ECU ISUZU KB P190 2007 Workshop Repair Manual

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-117

(3) All of the following conditions are met.
• Device Control is not operating.
• Disable Normal Communication is receiving
enable.
• DTC Clear is not operating.
(4) DTC U2104 is not detecting failure or not deciding failure.
Condition For Setting The DTC
Detection standard is met for 2.5 second continuously.
Detection standard:
If one or more ID sent from Engine Control Module
(ECM) is not completed receiving for 2 basic cycles
since last receiving completion.
Action Taken When The DTC Sets
• Throttle judgment on torque reduction control, line
pressure control at stationary status, line pressure
reduction control at gear change and line pressure
reduction control at garage. (Throttle opening 100%)
• Line pressure FULL output.
• Throttle judgment on gear change control (Throttle
opening 0%).
• No line pressure reduction control at gear change.
• No torque reduction control.
• No squat control.
• No slope control (keep mode).
• No L-up control.
• Control Engine rpm at 7000rpm (No inertia
calculation).
• Control actual torque at MAX.
• Control driver torque at MAX.
• Control engine coolant temperature at 80 °C (176 °F).
• No coast control.
• No 3rd Start mode control.
• No line pressure reduction control at garage.
• No output revolution sensor failure detection.
• No C-0 rev sensor failure detection.
• No selector position switch failure detection.
• No oil temperature sensor failure detection.
• No T/F Hi-Low SW failure detection (Execute T/F
judgment using only T/F-SW ).
• No speed mater signal failure detection.
• No throttle signal failure detection.
• No Engine torque signal failure detection.
• No engine coolant temperature signal failure
detection.
• No Engine revolution signal failure detection.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• Cancel engine rpm condition of prerequisite of suppl
y
voltage failure detection.
• Control vehicle speed of speed meter at 0km/h.
• No torque reduction at stall.
• No cruise control.
• No warm up control.
• Check Trans “ON”.
• DTC stored.
• MIL request “ON”. (EURO 4 only)
Conditions For Clearing The DTC
• The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without a
failure reported.
• After more than 1 second has elapsed after the ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
• Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
• Inspect the wiring for EMI (Electro-Magnetic
Interference). Check that all wires are properly routed
away from coil, and generator. Also check fo
r
improperly installed electrical options. W hen this test
is performed, turn “OFF” on electronic auto parts
switches to improperly for a noise preventing.


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ISUZU KB P190 2007

ON-VEHICLE SERVICE (AW30–40LE) 7A3-19
ATF Replacement
Inspection
NOTE: Do not overfill.
1. Remove the drain plug from oil pan and drain the
fluid.





RUW 17ASH013401
2. Reinstall the drain plug securely.
Torque: 19 N ⋅
⋅⋅
⋅
m (1.9 kgf ⋅
⋅⋅
⋅
m/14 Ib ⋅
⋅⋅
⋅
ft)
3. W ith the engine OFF, add new fluid through the fille
r
tube.



Drain and refill 5.2 liter
Dry fill 8.7 liter
Fluid Exxon Mobil ATF-3309
4. Start the engine and shift the selector into all
position from “P" through “L", and then shift into “P".
5. W ith the engine idling, check the fluid level. Add fluid up to the “COLD" level on the dipstick.
6. The ATF level must be checked again for correct level with the “HOT" level.
NOTE: To prevent fluid leaks, the drain plug gasket
must be replaced each time this plug is removed.



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7A3-26 ON-VEHICLE SERVICE (AW30–40LE)
Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Remove the rear console and the front console.
4. Remove the 2 screws fixing the select lever knob.
5. Remove the knob together with the knob button and spring from the lever.
6. Turn the sleeve counterclockwise to remove it. Make a note of the number of turns required to free
the sleeve.
7. Remove the harness connectors from the base plate.
8. Remove the upper housing (held in place by 4 latched fasteners).
9. Remove the lamp assembly by turning it counterclockwise.
10. Remove the spring plate.
11. Remove the grooved pin.
12. Disconnect the shift cable from the select lever.
13. Remove the lever assembly by pressing the rod down (lever in N position).
14. Remove the harness connectors from the shift lock unit, then remove the shift lock unit.
15. Remove the interlock controller.
16. If the replacement of shift lock release button o
r
shift lock button spring is required, remove the
position indicator housing, the shift lock button
spring and shift lock release button can be
removed.


