Number (VIN) screen, then click
“Next”.
Notice: If the TCM is replaced to new one, VIN does
not displayed. Input correct VIN reading from stamped
VIN or affixed VIN plate on the vehicle. If the TCM from
another vehicle is installed, input correct VIN by same
way.
g. Highlight Transmission on the Select SystemType screen, then click “Next”, if on-screen
instruction displayed.
h. Complete the following information based on the service ID plate on the Validate Vehicle
Data screen until “Next” is highlighted, then
click “Next”.
• Model • Model year
• Engine type
• Model designator
• Destination code
• Transmission type
i. Verify your selection on the Summary screen.
Notice: Refer to Service Bulletin and Description
column before service programming is performed if the
bulletins are listed along with the calibration files.
Notice: Select Cancel if you receive a message stating
that the calibration selected is already the current
calibration in the TCM and reprogramming with the
same download is not allowed.
j. Click “Reprog”.
k. The Transfer Data screen will appear until the progress bar reaches 100%.
5. Close the application and return to the TIS application selection screen after the download is
completed.
6. Turn OFF the scan tool and disconnect from the terminal.
7. Transfer the data from the scan tool to the TCM using the following procedure:
a. Install a scan tool.
b. Turn ON the ignition, with the engine OFF.
c. Select Service Programming System (SPS) > Program ECU.
d. Turn OFF all accessories and press “Continue”.
e. Programming in Process will appear until the progress bar reaches 100%.
Notice: Some warning lamp may turn ON or blink while
programming the TCM since communication between
the TCM and other modules are interrupted. Clear DTC
in any module after programming.
f. Press “Continue” and exit the program after thescan tool displays “Programming Was
Successful”.
8. Turn OFF the ignition.
9. Turn OFF the scan tool and disconnect from the vehicle.
Service Programming System (SPS) (Pass-
Thru Procedure)
Pass-Thru programming allows the scan tool to remain
connected to the terminal and to the vehicle throughout
the programming process. The vehicle must be in close
proximity to the terminal while using Pass-Thru.
1. Launch the TIS application.
2. Select the Service Programming System at the main screen.
3. Highlight the following information on the Select Diagnostic Tool and Programming Process screen,
then click “Next”:
• Select Diagnostic Tool-Select Pass - Thru

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7A2-142 TRANSMISSION CONTROL SYSTEM (JR405E)
• Select Programming Process - Identifywhether as existing TCM is being
reprogrammed or an TCM is being replaced
with a new one.
• Select ECU Location - Vehicle
4. Complete all vehicle data on the Preparing for Communication/ Determine Vehicle screen until
“Next” is highlighted, then click “Next”.
5. Follow the instruction on the Preparing for Communication screen, then click “Next”.
Notice: In order to reduce the potential for signal loss,
the RS-232 cable should not be more than 25 feet long.
6. Verify the VIN on the Validate Vehicle Identification Number (VIN) screen, then click “Next”.
Notice: If the TCM is replaced to new one, VIN does
not displayed. Input correct VIN reading from stamped
VIN or affixed VIN plate on the vehicle. If the TCM from
another vehicle is installed, input correct VIN by same
way.
7. Highlight Transmission on the Select System Type screen, then click “Next”, if on-screen instruction
displayed.
8. Complete the following information based on the service ID plate on the Validate Vehicle Data
screen until “Next” is highlighted, then click “Next”.
• Model
• Model year
• Engine type
• Model designator
• Destination code
• Transmission type
9. Verify your selection on the Summary screen.
Notice: Refer to Service Bulletin and Description
column before service programming is performed if the
bulletins are listed along with the calibration files.
Notice: Select Cancel if you receive a message stating
that the calibration selected is already the current
calibration in the TCM and reprogramming with the
same download is not allowed.
10. Click “Reprog”.
11. The Transfer Data screen will appear until the progress bar reaches 100%.
Notice: Some warning lamp may turn ON or blink while
programming the TCM since communication between
the TCM and other modules are interrupted. Clear DTC
in any module after programming.
12. Close the application and return to the TIS application selection screen after the download is
completed.
13. Turn OFF the ignition.
14. Turn OFF the scan tool and disconnect from the vehicle.

