torque ISUZU KB P190 2007 Workshop Repair Manual

UNIT REPAIR (JR405E) 7A4-3
Disassembly steps
1. Torque converter
• Pull the torque converter free.
NOTE:
Place a pan beneath the torque converter to catch
automatic transmission fluid (ATF) spillage.
• Drain the ATF from the torque converter.


01ASSY101

2. Turbine sensor and speed sensor
• Remove the turbine sensor from the transmission case.



02ASSY103

•
Remove the speed sensor from the transmission case.



03ASSY106

3. Inhibitor switch
Remove the 2 bolts and the inhibitor switch from the
transmission case.



240L300002

4. Oil pan
• Lift and support the transmission with the holding fixture
and holding fixture base.
Holding fixture: 5-8841-0841-0
Holding fixture base: 5-8840-0003-0
• Remove the drain plug from the oil pan and drain the
ATF from the oil pan.
• Rotate the automatic transmission so that the converte
r
housing is facing up and drain the ATF.
• Rotate the automatic transmission so that the oil pan is
facing up.
• Remove the 19 bolts and the oil pan.

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UNIT REPAIR (JR405E) 7A4-13
Reassembly steps
Coat the parts with ATF before installing them.

11CV18

1. Control valve upper body
2. Control valve lower body
3. Separation plate Assemble the control valve upper body, the lower body, and
the separation plate.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)


244L300002





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7A4-16 UNIT REPAIR (JR405E)

12CV19

4. Solenoid
5. Oil pressure switch • Install the O-rings to each of the solenoids.
• Install the 6 solenoids together and the 3 oil pressure
switches.
NOTE:
Be sure the high clutch oil pressure switch is marked.
• Tighten the bolts to the specified torque.
Torque:
Oil pressure switch bolts – 4 N ⋅
⋅⋅
⋅
m (0.4 kgf ⋅
⋅⋅
⋅
m/35 Ib ⋅
⋅⋅
⋅
in)
Line pressure solenoid bolt (Single gold-colored bolt 16
mm) – 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
6. Solenoid fixing plate
7. Harness bracket Install the solenoid fixing plate together with the harness
bracket.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
Number Length (Color)
Solenoid fixing plate bolt
(A) 4 16 mm (0.63 in) (Gold)
(B) 7 45 mm (1.77 in) (Silver)

13CV20




14CV21



15CV26

8. Harness assembly
Install the harness assembly.


















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UNIT REPAIR (JR405E) 7A4-17
9. Oil strainer Install the oil strainer.
Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 Ib ⋅
⋅⋅
⋅
in)
Number Length (Color)
Oil strainer bolt
(C) 9 13 mm (0.51 in) (Silver)
(D) 4 45 mm (1.77 in) (Silver)

16CV40




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UNIT REPAIR (JR405E) 7A4-23
CONTROL VALVE LOWER BODY

10CV11
Legend
1. Retainer plate, spring, and steel ball
2. Retainer plate, plug, spring, and pressure regulator valve
3. Retainer plate, spring, and high clutch accumulator
4. Retainer plate, plug, low and reverse brake fail valve A, and spring
5. Retainer plate, plug, spring, and fail valve
6. Retainer plate, plug, low and reverse brake amp valve, and spring
7. Oil pressure switch
8. Oil filter
9. Solenoid
10. Line pressure solenoid
11. Lock-up solenoid


12. Harness bracket
13. Solenoid fixing plate
14. Harness assembly
15. Retainer plate, plug, spring, and 2-4 brake fail valve A
16. Retainer plate, plug, spring, and low clutch amp valve B
17. Retainer plate, spring, and torque converter relief valve
18. Oil strainer
19. Control valve lower body
20. Retainer plate, spring, and 2-4 brake solenoid accumulator
21. Oil pressure switch


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7A4-26 UNIT REPAIR (JR405E)
No. Valve
nomenclature Diameter
(mm / in) Length
(mm / in) Configuration
14 Pressure relief ---- ----

15 Pressure
regulator 16.0 /
0.630 89.5 /
3.524
16 Low and reverse
brake fail (A) 10.0 /
0.394 52.0 /
2.047
17 Fail 12.0 /
0.472 53.5 /
2.106
18 Low and reverse
brake amp 12.0 /
0.472 55.5 /
2.185
19 2 – 4 brake fail
(A) 10.0 /
0.394 65.5 /
2.579
20 Low clutch amp
(B) 12.0 /
0.472 53.0 /
2.087
21 Torque
converter relief 10.0 /
0.394 37.4 /
1.472
22 2 – 4 brake
solenoid
accumulator 14.0 /
0.551 19.5 /
0.768
23 High clutch
accumulator 10.0 /
0.394 31.0 /
1.220