Install or Connect
NOTE
Apply MULTEMP No. 2 grease (or equivalent) to the
select lever. Refer to the illustration.


RTW 77ALH000201
1. Install the interlock controller.
2. Install the shift lock unit and connect the harness to the shift lock unit.
3. Install the lever assembly to the base plate. a. Insert and secure the shaft and connect the cable.
b. Insert pawled end of the shaft into the base plate hole.
c. Insert the detent pin of the shaft into detent aperture (lever assembly in N position).
d. Install the grooved pin.



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ON-VEHICLE SERVICE (AW30–40LE) 7A3-27
4. Install the spring plate.
a. Insert the detent pin into the base plate detent groove until it touches the front wall (leve
r
assembly in N position).
RTW 37ASH001001
b. Stack the short spring plate and tighten thescrews to the specified torque.


Screw torque 2 N ⋅m (0.2kgf ⋅m/17 lb ⋅in)
c. Check that the detent pin moves smoothly in the
detent groove (shift knob temporarily installed).
5. Temporarily install the sleeve.
6. Move the lever to the “P” position.
7. Adjust the clearance (2) between the detent plate and the pin by moving the select lever knob sleeve
(1).
Detent plate and pin clearance mm(in
)
0.2 - 1.0 (0.01 - 0.04)




255R300002
8. Install the lamp assembly to the lamp socket.
a.
Align the recessed portion of the lamp socket with
the protruding portion of the lamp assembly.
b. Insert the lamp assembly into the lamp socket and rotate it 90 degrees clockwise.
9. Remove the sleeve and move the lever to the “N” position.
10. Install the upper housing. Make sure that the 4 latched fasteners are securely closed.
11. Attach the harness connectors to the base plate.
12. Install the sleeve (rotate the sleeve clockwise the same number of turns it was rotated
counterclockwise at disassembly).
13. Install the knob, the knob button, and the knob spring.
14. Install the 2 screws securing the knob and tighten them to the specified torque.
Screw torque: 2 N ⋅
⋅⋅
⋅
m (0.2kgf ⋅
⋅⋅
⋅
m/17 lb ⋅
⋅⋅
⋅
in)








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ON-VEHICLE SERVICE (AW30–40LE) 7A3-29
Install or Connect
1. Install the shift cable toward the inside of the cabin
from the bottom of the vehicle.
2. Push the shift cable into the select lever base.
3. Connect the shift cable to the select lever.
4. Fix the shift cable to the bracket.
Install the clip on the marking of shift cable.
5. Check that the select lever is in the “N” position.
6. Check that the transmission is in the “N” position.





249R300002
7. Slide the cover in the direction shown by the arrow
(1).
8. Use an ordinary screwdriver to move the lock piece
from the position indicated by the arrow (2). Continue
to move the lock piece until the adjuster position
begins to change.

P1010012

9. Connect the shift cable to the manual shaft select
lever at the transmission side.
10. Insert the lock piece to the adjuster (cable length
adjustment).
11. Slide the cover on the adjuster and secure lock
piece.

P1010016-2
11. Press the select lever knob button 5 times.
Then check that the select lever moves smoothly to each of its positions.
13. Check that the shift position indicated by the select
lever and the actual shift position are the same.
14. Install the front console and rear console.
15. Connect the negative battery cable.
16. Remove the wheel blocks.



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CONSTRUCTION AND FUNCTION 7A1-31
As a result, the lock-up piston is fitted slowly to the converter cover under pressure securing smooth lock-
up engagement.


