engine ISUZU KB P190 2007 Workshop Repair Manual

7D1-20 TRANSFER CONTROL SYSTEM
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
During
operation (4H
waiting) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed 4L to 4H
while
waiting
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Open Open Closed
Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation1,0,1,0 Open Open Closed -----
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----

• Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts
in both directions (H ←→Neutral ←→L).

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ISUZU KB P190 2007

7D1-22 TRANSFER CONTROL SYSTEM
• Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts
in both directions (H ←→Neutral ←→L).

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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-41
CONNECTOR LIST
No. Connector face No. Connector face
B13



White
Fan switch B85



W eld splice 7 (Ground)
B23


White
Meter-A B95



White

Keyless entry control unit
B24


White
Meter-B B96



Gray PIM1
B54


White
J/B I2 B97



WhitePIM2
B56


White
J/B I4 C2



SilverEngine room-RH ground
B62


White
Ignition switch (IGSUB: G1) C4



Sky blueFront wiper motor
B63


White
Ignition switch (IGSUB: G2) C5

~
C14 NOT USED
B64




W eld splice 1 (Illumination) C36



SilverEngine room-LH; ground
B65



W eld splice 2 (Ground) C56
(C24SE)

ECM
B66


White
4 ×4 switch C56
(4JH1-TC)


Black
ECM-A


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ISUZU KB P190 2007

7D1-42 TRANSFER CONTROL SYSTEM

No. Connector face No. Connector face
C56
(HFV6)

Black
ECM-A C107



WhiteJ/B E2
C57


Black ECM-B C108



WhiteJ/B E1
C58


Black ECM J2 C109



SilverBody-CTR; ground
C67


Black
EHCU C111



BlackTransfer case control module
C77


White
Clutch switch C112



BlackTransfer case control module
C94


White
TCM-A (AW 30-40LE) C118




A/C Resister & Neutral switch
C94


Gray
TCM-A (JR405E) C134



Gray Sof actuator
C95


White
TCM-B (AW 30-40LE) E6



Injector pump
C95


White
TCM-B (JR405E) E10



SilverEngine ground
C106


NOT USED E11


Natural green
Neutral switch


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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-43

No. Connector face No. Connector face
E12


Natural green
Neutral switch E78

~
E80 NOT USED
E35



Black
Motor actuator E96



BlackReverse switch
E36



TACHO sensor E110



BrownBackup light switch
E42

Natural green
Backup light switch E111



BrownNeutral switch
E43

Natural green
Backup light switch E116



Backup light switch
E44


Black
Vehicle speed sensor F5



Gray Rear combination light-RH
E45


Gray
2W D-4W D switch F6



BlackRear combination light-LH
E46


Brown
H-L neutral switch H3
(HFV6
4JH1-TC)

Gray
GBattery (+) ~ Engine room
E51


Gray
Inhibiter switch (AW 30-40LE) H4
(HFV6)
(C24SE)
WhiteEngine room ~ Mission
E51


Black
Inhibitor switch (JR405E) H4
(4JH1-TC)


White
Engine ~ Engine room


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ISUZU KB P190 2007

7D1-44 TRANSFER CONTROL SYSTEM

No. Connector face No. Connector face
H4
(4JJ1-TC)


White
Engine ~ Engine room H23
(4JA1-L)

WhiteEngine room B ~ T/misson
H5
(HFV6
4JH1-TC)

White
Engine room ~ Mission H27



NOT USED
H5
(4JJ1-TC
4JA1-L)


White
Engine ~ Engine room H29
(C24SE)

Battery (+) ~ Engine room
H6


White
Engine room ~ INST H32
(C24SE)

Engine room ~ Rear body
H7


White
Engine room ~ INST H48



WhiteEngine room ~ INST
H7
(4JJ1-TC)


White
Engine room ~ INST H50



Engine & Mission ~
H15
(HFV6
4JH1-TC)

Black
Engine room ~ Chassis M26
(C24SE)

Brown2W D-4W D switch
H15
(
4JJ1-TC,
4JA1-L)
Black
Engine room ~ Chassis M27
(C24SE)

BrownHead leveling neutral switch
H18


White
Engine room ~ INST P1



SilverBattery (+)
H23


White
Engine ~ Engine room B P2



SilverRelay & Fuse box


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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-45

No. Connector face No. Connector face
P5



Silver
Battery (-)

P6



Silver
Body earth (Ground)

P7




Battery (ALT)

P10



Silver
Engine ground

P11



Silver
Fuse & relay box

P13



Gray
Shift on the fly actuator

R14



Black
2W D-4W D control unit

R15



Black
2W D-4W D control unit

X12



Black
ECM main relay





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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-47
3. Shifting from 4H to 4L
3-1 When the 4L indicator flashes at 2Hz
W hen shifting from 4H to 4L, the 4L indicator continues flashing at 2Hz until shifting in the transfer case is
completed. The phases of the engaged splines may sometimes deviate preventing completion of shifting. By
correcting the deviation of phases, shifting is completed.

Step 3-1:
(In case of AT): Set the select bar of the transmission to the D position.
(In case of MT): Set the lever of the transmission to a position allowing running and engage the clutch gently.
At this time, some rotating force acts on the engaged splines, phase is corrected and the engagement is
completed.
3-2 When the 4L indicator flashes at 2Hz for 10 seconds and then keeps ON again (AT vehicle)
This condition occurs when torsional torque has been generated between the transmission and road surface
and the transfer standby mechanism cannot absorb it completely.