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7A2-144 TRANSMISSION CONTROL SYSTEM (JR405E)
The JR405E automatic transmission is electrically
controlled by a transmission control module (TCM).
There are four forward speeds and one reverse speed.
This JR405E automatic transmission employs a clutch
pressure direct control system (Direct Electronic Shift
Control: DESC) using duty cycle type solenoid valves,
which ensure high shift quality. This transmission also
has a learning function and constantly checks the time
of each clutch and brake required for the shift in order
to match this time with the target value for the optimum
shift. The TCM will automatically select the most
appropriate shift points and lock-up points depending
on the accelerator pedal opening, the vehicle speed
and the vehicle load. If any trouble arises in the speed
sensor, solenoid valve, etc., the fail-safe control
function is activated to keep the running performance.
The JR405E automatic transmission consists of the
torque converter, oil pump, input shaft, out put shaft,
planetary gears and valve body. The gear train consists
of two planetary gear sets and three multiple plate
clutches in combination with two multiple plate brakes
and a one-way clutch.
Transmission Component Description
Torque Converter
Legend
1. Pump impeller
2. Turbine runner
3. Stator
4. Converter front cover
5. One-way clutch
6. Torque converter clutch (TCC) piston
7. Torsion damper
The torque converter is a device for transmitting the
engine torque to the transmission. It transmits power by
means of oil when the lock up clutch is disengaged,
and by means of a lock up clutch when it is engaged. The torque converter is of the symmetrical, three-
element, single-stage, two-phase type. As shown in the
picture, the symmetrical three-elements refer to three
elements (components) consisting of impeller (1),
turbine (2) and stator (3) that are arranged
symmetrically. Single-stage means that there is only
one turbine as an output element; two-phase means
that the pump impeller acts as a torque converter when
the turbine speed is comparatively low, and as a fluid
coupling when the speed is high. Lock up refers to a
fixed state of the lock up clutch (=torque converter
clutch (TCC) inside the torque converter and thus
connects the engine directly to the transmission.
Oil Pump
Legend 1. Torque converter
2. Oil pump

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TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-145
Legend1. Oil pump cover
2. Inner rotor
3. Outer rotor
4. Oil pump housing
The oil pump generating oil pressure is a small sized
trochoid gear type oil pump. It feeds oil to the torque
converter, lubricates the power train mechanism, and
feeds the oil pressure to the oil pressure control unit
under pressure. The oil pump is located behind the
torque converter. Since the inner rotor in the oil pump is
fitted with the drive sleeve of the torque converter, it
works using power from the engine.
Legend
1. Pressure regulator valve
2. Outlet
3. Inlet
When the inner rotor in the oil pump rotates,
transmission fluid is sucked in from the oil pan, passed
between the inner rotor, outer rotor and crescent, and
then discharged. This discharged pressure is sent to
the pressure regulator valve in the valve body, and
adjusted as required for operating the transmission.
The flow rate under pressure increases or decreases in
proportion to the number of rotations.
Input Shaft
The input shaft has some oil holes, through which
lubricating transmission fluid is supplied to the torque
converter, the bearings, etc. The input shaft is fitted to
the turbine runner in the torque converter, the reverse &
high clutch drum and the rear sun gear by means of the
spline. Therefore, the engine driving force received by
the torque converter is transmitted to the reverse &
high clutch drum and rear sun gear.
Output Shaft
The output shaft has some oil holes, through which the
lubricating transmission fluid is supplied to the
bearings, the planetary gear unit, etc. The output shaft
transmits the engine driving force from the planetary
gear to the propeller shaft. The front internal gear is
fitted with the rear carrier assembly by spline. The
parking gear is also fitted by spline. By fixing this gear
mechanically, the output shaft is fixed as required when
parking the vehicle.

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TRANSMISSION CONTROL SYSTEM (JR405E) 7A2-151
The transmission fluid temperature (TFT) sensor is part
of the harness assembly. The sensor is a variable
resistor and it measures the temperature of the
transmission fluid. When the TFT sensor is cold, the
sensor resistance is high. When the transmission fluid
temperature increases, the sensor resistance
decreases. With high sensor resistance, the TCM
detects a high voltage on the signal circuit. With lower
sensor resistance, the TCM detects a lower voltage on
the signal circuit.
If the fluid temperature increases to 135 °C (275 °F), the
TCM illuminates A/T Oil Temp lamp on the instrument
panel cluster. When the fluid temperature deceases
below 125 °C (257 °F), the lamp goes off.
Transmission Range (TR) Switch
Legend 1. Input shaft speed (ISS) sensor
2. Output shaft speed (OSS) sensor
3. TR switch
4. In-line harness connector
The transmission range (TR) switch is connected to the
transmission manual shaft and installed externally to
the transmission case. The selector lever moves the
TR switch position via control cable. The TR switch
relays a signal to the TCM indicating transmission
range position by detecting ignition voltage through an
internal switch. Only one of the seven internal switches
will close for each P, R, N, D, 3, 2 and L position.
Normally, the TCM expects to detect one high voltage
input for each position.
The engine will not crank when the selector lever is at
any position other than the P or N range.
Input Shaft Speed (ISS) Sensor
Legend 1. ISS sensor
2. Reverse & high clutch drum
The input shaft speed (ISS) sensor is located on right-
hand of the transmission case. The ISS sensor is a hall
effect element type sensor, which generates a square
wave signal pulse based on the reverse & high clutch
drum rotational speed (32 pulses per a rotation of the
reverse & high clutch drum that is fitted with the input
shaft by spline). The TCM calculates the turbine speed
by the ISS sensor signal, and uses it to calculate torque
converter slip speed and gear ratio.
3
1
24
P
R
N
D
3
2
L
10732485196
1
2

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