torque ISUZU KB P190 2007 Workshop Repair Manual

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–44
b Starter motor, refer to 6D1-2 Starting System.
b Rear propeller shaft and for 4WD front propeller shaft, refer to 4A Propeller Shaft.
6 On 4WD vehicle, disconnect the harness two clips from the upper side of the transfer case.
7 From within the starter motor access hole, remove the three bolts (2) attaching the torque converter to the flexplate and discard, refer to Figure 7C4 – 62.
8 Remove the transmission support, refer to 3.7 Transmission Support and Mount.
9 Disconnect the fuel and EVAP pipes three brackets and clips, refer to 6C Fuel System – V6.

Before lowering the transmission take care of
the following:
• Do not strain the harness and connector
as the connector pins could be
permanently damaged.
• Ensure the inlet manifold does not hit the
firewall.
10 Carefully lower the transmission to provide enough clearance to disconnect the harness connector (1).

Do not wiggle the connector from side to side
during removal as the connector pins could
be permanently damaged.
11 Disconnect the harness connector from the transmission as follows:
a Roll back the dust boot to access the connector.
b Squeeze the widest side of the connector (A) inward and pull it directly upward.
Figure 7C4 – 61
12 Remove the screws attaching the harness clips to the right-hand and left-hand sides of the transmission case, refer to 12O Fuses, Relays and W iring Harnesses.
13 Place a suitable sized drip tray underneath the transmission.
14 Remove the transmission cooler lines, refer to 3.17 Transmission Cooler Line/Hose Assemblies.
15 Disconnect the breather hose from the top of the transmission case.


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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–45

Support the transmission when removing the
attaching bolts to avoid damage to the torque
converter and flexplate. Do not have the
transmission hanging.
NOTE
The bolts attaching the torque converter housing
are facing forward except for the bolt in position ℑ

which is facing rearward.
16 W ith the transmission supported, using a long socket extension, universal joint and suitable size socket, remove the bolt (1), nine places, attaching the torque converter housing to the engine, in the reverse order of the torque
sequence shown in
within Figure 7C4 – 62.

The transmission assembly must not be
allowed to rest on its oil pan.
17 Support the transmission assembly on a suitable cradle and secure it. Place a suitable support under the engine oil pan rail to support the engine after the transmission has been removed.
18 Remove the transmission assembly, disengaging the filler tube attached to the engine.
19 Remove the bolt (3) and torque converter cover (4) on the transmission right-hand side, remove the bolt (5) and torque converter cover (6) on the transmission left-hand side.
20 Install a suitable holding tool to prevent the torque converter from becoming dislodged.
21 If required on 4W D vehicle, remove the transfer case, refer to 7D Transfer Case and Adaptor Housing.

Figure 7C4 – 62

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–46
Reinstall
1 If required on 4W D vehicle, reinstall the transfer case, refer to 7D Transfer Case and Adaptor Housing.
2 Ensure the transmission and the engine mating surfaces are clean and free of burrs.
3 Lubricate the torque converter spigot (7) with a small amount of high temperature wheel bearing grease, refer to Figure 7C4 – 62.
4 Install a new filler tube seal into the transmission case.

Support the transmission while installing the
attaching bolts to avoid damage to the torque
converter and flexplate. Do not have the
transmission hanging.
5 Bring the transmission up to the engine, inserting the filler tube and ensuring the locating dowels completely enter the torque converter housing.
6 Reconnect the breather hose to the top of the transmission case.
NOTE
The bolts attaching the torque converter housing
are facing forward except for the bolt in position ℑ

which is facing rearward.
7 With the transmission supported, install the bolt (1), nine places, attaching the torque converter housing to the engine and tighten to the correct torque specification following the sequence shown in
within Figure 7C4 – 62.
Torque converter housing attaching
bolt torque specification .......................... 52.0 – 66.0 Nm
8 Remove the access hole cover plate from the lower surface of the housing and push the torque converter forward to meet the flexplate, then hand start three new bolts (2) before tightening to the correct torque specification.
Reinstall the access hole cover plate.
Torque converter to flexplate attaching
bolt torque specification .......................... 60.0 – 70.0 Nm
9 Reinstall the bolt (3) and torque converter cover (4) on the transmission right-hand side and the bolt (5) and torque converter cover (6) on the transmission left-hand side, tighten the bolts to the correct torque specification.
Torque converter cover attaching
bolt torque specification .......................... 12.0 – 16.0 Nm
10 Reinstall the transmission fluid lines, refer to 3.17 Transmission Cooler Line/Hose Assemblies.

