torque ISUZU KB P190 2007 Workshop Repair Manual

Exhaust System – V6 Page 6F – 8

NOTE:
• Support the exhaust system at all times.

• Clean the threads of the attaching bolts, nuts,
studs and flanges with a suitable cleaning
solvent.
• Apply a high temperature anti-seize
compound to the manifold front pipe flange
joint studs, then align the flange over the
studs.
Reinstallation
1. Install any removed O2 sensors, Refer to 6C1 – 1 Engine Management General Info.
2. Position the centre exhaust pipe into location under the vehicle.
3. Install the two rear exhaust flange nuts and bolts (9).
4. Position the front exhaust pipes into location under the vehicle.
5. Install the centre exhaust pipes into the rubber mounts (6).
6. Install the exhaust flange fixing nuts (1), three each bank.
7. Install the rear exhaust pipe flange nuts (7), two each bank.
8. Reconnect the O2 sensor harness connectors (4), two each bank.
9. Install the two front torsion bar springs, Refer to 3C Suspension.
10. Install the suspension cross member, Refer to 7B1 Manual transmission.
11. Reconnect the battery ground cable.


O2 Sensor
tightening torque.....................................................50 Nm
Front Exhaust Flange Nuts
tightening torque.......................................40.0 – 60.0 Nm
Centre Exhaust Flange Nuts
tightening torque.....................................................43 Nm
Rear Exhaust Flange Nuts
tightening torque.....................................................43 Nm

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 9

3 Silencer and Rear Exhaust Pipe

Figure 6F– 5
1 Centre Exhaust Pipe
2 Exhaust Flange Bolts
3 Exhaust Flange Nuts 4 Exhaust Silencer Mounting Rubber
5 Exhaust Silencer and Tail Pipe
6 Rear Exhaust Pipe Mounting Rubber
Removal
1. Disconnect the battery ground cable.
2. Remove the exhaust flange bolts (2) and nuts (3).
3. Remove the silencer and rear exhaust pipe mounting rubbers (4 and 6).
4. Remove the silencer and exhaust pipe from the vehicle.
NOTE:
• Support the exhaust system at all times.
• Clean the threads of the attaching bolts, nuts,
studs and flanges with a suitable cleaning
solvent.
Reinstallation
1. Position the silencer and exhaust pipe into the vehicle.
2. Install the silencer and rear exhaust pipe mounting rubbers (4 and 6).
3. Install the exhaust pipe flange bolts (2) and nuts (3).
4. Reconnect the battery ground cable.
Rear Exhaust Flange Nuts
tightening torque.....................................................43 Nm

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 10

4 Torque Wrench Specifications
..................................................................................................................... Nm
Front Exhaust Flange Nuts...............................................................40.0 – 60.0
Centre Exhaust Flange Nuts .......................................................................43.0
Rear Exhaust Flange Nuts ..........................................................................43.0
O2 Sensor ...................................................................................................50.0



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–1
7C1
Automatic Transmission – 4L60E –
General Information
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.
1 Section Descriptions ........................................................................................................... ...................3
1.1 WARNINGS, CAUTIONS and NOTES................................................................................................... ................. 3
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 3
WARNING Defined............................................................................................................................................. 3
CAUTION Defined .............................................................................................................................................. 3
NOTE Defined .................................................................................................................................................... 3
1.2 7C1 Automatic Transmission – 4L60E – General Information ....................................................................... .... 4
Recommendations ................................................................................................................................................. 4
Oil Cooler Pipes ..................................................................................................................................................... 4
Clean and Inspect .............................................................................................................. .................................... 5
1.3 7C2 Automatic Transmission – 4L60E – Electrical Diagnosis ...................................................................... ..... 5
1.4 7C3 Automatic Transmission – 4L60E – Hydraulic and Mechanical Diagnosis ............................................... 5
1.5 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing ...................................................................... .... 5
2 General information ...............................................................................................................................6
2.1 Transmission Control Module – HFV6 ............................................................................................. .................... 6
2.2 Transmission Identification .................................................................................................................................. 6
2.3 Economy, Power and Cruise Modes .................................................................................................................... 7
Economy Mode ...................................................................................................................................................... 7
Power Mode ............................................................................................................................................................ 7
Cruise Mode ........................................................................................................................................................... 7
2.4 System Protection Devices ...................................................................................................... ............................. 8
2.5 Self Diagnosis ........................................................................................................................................................ 8
2.6 TCM Sensors and Actuators ................................................................................................................................. 8
3 Transmission Control Module Operation Overview ...........................................................................9
3.1 Transmission Control Module .............................................................................................................................. 9
Component Location ............................................................................................................. ................................ 9
Transmission Control Module Data Transfer ...................................................................................... ................ 9
Transmission Control Module Operation........................................................................................................... 10
3.2 TCM Wiring Diagrams.......................................................................................................................................... 10
4 Transmission Definitions and Abbreviations ....................................................................................1 1
4.1 Throttle Position Related Definitions ................................................................................................................. 11
4.2 Noise Condition Related Definitions ............................................................................................ ...................... 11
4.3 General Definitions .............................................................................................................................................. 11
4.4 Abbreviations ....................................................................................................................................................... 14
5 Service Notes ........................................................................................................................................15
Fasteners .............................................................................................................................................................. 15
General Workshop Practice ................................................................................................................................ 15
6 Torque Specifications .......................................................................................................... ................16
7 Transmission Specifications.................................................................................................... ...........17

