lock ISUZU KB P190 2007 Workshop Repair Manual

7A2-2 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
General Description
The AW 30-40LE is a 4–speed fully electronically
controlled automatic transmission. It uses a
microcomputer as a control unit to judge driving
conditions including throttle opening rate and vehicle
speed, then it sets the shifting point in the optimum
timing so that best driving performance can be
achieved.
In addition, the built–in driving mode select function can
select three driving modes according to the driver's
preference:
• Normal mode –Normal shift pattern.
• 3rd Start mode –Starts in 3rd gear to reduce slippage
on mud, ice or snow.
• Power mode –Delays upshift timing when more
powerful acceleration is required.
Also, the built–in fail–safe function (“emergency mode")
assures driving performance even if the vehicle speed
sensor, throttle signal or any solenoid fails.
Further, the self–diagnostic function conducts diagnosis
in a short time when the control system fails, thus
improving serviceability.
The major features of AW 30-40LE are as follows:
•
A compact structure consisting of 2 sets of planetary
gears and flat torque converter.
• Electronic control selects the optimum driving mode according to the driving conditions.
• Electronic control maintains the optimum hydraulic
pressure for clutch, band brake as well as
transmission so that shift feeling is improved.
• W ide gear ratio and high torque rate of torque
converter provide excellent starting performance.
• Optimum Lock-up control of each driving mode can
have it both ways driving performance and fuel
economy.
• Excellent shift quality can be achieved by the torque
management control through the CAN
communication with the engine.



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TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-3
Components Location




RTW 77ALF002101

Legend (8) One-way clutch (No.2) (F-2)
(1) Overdrive direct clutch (C-0)
(9) Shift solenoid (S-1)
(2) Overdrive brake (B-0)
(10) Shift solenoid (S-2)
(3) Direct clutch (C-2)
(11) One-way clutch (No.1) (F-1)
(4) Second coast brake (B-1)
(12) Pressure control solenoid (STH)
(5) Forward clutch (C-1)
(13) Lock-up solenoid (SL)
(6) Second brake (B-2)
(14) Overdrive one-way clutch (F-0)
(7) First and reverse brake (B-3)



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7A2-10 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
CHECK ITEM PIN No. VALUE NOTE
Shift Solenoid B (S2) C-94: 15–1 P 0V Engine run.
R 0V Engine run. (W ithout the
Reverse position lock out)
N 0V Engine run.
D–1 0V
D–2 VIGN
D–3 VIGN
D–4 0V
Lock-up Solenoid C-94: 5–1 “ON” VIGN (ex.) It is “ON” when the
vehicle speed is more than
65km/h.
“OFF” 0V
Check Trans Lamp C-95: 3–C-94: 1 “ON” 0V Key “ON”
(The lamp is “ON” for 3
second after key “ON”)
“OFF” VIGN
AT Oil Temperature Lamp C-95: 11–C-94: 1 “ON” 0V Key “ON”
(The lamp is “ON” for 3
second after key “ON”)
“OFF” VIGN
Power Lamp C-95: 2–C-94: 1 “ON” 0V Key “ON”
(The lamp is “ON” when the
Power switch is “ON”)
“OFF” VIGN
3rd Start Lamp C-95: 10–C-94: 1 “ON” 0V Key “ON”
(The lamp is “ON” when the
3rd Start switch is “ON”)
“OFF” VIGN
AT Oil Temp Sensor
Resistance C-94: 11–C-94: 12 20
°C/68 °F 12kΩ Key “OFF”
50°C/122 °F 1.5kΩ
155°C/311 °F 293Ω
Pressure Control Solenoid
Resistance C-94: 11–C-942 About

4–7
Ω(20 °C/68 °F)
Key “OFF”
Speed Sensor Resistance C-95: 5–C-95: 14 About 560Ω–
120
Ω(20 °C/68 °F)
Key “OFF”
Input Revolution Sensor
Resistance C-95: 6–C-95: 16 About 560Ω–

120
Ω(20 °C/68 °F)
Key “OFF”
Lock-up Solenoid
Resistance C-94: 5–C-94: 1 About 10Ω–

15
Ω(20 °C/68 °F)
Key “OFF”
Shift Solenoid A (S1)
Resistance C-94: 16–C-94: 1 About 10Ω–

15
Ω(20 °C/68 °F)
Key “OFF”
Shift Solenoid B (S2)
Resistance C-94: 15–C-94: 1 About 10Ω–

15
Ω(20 °C/68 °F)
Key “OFF”