Step 3-2:
Set the select lever of the transmission to the N position. (Stepping on the brake pedal is effective at
this time.)
3-3 When the 4L indicator flashes at a frequency of 4Hz
Shifting from 4H to 4L is restricted.
W hen the vehicle is running, the transmission lever is at the running range and the engine speed is high (L4:
3000rpm or more V6: 2000rpm), the transfer cannot be shifted from 4H to 4L (restriction on operation).
Restriction on operation (Except 4JA1-T)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, engine speed and TM
position).
Requirement to restrict the speed: Vehicle should be in stop. Due to the detection logic, time to wait for start of operation may be required.
A/T: If the vehicle is in stop for a long time at the TM running range (D, 1, 2) before operating the AT, waiting
time becomes longer (from 1 second to 3 minutes at the maximum).
M/T: If the vehicle is at stop with the clutch stepped on at the T/M running position (1 – R), the time to wait
becomes longer.
W aiting time means the time commencing from when other requirements (engine speed and T/M position) are
met to permission of the speed restriction. Operation during the waiting time is not permissible.
The waiting time is 1 second at the minimum and increases up to 5 seconds if the above condition continues for
3 minutes. After that, the waiting time increases up to 3 minutes in 2 minute intervals.
W hen it is clear that the above condition has continued and reduction of waiting time is required, turn on or off
the ignition or start and stop the vehicle several meters.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.
Requirements for permission of restriction on T/M position restriction:
(AT) N range is recommended
(MT) should be at the neutral.

These requirements for permission should all be met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.

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7D1-48 TRANSFER CONTROL SYSTEM
Restriction on operation (4JA1-T)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, and TM position).
Requirement to restrict the speed: Vehicle should be in stop.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm or below is advisable.
Requirements for permission of restriction on T/M position restriction:
should be at the neutral.

These requirements for permission should be all met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.
Note: Don’t’ accelerate engine speed a the time of this operation.

Step 3-3:
Stop the vehicle. (Close the accelerator and decrease the engine speed to below L4: 3000rpm, V6: 2000rpm.)
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position. (Stepping on the clutch is recommended.) Push the 4L button.
If shifting operation is not completed (the lamp flashes at 2Hz), perform step 3-1.

4. Shifting from 4L to 4H
4-1 When 4L indicator continues flashing at 2Hz
W hen shifting from 4L to 4H, the 4L indicator continues flashing at 2Hz until the shifting in the transfer case is
completed. Phases of engaged splines may deviate and the operation may not be completed in some cases.
Shifting is completed by correcting the deviation of the splines.

Step 4-1: (same as step 3-1)
(In case of AT): Set the transmission select lever to the D position.
(In case of MT): Shift the transmission lever to a position allowing running and engage the clutch gently.

4-2 When the indicator continues flashing at 2Hz for 10 seconds and then keeps on at 4L again (AT
vehicle)
This condition occurs when torsional torque has been generated between the transmission and the road
surface (use of the parking position on a slope). Resistance against the separation of the driving force cannot
be completed by the waiting mechanism of the transfer.
Shifting is also possible by using the brake at the neutral position of the transmission

Step 4-2: (Same procedure as the step 3-2)
Set the transmission select lever to the N position.
(Leaving the brake lever and stepping on it again is recommended.)

4-3 When the 4L indicator flashes at 4Hz
Shifting from 4L to 4H is restricted.
W hen the vehicle is running, the transmission lever is at the running range, and the engine speed is high, the
transfer 4L cannot be shifted to 4H.


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TRANSFER CONTROL SYSTEM 7D1-49
Step 4-3: (Same procedure as the step 3-3)
Stop the vehicle (close the accelerator and decrease the engine speed to L4: 3000rpm V6: 2000rpm or below).
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position (stepping on the clutch lever is recommended).
Push the 4H button.
If shifting is not complete (indicator flashes at 2Hz), go to step 4-1.

5. When shifting from 4H or 4L to neutral
(Same procedure is required when shifting from 2H but in such a case, requirements for shifting from
2H to 4H are also applied.)
5-1 Neutral indicator continues flashing at 2Hz The neutral indicator continues flashing at 2Hz until 4H (4L) is completely separated in the transfer. If torsional
torque has accumulated between the transmission and road surface, separation may be difficult.
Step 5-1:
If the operation is not complete, execute step 7 for confirmation.
(In case of AT): Set the transmission select lever to the D position. After confirming that the gears are at the neutral position, return the lever to the N
position.
(In case of MT): Set the transmission lever to a vehicle running position and engage the clutch gently. After confirming that the gears are at the neutral position, return the lever to the
neutral position
5-2 When the neutral indicator flashes at 4Hz
As in the case of shifting from 4L to 4H, restriction is imposed to the operation from 4L or 4H (including 2H). If
the transmission lever is at a running range and engine speed is high (L4: 3000rpm, V6: 2000rpm or more)
while the vehicle is running, operation from the 4L or 4H (including 2H) of the transfer to the neutral is
impossible (restriction on operation).
Step 5-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch is recommended).
Keep pushing the 2H and 4L button for 10 seconds.
Follow the start procedure for confirmation. (Confirmation of drive force is not transferred; same as in
step 5-1)
After the confirmation, set the transmission to the neutral position in the case of MT or to the neutral
position in the case of AT.

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ISUZU KB P190 2007