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–4
1.2 7C1 Automatic Transmission – 4L60E –
General Information
This section provides general information about the automatic transmission, including:
• A glossary of terms,
• Transmission identification information,
• Electrical overview of the Transmission Control Module (TCM),
• Some notes that address safe workshop practices,
• Service notes relating to fasteners and consumable items used at various stages throughout this section,
• Special tools required to work on the transmission,
• Fastener torque specifications, and
• Transmission specifications.
For all information relating to the mechanical construction and function of the 4L60E automatic transmission, refer to the
General Motors Powertrain Group Electronically Controlled Automatic Transmission Technician’s Guide.
This guide includes such information as:
• Transmission Cutaway Views,
• Principles of Operation,
• Power Flow,
• Complete Hydraulic Circuits,
• Bushing and Bearing Locations,
• Seal Locations and
• Illustrated Parts List.
NOTE
Specifications quoted in this General Motors
Powertrain Group Electronically Controlled
Automatic Transmission Technician Guide may
not be for the vehicle you are working on. For
correct specifications refer to
7 Transmission Specifications.
Recommendations
When servicing the transmission, all parts should be cleaned and inspected. Individual units should be reassembled
before disassembly of other units to avoid confusion and interchanging of parts.
a Thoroughly clean the transmission exterior before removal of any component.
b Disassembly and reassembly must be made on a clean work bench. Cleanliness is of the utmost importance, the bench tools and parts must be kept clean at all times.
c Before installing screws and other fasteners into aluminium parts, dip screw threads into transmission fluid to prevent galling aluminium threads and to prevent screws from seizing.
d To prevent thread stripping, always use a torque wrench when installing screws or nuts.
e If threads in aluminium parts are stripped or damaged, the parts can be made serviceable by the use of commercially available thread inserts.
f Protective tools must be used when assembling seals to prevent damage. The slightest flaw in the sealing surface of the seal can cause an oil leak.
g Aluminium castings and valve parts are very susceptible to nicks, burrs, etc. and should be handled with care.
h Expand Internal snap rings and compress external snap rings if they are to be re-used to ensure proper seating when reinstalled.
i Do not re-use removed O-rings, gaskets and oil seals.
j Teflon oil seal rings should not be removed unless damaged.
k During assembly of each unit, all internal moving parts must be lubricated with transmission fluid.
Oil Cooler Pipes
Should any transmission fluid cooling pipe suffer accidental damage, a genuine replacement pipe must be fitted. Refer to
the current release of PartFinder™ to determine the correct part number for the particular engine and pipe involved.
Reworking of damaged pipes or hand made replacements are not permitted.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–7

