start ISUZU KB P190 2007 Workshop Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 4081 of 6020
TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-115
Step Action Value(s) YES NO
9 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 10
10 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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Page 4083 of 6020
TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-117
(3) All of the following conditions are met.
• Device Control is not operating.
• Disable Normal Communication is receiving
enable.
• DTC Clear is not operating.
(4) DTC U2104 is not detecting failure or not deciding failure.
Condition For Setting The DTC
Detection standard is met for 2.5 second continuously.
Detection standard:
If one or more ID sent from Engine Control Module
(ECM) is not completed receiving for 2 basic cycles
since last receiving completion.
Action Taken When The DTC Sets
• Throttle judgment on torque reduction control, line
pressure control at stationary status, line pressure
reduction control at gear change and line pressure
reduction control at garage. (Throttle opening 100%)
• Line pressure FULL output.
• Throttle judgment on gear change control (Throttle
opening 0%).
• No line pressure reduction control at gear change.
• No torque reduction control.
• No squat control.
• No slope control (keep mode).
• No L-up control.
• Control Engine rpm at 7000rpm (No inertia
calculation).
• Control actual torque at MAX.
• Control driver torque at MAX.
• Control engine coolant temperature at 80 °C (176 °F).
• No coast control.
• No 3rd Start mode control.
• No line pressure reduction control at garage.
• No output revolution sensor failure detection.
• No C-0 rev sensor failure detection.
• No selector position switch failure detection.
• No oil temperature sensor failure detection.
• No T/F Hi-Low SW failure detection (Execute T/F
judgment using only T/F-SW ).
• No speed mater signal failure detection.
• No throttle signal failure detection.
• No Engine torque signal failure detection.
• No engine coolant temperature signal failure
detection.
• No Engine revolution signal failure detection.
• No shift solenoid functional failure detection.
• No L-up solenoid functional failure detection.
• Cancel engine rpm condition of prerequisite of suppl
y
voltage failure detection.
• Control vehicle speed of speed meter at 0km/h.
• No torque reduction at stall.
• No cruise control.
• No warm up control.
• 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.
• Inspect the wiring for EMI (Electro-Magnetic
Interference). Check that all wires are properly routed
away from coil, and generator. Also check fo
r
improperly installed electrical options. W hen this test
is performed, turn “OFF” on electronic auto parts
switches to improperly for a noise preventing.
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Page 4085 of 6020
TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-119
Step Action Value(s) YES NO
9 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 10
10 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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Page 4086 of 6020
ON-VEHICLE SERVICE (AW30–40LE) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (AW30–40LE)
TABLE OF CONTENTS
Service Precaution .................................................. 7A3-2
Diagnosis ................................................................. 7A3-3
Basic Troubleshooting ........................................ 7A3-3
Manual Shifting Test ........................................... 7A3-9
Stall Test ............................................................... 7A3-9
Time Lag Test ...................................................... 7A3-10
Hydraulic Test ...................................................... 7A3-11
Road Test ............................................................. 7A3-12
Shift Point Chart and Lock-Up Point Chart ..........7A3-16
Shift Point Chart ................................................... 7A3-16
Lock-Up Point Chart ............................................ 7A3-17
Transmission Fluid Level and Condition ..............7A3-18
Inspection ............................................................. 7A3-18
ATF Replacement ................................................... 7A3-19
Inspection ............................................................. 7A3-19
Neutral Start Switch (Mode Switch) ......................7A3-20
Inspection ............................................................. 7A3-20
Removal ................................................................ 7A3-20
Installation ............................................................. 7A3-20
Brake Signal ............................................................ 7A3-21
Inspection ............................................................. 7A3-21
Input and Output Revolution Sensor ....................7A3-22
Inspection ............................................................. 7A3-22
Power and 3rd Start switch ....................................7A3-22
Inspection ............................................................. 7A3-22
Solenoid .................................................................... 7A3-23
Inspection ............................................................. 7A3-23
ATF Temperature Sensor ......................................7A3-24
Inspection ............................................................. 7A3-24
Select Lever ....................................................... 7A3-25 Remove or Disconnect .......................................7A3-26
Install or Connect ................................................ 7A3-26
Shift Cable .......................................................... 7A3-28 Remove or Disconnect .......................................7A3-28
Install or Connect ................................................ 7A3-29
Torque Specifications ......................................... 7A3-30
Transmission Control Module (TCM) ...................7A3-31
Removal ............................................................... 7A3-31
Installation ............................................................ 7A3-31
Shift Solenoid and Lock-Up Solenoid ..................7A3-32
Removal ............................................................... 7A3-32
Installation ............................................................ 7A3-33
Valve Body Assembly and Pressure Control Solenoid ................................................. 7A3-34
Removal ............................................................... 7A3-34
Installation ............................................................ 7A3-36
Rear Oil Seal (Adapter Housing, 4 ×4) ................. 7A3-37
Removal ............................................................... 7A3-37
Installation ............................................................ 7A3-37
Rear Oil Seal (Extension Housing, 4 ×2) .............. 7A3-38
Removal ............................................................... 7A3-38
Installation ............................................................ 7A3-38
Transmission Assembly .........................................7A3-39
Transmission and Associated Parts .................7A3-39
Removal ............................................................... 7A3-40
Installation ............................................................ 7A3-44
Major Components .............................................. 7A3-49
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Page 4089 of 6020
7A3-4 ON-VEHICLE SERVICE (AW30–40LE)
Troubleshooting Chart
Numbers are arranged in order of probability.