Figure 51. Lock-up Control

DIRECT ELECTRIC SHIFT CONTROL (DESC)
Feature
• Based on each switch signal (low & reverse brake pressure, 2-4 brake pressure & high clutch pressure)
and each sensor signal (turbine sensor, speed sensor, engine speed signal & APP position signal), the
duty cycle type solenoid adjusts the clutch pressure to match the engine load and vehicle travel
conditions. Controlling the engagement and disengagement of the clutch and brake pressure is directly
and accurately controlled via TCM, which is different to the previous accumulator type.
Operation
• Instead of the previous system (on/off type of shift solenoid and shift valve), the combination of the duty
cycle type solenoid and the amplifier (Amp) valve are used to adjust the clutch pressure to match the
engine load and vehicle travel conditions, based on the signal from the TCM. Also, the pressure switch
provided in the oil passage of the control valve transmits the oil pressure condition (at that time) to TCM,
enabling the engagement and disengagement control of the clutch and brake to be directly and finely
carried out.
• When the gear is shifted from the 2nd to 3rd, 3rd to 4th (O/D), 4th (O/D) to 3rd and 3rd to 2nd, the clutch
pressures on the engagement side and disengagement side are simultaneously controlled.
As a result, engine racing or clutch drag is prevented which enables a smooth and quick shift response.


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7A2-52 TRANSMISSION CONTROL SYSTEM (JR405E)
DTC P0731, P0732, P0733 or P0734 (Flash Code 41, 42, 43 or 44)
Circuit Description
The TCM calculates the gear ratio based on the input
shaft speed signal from the input shaft speed (ISS)
sensor and the output speed signal from the output
shaft speed (OSS) sensor. The TCM compares the
known transmission gear ratio to the calculated ratio for
the selected gear ranges. If the TCM detects an
unknown transmission gear ratio two consecutive
driving cycles, this DTC will set.
Condition for Running the DTC • Other than DTCs P0731, P0732, P0733 and P0734 are not set.
• The ignition switch is ON.
• The transmission fluid temperature is more than 60 °C (140 °F).
• The input shaft speed is more than 1000 RPM.
• The vehicle speed is more than 10 km/h (6 MPH).
• The selector lever is forward range for longer than 2 seconds.
• The TCM is not under gearshift control.
Condition for Setting the DTC • The TCM detects that the output shaft speed is more than 500 RPM over the calculated speed
(based on the input shaft speed and the gear ratio)
for 7 seconds after each gearshift has completed.
Action Taken When the DTC Sets • The TCM blinks the Check Trans lamp on the second consecutive driving cycle when the
diagnostic runs and fails.
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.
• Electromagnetic interference in the ISS sensor or OSS sensor circuits may set this DTC.
• An intermittent ISS sensor or OSS sensor signal pulse may set this DTC.
• Ensure the ISS sensor and OSS sensor is tight.
• Use the Clutch, Brake, Solenoid and Pressure Switch Logic table to verify each component works
properly within the selected gear range.
• A transmission mechanical problem will cause this DTC to set.
• Sticking or contamination of shift valves may cause intermittent incorrect gear ratios.
• If multiple incorrect gear ratio codes are set, problem in fluid pressure, low ATF level, plugged
filter or oil pump problem may exist.
Notice: • Each DTC agrees with the following gear positions.
- P0731: 1st gear
- P0732: 2nd gear
- P0733: 3rd gear
- P0734: 4th gear
Schematic Reference: Transmission Controls
Schematics
Connector End View Reference: Transmission
Controls Connector End Views or TCM Connector End
Views
Circuit/ System Testing DTC P0731, P0732, P0733 or P0734
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 Perform the ATF level check. Refer to repair
instructions (On-Vehicle Service).
Did you perform the ATF level check? —
Go to Step 3 Go to Transmission
Fluid Checking Procedure
3 1. Install a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Drive the vehicle while observing the DTC Information with a scan tool.
Is there any DTCs set other than P0731, P0732,
P0733 or P0734? —
Refer to Applicable DTC Go to Step 4

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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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