Figure 7C1 – 1
Legend
1 Model year
2 Broad Cast Code Identifier
3 Manufacturer Source Code 4 Julian Date
5 Shift Build 6 Individual Transmission Serial Number
7 Identification Stamping Location
2.3 Economy, Power and Cruise Modes
The programming in the transmission control module (TCM) allows for different shift patterns, which are driver
controllable through the use of the power (PWR) button. The power button is located in the centre console.
Economy Mode
The calibration for this mode is for maximum comfort, with minimal intrusion of engine noise and smooth shifts under all
driving conditions. When additional power is required for acceleration, full throttle upshifts are similar to those calibrated
for the power mode.
Power Mode
When activated, the TCM modifies the transmission calibration in the following ways:
1 When the throttle is less than 80% open, later upshift points are provided.
2 Shift time is reduced.
3 The torque converter clutch (TCC) will be applied in both the third and fourth speed ranges.
Cruise Mode
When the driver activates the cruise control (where fitted), the power icon in the instrument clusters multi-function display
(MFD) will be deactivated (provided the vehicle was operating in power mode) and the transmission shift pattern will
switch to the cruise control pattern. When in this mode, the TCM modifies the shift pattern so that earlier downshift and
later upshift points are provided.
Through the electronic programming of the logic processes contained in the TCM, the frequency of gear shifting and
torque converter clutch application and release is minimised. The end result of these logic processes, is that a quick
series of upshifts and downshifts (e.g. a '4 – 3 – 4' shift pattern) is minimised.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–8
2.4 System Protection Devices
Should 1st gear be selected and left in that range, the TCM will protect the engine from an over-speeding condition by
upshifting to 2nd gear at a pre-determined point. Similarly, the TCM provides high speed, downshift protection by
preventing a manual shift into 1st gear above pre-determined engine speeds.
Under severe operating conditions such as towing in high ambient temperatures, fluid temperatures can rise to a point
where lubrication breakdown can occur. In addition to having an oil cooler fitted to the vehicle, the 4L60E transmission is
also fitted with a transmission fluid temperature sensor located in the Transmission Range (TR) Pressure Switch
Assembly (PSA).
When fluid temperatures in excess of 135 °C are sensed, the torque converter clutch is applied as programmed, in 3rd or
4th gear. This action reduces further the fluid temperature during normal operation of the torque converter. While these
high fluid temperatures are sensed however, torque converter clutch apply is not available when the throttle opening is
above 50%.
Similarly, when the fluid temperature is below 29 °C, the TCM prevents torque converter clutch apply.
If a condition occurs, preventing electronic control of the transmission's functions, a 'Fail Safe' mode will default the
transmission to 3rd gear when either Drive or 3 is selected, applying also maximum line pressure. W hile in this mode, the
vehicle operator can still manually select 2, 1, Reverse, Park or Neutral, should the need arise.
2.5 Self Diagnosis
If any transmission operation controlled by the TCM begins to operate outside its pre-set parameters, the TCM has the
ability to store a range of diagnostic codes which can be accessed by the servicing technician, thereby localising the
problem.
2.6 TCM Sensors and Actuators
As indicated earlier, there are a number of sensors and switches providing input information for the TCM programming
that will allow the TCM to change the shift pattern, shift feel and torque converter clutch operation.
The TCM does this by comparing this input information with its predetermined values on shift pattern, fluid pressure
maps, shift duration parameters, extreme heat protection programming and adaptive controls.
In addition, each input signal and output actuator operation is also monitored and if outside its pre-set parameters, a
diagnostic code is logged for future reference by the servicing technician.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–9
3 Transmission Control Module
Operation Overview
3.1 Transmission Control Module
W ith the introduction of the new HFV6 engine, the powertrain architecture has been redesigned to accommodate this
introduction. W ith this design, a new bus architecture and protocol has also been introduced. The new bus connects the
following modules:
• engine control module (ECM),
• transmission control module (TCM),
• powertrain interface module (PIM) and
• ABS module.
The protocol used to communicate between these modules is called General Motors Local Area Network (GM LAN)
which is based on Controller Area Network (CAN) communication protocol. For further information on GM LAN protocol
and data bus structure, refer to 6E1 Powertrain Interface Module – V6.
Component Location
The TCM (1) is located under the instrument panel, it is attached to a bracket mounted to the firewall as shown in
Figure 7C1 – 2.
For the other components using the GM LAN databus, refer to 6E1 Powertrain Interface Module – V6.