Prior to connecting the harness connector to
the transmission, check that all pins and
seals are in sound condition and the dust
boot is not torn or damaged.
11 Reconnect the transmission harness connector to the transmission as follows: a Push straight down on the connector body until a click is heard.
b Reinstall the dust boot ensuring it is correctly located.
12 Attach the harness clips to the right-hand and left-hand sides of the transmission case, refer to 12O Fuses, Relays and Wiring Harnesses.
13 On 4WD vehicle, connect the harness two clips from the upper side of the transfer case.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–47
14 Reconnect the fuel and EVAP pipes three brackets and clips, refer to 6C Fuel System – V6.
15 Reinstall the following components:
a Starter motor, refer to 6D1-2 Starting System.
b Transmission support, refer to 3.7 Transmission Support and Mount.
c Front and centre exhaust assemblies, refer to 6F Exhaust System.
d Rear propeller shaft and for 4WD front propeller shaft, refer to 4A Propeller Shaft.
16 Reconnect the harness connectors to the following: a Vehicle speed sensor, refer to 3.5 Vehicle Speed Sensor.
b Neutral start and back-up switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
c For the following on 4W D vehicles, refer to 7D Transfer Case and Adaptor Housing:
• neutral switch,
• 2WD – 4WD shift actuator switch,
• speed sensor.
17 Reinstall the selector cable to the transmission external manual shaft linkage, secure the selector cable to the bracket and attach the heat shield to the neutral start and back-up lamp switch, refer to 3.3 Selector Cable
Assembly.
18 Perform a reverse flush of the cooler lines and a flow rate test, refer to 2.2 Reverse Flush and Flow Rate, if either of the following applies:
• the transmission fluid is contaminated,
• the transmission has been replaced,
• the torque converter has been replaced, or
• the transmission oil pump has been replaced.
19 Lower the vehicle to the ground.
20 If required, top up the transmission fluid level (cold).
21 Reconnect the battery ground lead.
22 Start the engine and check for any fluid leaking at the fittings. If a leak is found, stop the engine and rectify the leak.
23 Road test until the transmission has reached operating temperature. Re-check the fluid level and for any fluid leaks, refer to 2.1 Transmission Fluid.
3.19 Transmission Control Module
Remove
1 Ensure the ignition switch is in the OFF position.
2 Disconnect the connector (1) from the transmission control module (TCM) (2) as follows, refer to Figure 7C4 – 63: a remove the securing pin (3),
b press the locking tab and swing the lever (4) to free the connector,
c remove the connector.
3 Remove the four bolts (5) and nuts (6), then the TCM from the mounting bracket (7).
4 If required, remove the two nuts (8) and the mounting bracket from the firewall.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–48

Figure 7C4 – 63
Reinstall
Reinstallation of the transmission control module (TCM) is the reverse of the removal procedure, noting the following:
1 If a new TCM is installed it must be programmed, refer to TCM Programming Procedure in this Section.
2 If required, install the mounting bracket to the firewall and tighten the nuts to the correct torque specification.
TCM bracket attaching
nut torque specification ........................................7.0 Nm
3 Install the TCM onto the bracket and tighten the bolts and nuts to the correct torque specification. TCM attaching bolt and nut
torque specification ..............................................7.0 Nm
4 Lock the connector securely to the TCM by with the locking lever and the securing pin.
5 Using Tech 2, clear any TCM diagnostic trouble code (DTC) that may have set during the removal procedure, refer to 0C Tech 2.
TCM Programming Procedure
1 The transmission control module (TCM) must be programmed with the correct software/calibration. Ensure the following conditions exist before starting the TCM programming procedure:
a The battery is fully charged.
b The Tech 2 cable connection at the data link connector (DLC) is secure.
c The ignition switch is in the ON position.
2 Program the TCM using the latest software for the vehicle, refer to the following: a Current release of TIS for the latest software and
b 0C Tech 2 for TCM service programming.