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UNIT REPAIR (JR405E) 7A4-27

Spring specifications
No. Valve nomenclature Free length
(mm / in) Outside
diameter
(mm / in) Linear
diameter
(mm / in) Number of
coils
14 Pressure relief 49.0 / 1.929 7.6 / 0.299 1.1 / 0.043 17.3
15 Pressure regulator 30.5 / 1.201 14.0 / 0.551 1.4 / 0.055 5.7
16 Low and reverse brake fail (A) 22.0 / 0.866 7.0 / 0.276 0.6 / 0.024 10.0
17 Fail 23.0 / 0.906 11.0 / 0.433 0.5 / 0.020 13.2
18 Low and reverse brake amp 19.5 / 0.768 7.9 / 0.311 0.5 / 0.020 6.9
19 2 – 4 brake fail (A) 24.8 / 0.976 8.5 / 0.335 0.9 / 0.035 7.8
20 Low clutch amp (B) 26.0 / 1.024 11.0 / 0.433 0.5 / 0.020 6.9
21
Torque converter relief More than 47.2
/ 1.858 9.2 / 0.362 1.6 / 0.063 20.2
22 2 – 4 brake solenoid accumulator 31.4 / 1.236 9.8 / 0.386 1.3 / 0.051 9.3
23 High clutch accumulator
51.0 / 2.008 6.5 / 0.256 0.8 / 0.031 23.5

Oil pressure switch
Apply compressed air (390 kPa/4.0 kgf/cm2/57 psi) to the oil
pressure switch to check the oil pressure switch continuity
between the connector and screw.






244L300011

Oil temperature sensor (harness assembly)
Check the oil temperature sensor resistance between harness
terminals 7 and 6 (ground).

Oil temperature sensor resistance: 2,400 ～
～～
～
2,600 ohms
(20 °
°°
°
C)


Solenoids
Measure the resistance of each solenoid.

Resistance:
Brown connector – 3.0 ∼
∼∼
∼
3.4 ohms (20 °
°°
°
C)
Gray connector – 12.0 ∼
∼∼
∼
13.2 ohms (20 °
°°
°
C)
White connector – 12.2 ∼
∼∼
∼
13.4 ohms (20 °
°°
°
C)

Reassembly steps
• Coat the parts with ATF before installing them.
• Install the control valve to the control valve lower body.
• Install the oil filter to the control valve lower body.



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UNIT REPAIR (JR405E) 7A4-31


Reassembly steps

15PUMP18

1. O-ring (small)
Install new O-ring (small) to the oil pump housing.

16PUMP29

2. Outer rotor
3. Inner rotor Install the outer rotor and the inner rotor to the oil pump
housing.

17PUMP42

NOTE:
The identification mark on the inner rotor must be facing
the inside of the oil pump housing.

18PUMP07

4. Oil pump cover
5. Oil pump housing Install the oil pump cover to the oil pump housing.
Tighten the 8 bolts to the specified torque.
Torque: 9 N ⋅
⋅⋅
⋅
m (0.9 kgf ⋅
⋅⋅
⋅
m/78 Ib ⋅
⋅⋅
⋅
in)



6. O-ring (large)
Install the O-ring (large) to the oil pump cover.
7. Seal ring Install the 4 seal rings to the oil pump cover.

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UNIT REPAIR (JR405E) 7A4-59

18CASE-AY43

•
Use a pin punch to drive the manual plate spring pin into
place.


21CASE-AY48

3. Detent spring
• Install the detent spring and tighten the fixing bolt to the
specified torque.
Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 Ib ⋅
⋅⋅
⋅
in)


23CASE-AY53

4. Harness assembly
• Apply automatic transmission fluid to the new O-ring and
install them to the harness assembly.
• Install the harness assembly to the transmission case.
Tighten the fixing bolt to the specified torque.
Torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kgf ⋅
⋅⋅
⋅
m/52 Ib ⋅
⋅⋅
⋅
in)


24ASSY003

5. Low one-way clutch inner race
• Install new seal rings to the low one-way clutch inne
r
race.


25ASSY126

•
Measure the gap between the seal ring and the ring
groove.
If the measured valve is outside the specified range the
low one-way clutch inner race must be replaced.
Sealing ring and ring groove gap:
0.10~0.25 mm (0.0039~0.0098 in)


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UNIT REPAIR (JR405E) 7A4-61

31ASSY074

•
Tighten each of the bolts a little at a time to the specified
torque.
Be sure that the return spring and the low one-wa
y
clutch inner race installation position does not change as
you tighten the bolts.
Torque: 24 N ⋅
⋅⋅
⋅
m (2.4 kgf ⋅
⋅⋅
⋅
m/17 Ib ⋅
⋅⋅
⋅
ft)


32ASSY007

9. Dish plate, driven plates, drive plates, and retaining
plate (low and reverse brake)
• Install the dish plate (1) followed by the 6 driven plates
(2) and drive plates (3) sets.


33ASSY008



34ASSY009



35N-SPG02

•
Install the N-type spring.


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