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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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TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-13
Item Description
Reverse lock out control If the select lever is moved to "R" position during forward driving, the TCM prohibits
reverse driving by turn off the S1 and turn on the S2 for prevention of danger and
protection of the automatic transmission.
1. Enable condition a) Vehicle speed is more than 11km/h (7mph).
2. Disable condition a) Vehicle speed is less than 9km/h (6mph).
b) W hen except "R" position is detected.
Auto cruise mode control If the auto cruise control can’t keep the setting speed like a uphill driving, the TCM selects the auto cruise mode shift pattern for downshifting, thus keeping the vehicle
speed.
W arm-up mode control TCM selects the warm-up mode shift pattern in engine cold condition for improvement of drivability and facilitation of warm-up.
Squat control W hen the TCM detects N→D garage shift, the TCM controls 1-3-1 shift by setting
timer, in order to improve the shift feel at N →D.
Coast down control The TCM switches to the coast down control at the coasting, in order to reduce the
roughness of shifting.
Uphill control W hen the TCM detected uphill, the TCM automatically switches to the uphill mode
in two-stage in proportion to inclination pitch to prevent the busy shifting and to
obtain an enough torque.
Downhill control W hen the TCM detected downhill, the TCM automatically switches to the downhill
mode, and shifts to the 3rd or keeps in the 3rd in order to prevent the vehicle
acceleration. Then, the brake load is reduced by a moderate engine brake and fuel
consumption is improved by the fuel cut.
Line pressure control The TCM controls the impressed current of the pressure control solenoid based on the throttle opening, and regulates suitable throttle pressure.
Engine truque management
control The TCM controls engine torque for improvement of shift quality or durability under
the following conditions.
• Upshift and downshift
• Garageshift
Indicate driving mode function The TCM indicates the following driving mode on instrument panel.
• Power mode
• 3rd start mode
Indicate oil temperature
warning function If the transmission oil temperature sensor senses that transmission oil temperature
is greater than 146 °C (295 °F) , the TCM turns on ATF warning lamp. (The warning
lamp is turned off, if oil temperature is less than 126 °C/ 259 °F .)
Fail-safe function W hen trouble occurs to vehicle sensor and each solenoid, TCM automatically exerts
fail-safe control not to spoil driveability.
• This control is exerted when sensor or actuator is in trouble, while TCM works
normally.
• The "CHECK TRANS" light flashes to alert the driver, and the transmission
must be manually shifted as follows.

Select lever position Gear position
D 4 (Fourth)
3 4 (Fourth)
2 3 (Third)
L 3 (Third)
R Reverse
Shift are firmer to prevent clutch slip and consequent wear. The fault should be
corrected as soon as possible.

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TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-43

DTC P0602 (Flash Code 63)
Circuit Description
The Service Programming System (SPS) updates the
flash calibration files that are stored in a Transmission
Control Module (TCM). The calibration file
custom-tailors a module to a certain vehicle. The
calibration file contains data for things such as spark
curves and fuel control. W hen troubleshooting a
driveability problem, diagnosis may call fo
r
reprogramming the controller with newer calibration
information to correct a customer concern and Vehicle
Identification Number (VIN).
Condition for setting the DTC
W hen a VIN No. is not written into the TCM.
Action Taken When The DTC Sets
• DTC stored.
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
DTC P0602 is indicated when a VIN No. is not written
into the TCM.
A security lock is performed by SPS. And
not replace the TCM when DTC P0602 can repair b
y
SPS.



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7A2-44 TRANSMISSION CONTROL SYSTEM (AW30–40LE)

Circuit/System Testing DTC P0602

Step Action Value(s) YES NO
1
W as the “On-Board Diagnostic (OBD) System Check”
performed? — Go to
Step 2 Go to OBD
System Check
2 1. Install a scan tool.
2. Turn “ON” the ignition.
3. Check the Vehicle Identification Number (VIN) by the scan tool.

Is VIN on the scan tool same as VIN of vehicles? — Go to
Step 4 Go to Step 3
3 W rite a VIN by a scan tool. (Refer to SPS for
procedure.)

Is the action complete? — Go to
Step 4 —
4 Clear the DTC P0602 with a scan tool.

Is the action complete? — Go to
Step 5 —
5 Perform the SPS and perform security lock. (Refer to
SPS for procedure)

Is the action complete? — Go to
Step 6 —
6 Recheck the DTC with a scan tool.
1. Turn “OFF” the ignition.
2. W ait a few seconds.
3. Turn “ON” the ignition.

Does a scan tool indicate DTC P0602? — Go to
Step 7 Go to Step 8
7 Replace the TCM.
Important: The replacement TCM must be
programmed. (Refer to SPS for procedure.)

W as the action complete? — Go to
Step 8 —
8 1. Reconnect all previously disconnected harness
connector(s).
2. Clear the DTCs with a scan tool.
3. Turn “OFF” the ignition.
4. Start the engine.
5. Operate the vehicle within the Conditions For Running the DTC. You may also operate the
vehicle within the conditions that you observed
from the Freeze Frame/ Failure Records.