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Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–51
5 Torque Wrench Specifications
For a complete listing of all torque wrench specifications for the 4L60E hydra-matic automatic transmission, refer to
7C1 Automatic transmission – 4L60E – General Information.

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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) 7A2-13
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) 7A2-37
2. The TCM must be maintained at a temperature
below 85 °C (185 °F) at all times. This is most
essential if the vehicle is put through a paint baking
process. The TCM will become inoperative if its
temperature exceeds 85 °C (185 °F). Therefore, it is
recommended that the TCM be removed or that
temporary insulation be placed around the TCM
during the time the vehicle is in a paint oven or othe
r
high temperature process.
3. The TCM is designed to process the various inputs and then respond by sending the appropriate
electrical signals to control transmission upshift,
downshift, shift feel and torque converter clutch
engagement.
4. The TCM constantly interprets information from the
various sensors, and controls the systems that
affect transmission and vehicle performance. B
y
analyzing operational problems, the TCM is able to
perform a diagnostic function by displaying DTC(s)
and aid the technician in making repairs.

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7A2-38 TRANSMISSION CONTROL SYSTEM (AW30–40LE)
TCM Diagnostic Trouble Codes
The following table lists the diagnostic trouble codes supported by this vehicle application. If any DTCs not listed here
are displayed by a scan tool, the scan tool data may be faulty; notify the scan tool manufacture of any DTCs displayed
that are not included in the following table.

DTC Type
DTC No. Flash
Code DTC NAME
EURO 4Except
EURO 4
P0562 72 System Voltage Error (Low) E E
P0563 73 System Voltage Error (High) E E
P0602 63 Transmission Control Module (TCM) Programming Error E E
P0707 17 Transmission Range Sensor Circuit Open B D
P0708 17 Transmission Range Sensor Circuit Short B D
P0712 15 Transmission Oil Temperature Circuit Short
B D
P0713 16 Transmission Oil Temperature Circuit Open
B D
P0717 14 Input Speed Sensor Signal Error
B D
P0722 11 Output Speed Sensor Signal Error
B D
P0741 43 Torque Converter Clutch Stuck “OFF”
B F
P0742 53 Torque Converter Clutch Stuck “ON”
B F
P0746 45 Pressure Control Solenoid F/B Stuck
B D
P0751 41 Shift Solenoid S1 Stuck “OFF” B D
P0752 51 Shift Solenoid S1 Stuck “ON” B F
P0756 42 Shift Solenoid S2 Stuck “OFF” B F
P0757 52 Shift Solenoid S2 Stuck “ON” B F
P0962 35 Pressure Control Solenoid Circuit Open or GND Short B F
P0963 35 Pressure Control Solenoid Circuit Ignition Short B D
P0973 31 Shift Solenoid S1 Circuit GND Short B D
P0974 31 Shift Solenoid S1 Circuit Open or Ignition Short B D
P0976 32 Shift Solenoid S2 Circuit GND Short B D
P0977 32 Shift Solenoid S2 Circuit Open or Ignition Short B D
P1790 61 Transmission Control Module (TCM) ROM Checksum Error B D
P1791 62 Transmission Control Module (TCM) RAM Error B D
P2769 33 Torque Converter Clutch Circuit GND Short B D
P2770 33 Torque Converter Clutch Circuit Open or Ignition Short B D
P2773 75 Transfer 4L Switch Circuit GND Short B D
P2774 75 Transfer 4L Switch Circuit Open or Ignition Short B D
U2104 65 CAN BUS OFF
A C
U2105 67 Lost of Communication with ECM A C


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