Figure 7C1 – 2
Transmission Control Module Data Transfer
The TCM uses various information to control the shift of the transmission. Besides the direct inputs from the various
transmission sensors directly into the TCM, the TCM uses data from the GM LAN databus.
The inputs/outputs directly connected to the TCM from the transmission are:
• shift solenoids,
• torque converter clutch control,
• pressure control solenoid,
• transmission fluid temperature sensor and
• vehicle speed sensor.
Refer to 3.2 TCM Wiring Diagrams.
The transmission also receives inputs from the park/neutral position and back up lamp switch assembly.
The TCM needs other various data parameters to control the transmission correctly. These include throttle plate angle,
whether cruise control is engaged and active or not, engine RPM etc. These are provided to the TCM from the ECM via
serial data using GM LAN communication protocol.
The TCM also supplies information that is used by other components and systems within the vehicle such as the engine
control module (ECM) and instrument cluster. Any information that is required on the body side of the data bus (UART
protocol) is translated by the powertrain interface module (PIM). For further information on the data bus structure, the
PIM and its operation, refer to 6E1 Powertrain Interface Module – V6.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–10
Transmission Control Module Operation
The TCM processes data every 10 milliseconds from various sensors, such as throttle position, vehicle speed, gear
range, temperature, engine load and other inputs. The TCM compares all its various inputs with the internal programming
and calibration of the TCM using this data, a signal is transmitted to the valve body shift solenoids, which activate the
shift valves for precise shift control. Shift points are therefore precisely controlled and are identical from vehicle to vehic le.
The TCM also control torque converter clutch apply and release.
Shift feel is also electronically controlled by the TCM, by signals sent to the variable force solenoid, which controls fluid
line pressure and it is this pressure that precisely determines how the shifts will feel. In this way, the TCM electronically
synchronises the engine and transmission into a single integrated powertrain system for optimum performance, shift
timing, fuel efficiency and emission control.
3.2 TCM Wiring Diagrams
For details of the transmission control module (TCM) wiring diagrams, refer to 8A Electrical-Body and Chassis.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – General Information Page 7C1–11
4 Transmission Definitions and
Abbreviations
The following definitions and abbreviations are provided to establish a common language and assist the user in
describing transmission related conditions. The use of these terms and/or conditions can be found in the various parts of
the automatic transmission sections, but more particularly in 7C3 Automatic Transmission – 4L60E – Hydraulic and
Mechanical Diagnosis.
4.1 Throttle Position Related Definitions
Throttle Position Definition
Minimum Throttle The least amount of throttle opening required for an upshift.
Light Throttle Approximately 1/4 of accelerator pedal travel (25% Throttle Position).
Medium Throttle Approximately 1/2 of accelerator pedal travel (50% Throttle Position).
Heavy Throttle Approximately 3/4 of accelerator pedal travel (75% Throttle Position).
Wide Open Throttle (WOT) Full travel of the accelerator pedal (100% Throttle Position).
Full Throttle Detent Downshift A quick apply of the accelerator pedal to its full travel, forcing a downshift.
Zero Throttle Coast Down A full release of the accelerator pedal while the car is in motion and in drive range.
Engine Braking A condition where the engine is used to slow the car by manually downshifting
during a zero throttle coast down.
4.2 Noise Condition Related Definitions
Noise Condition Definition
Planetary Gear Noise A whine related to car speed most noticeable in first gear or reverse. Becomes less
noticeable after an upshift.
Pump Noise A high pitch whine increasing with engine r.p.m.
4.3 General Definitions
General Definition
Accumulator A component of the transmission that absorbs hydraulic pressure during the apply of a
clutch or band. Accumulators are designed to control the quality of a shift from one gear range to another.
Adaptive Learning Programming within the TCM that automatically adjusts hydraulic pressures in order to compensate for changes in the transmission (i.e. component wear).
Applied An 'Applied Component' is holding another component to which it is splined or
assembled to. Also referred to as "engaged".
Apply Components Hydraulically operated clutches, servo’s, bands and mechanical one-way roller or
sprag clutches that drive or hold members of a planetary gear set.
Apply Plate A steel clutch plate in a clutch pack, located next to the (apply) piston.
Backing Plate A steel plate in a clutch pack that is usually the last plate in that clutch assembly
(furthest from the clutch piston).
Band An apply component that consists of a flexible strip of steel and friction material that
wraps around a drum. When applied, it tightens around the drum and prevents the drum from rotating.
Brake Switch An electrical device that provides signals to the transmission control module (TCM),
based on the position of the brake pedal. The TCM uses this information to apply or
release the torque converter clutch (TCC).
Centrifugal Force A force that is imparted on an object (due to rotation) that increases as that object moves further away from a centre-point of rotation.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007