Did the DTC fail this ignition? — Go to
Step 2 Go to Step 9
9 Observe the stored information, Capture Info with a
scan tool.

Are there any DTCs that you have not diagnosed? — Go
to
Diagnostic
Trouble Code (DTC) List Verify repair


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7A2-60 TRANSMISSION CONTROL SYSTEM (AW30–40LE)

(2) Select position switches is not detecting failure o
r
not deciding failure.
(3) Input revolution sensor is not detecting failure o
r
not deciding failure.
(4) Output revolution calculated by input revolution is more than 300rpm.
(5) If input revolution signal pulse count is more than 13 ×500, any pulse is not detected from output
revolution sensor.
Action Taken When The DTC Sets
• The TCM uses input speed sensor as a vehicle
speed.
• No squat control.
• No torque reduction control.
• No line pressure control.
• No use 4th gear.
• No lock-up control.
• No reverse lock out control.
• No slope control.
• Control gear change by calculating vehicle speed from input revolution sensor.
• No coast control.
• No input revolution sensor failure detection.
• Keep oil temperature sensor open failure detection accumulated timer.
• No select position switch (OPEN) failure decision.
• No T/F Hi-Low SW failure detection.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• No lockup “OFF” control at fuel cut.
• 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.
• Check output revolution sensor for proper mounting and adjustment.

Circuit/System Testing DTC P0722

Step Action Value(s) YES NO
1
W as the On-Board Diagnostic (OBD) System check
performed ? — Go to
Step 2 Go to OBD
system check
2 1. Install a scan tool.
2. Turn on the ignition.
3. Review and record scan tool data.
4. Operate the vehicle within scan tool data.

Does a scan tool indicate DTC P0722? — Go to
Step 3 Refer to
Diagnostic Aids

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TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-63

DTC P0741 (Flash Code 43)






RTW 77ALF001501

Circuit Description
The lock-up solenoid SL of the torque converter clutch
(TCC) controls the lock-up clutch by a signal according
to the lock-up position judgment of the Transmission
Control Module (TCM) when the vehicle runs.
This function can improve the fuel consumption to
almost the same extent as the manual transmission.
The lock-up solenoid SL is put into B+ by the TCM, so
that the solenoid is actuated with the result of lock-up.

Condition For Running The DTC
All of the following conditions are met.
(1)
All of the following conditions are met for 2
seconds or more continuously.
• The supply voltage is more than 10.2 volts and less than 15.5 volts.
• DTC U2104 is not detecting failure or not deciding failure.
• DTC U2105 is not detecting failure or not deciding failure.
• Engine revolution signal is not detecting failure or not deciding failure.
• The engine revolution is more than 550 rpm.

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7A2-64 TRANSMISSION CONTROL SYSTEM (AW30–40LE)

(2) Oil temperature is more than 20 °C (68 °F), and
water temperature signal is more than 70 °C
(158 °F).
(3) 20 seconds or more passed after D position is detected.
(4) Oil temperature sensor is not deciding failure.
(5) Engine coolant temperature sensor is not detecting failure or not deciding failure.
(6) The engine revolution is more than 600 rpm.
(7) Engine revolution sensor is not detecting failure o
r
not deciding failure.
(8) T/F condition is high.
(9) T/F Hi-Low SW is not detecting failure or not deciding failure.
(10) Output revolution sensor is not detecting failure o
r
not deciding failure.
(11) S1 solenoid is not detecting failure or not deciding
failure. (Electronic failure)
(12) S2 solenoid is not detecting failure or not deciding
failure. (Electronic failure)
(13) L-up solenoid is not detecting failure or not
deciding failure. (Electronic failure)
(14) Selector position switch is not detecting failure o
r
not deciding failure.
(15) DTC U2104 is not detecting failure or not deciding
failure.
(16) DTC U2105 is not detecting failure or not deciding
failure.
(17) Input revolution sensor is not deciding failure.
(18) Throttle signal is not detecting failure or not
deciding failure.
(19) Not emergency mode.
(20)Engine torque signal is not detecting failure or not deciding failure.
(21) Pressure control solenoid is not detecting failure
not deciding failure.
(22) All of the following conditions are met.
• Device Control is not operating.
• Disable Normal Communication Service is receiving enable.
• DTC Clear is not operating.
Condition For Setting The DTC
The TCM detects following conditions are met for 4
seconds continuously.
• 2 seconds passed after gear change output and L-up “ON”/”OFF” output.
• T/C revolution difference more than 150 rpm for 4.5 seconds continuously.
• 4th gear lock-up “ON”.
• The throttle position is more than 20% and less than 100%.
• The vehicle speed is more than 5 km/h (3 mph) and less than 100 km/h (62 mph).
Action Taken When The DTC Sets
• 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.


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ISUZU KB P190 2007