Perform inspections starting with number one and
working up.
A/T : Automatic Transmission
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Page 4095 of 6020
7A3-10 ON-VEHICLE SERVICE (AW30–40LE)
Measure Stall Speed
1. Chock the four wheels.
2. Mount an engine tachometer.
3. Fully apply the parking brake.
4. Step down strongly on the brake pedal with your left foot. (Keep the state until the test is completed)
5. Start the engine.
6. Turn off the A/C.
7. Select into the “D" position. Step all the way down on the accelerator pedal with your right foot. Quickl
y
record the highest speed as soon as the engine
speed gets stabilized.
8. Select into the “N” position and maintain the engine
idling condition more than 1 minute.
Stall speed: 2300 ±
±±
±
200 rpm *
* Ambient temperature to be between roughly 10 °C
(50 °F) and 40 °C (104 °F).
Evaluation
1. If the engine speed is the same for both positions
but lower than the specified value:
• Engine output is insufficient.
• Stator one-way clutch is not operating properly.
NOTE: If more than 600 rpm below the specified value,
the torque converter could be faulty.
2. If the stall speed in “D" position is higher than
specified:
• Line pressure too low
• Forward clutch slipping
• No.2 one-way clutch not operating properly
3. If the stall speed in “R" position is higher than
specified:
• Line pressure too low
• Direct clutch slipping
• No.3 brake slipping
4. If the stall speed in the “R" and “D" positions are
higher than specified:
• Line pressure too low
• Improper fluid level
Time Lag Test
F07RY00003
If the shift lever is shifted while the engine is idling,
there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the
condition of the forward clutch, direct clutch, No.3
brake, and No.2 one-way clutch.
NOTE:
1. Perform the test at normal operating fluid
temperature (50 – 80 °C or 122 – 176 °F)
2. Be sure to allow one minute interval between tests.
3. Make three measurements and take the average value.
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Page 4096 of 6020
ON-VEHICLE SERVICE (AW30–40LE) 7A3-11
Measure Time Lag
1. Fully apply the parking brake.
2. Start the engine. Check idling speed (A/C OFF).
3. Operate the select lever from “N" to “D" position.
Using a stopwatch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 0.7 seconds
4. In same manner, measure the time lag for “N" →
“R".
Time lag: Less than 1.2 seconds
Evaluation
1. If “N" → “D" time lag is longer than specified:
• Line pressure too low
• Forward clutch malfunction
• No.2 one-way clutch not operating properly
2. If “N" → “R" time lag is longer than specified:
• Line pressure too low
• Direct clutch malfunction
• First and Reverse brake malfunction
3. If both time lag is longer than specified:
• Line pressure too low
Hydraulic Test
RTW 67ALH000201
Preparation
1. W arm up the transmission fluid.
2. Remove the transmission case test plug and mount the hydraulic pressure gauge.
Oil pressure gauge: 5-8840-0093-0
NOTE: Perform the test at normal operating fluid
temperature (50 – 80 °C or 122 – 176 °F).
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Page 4097 of 6020
7A3-12 ON-VEHICLE SERVICE (AW30–40LE)
Measure Line Pressure
1. Fully apply the parking brake and chock the four
wheels.
2. Start the engine and check idling rpm.
3. Select into “D" position, step down strongly on the brake pedal with your left foot and while
manipulating the accelerator pedal with the right
foot, measure the line pressures at the engine
speeds specified in the table.
4. In the same manner, perform the test in “R" position.
Line pressure kPa (kg/cm
2/psi) Engine
speed “D" position “R" position
Idling 349 – 408
(3.6 – 4.2 /51 – 59) 577 – 675
(5.9 – 6.9/84 – 98)
Stall 1,206 – 1,353
(12.3–13.8/175–196) 1,646 – 1,979
(16.8–20.2/239–287)
Evaluation
1. If the measured values at all positions are higher
than specified:
• Pressure control solenoid defective
• Primary regulator valve defective
2. If the measured values at all positions are lowe
r
than specified:
• Primary regulator valve defective
• Oil pump defective
• Pressure control solenoid defective
3. If pressure is low in “D" position only:
• “D" position circuit fluid leakage
4. If pressure is low in “R" position only:
• “R" position circuit fluid leakage
Road Test
NOTE: Perform the test at normal operating fluid
temperature (50 – 80 °C or 122 – 176 °F).
“D" Position Test in “NORMAL", and
“POWER" Pattern
Select into the “D" position and hold the accelerator
pedal constant at the 50% and 100% throttle valve
opening positions.
Push in one of the pattern selector buttons and check
the following:
1. 1–2, 2–3, 3–OD and lock-up, upshifts should take
place, and shift points should conform to those
shown in the automatic shift diagram.
RTW 77ASH003001
RUA37ASH000101
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Page 4100 of 6020
ON-VEHICLE SERVICE (AW30–40LE) 7A3-15
“L" Position Test
1. W hile running above 80 km/h (50 mph) in the “D"
position, release your foot from the accelerato
r
pedal and shift into the “L" position.
Then check to see that the 2 →1 downshift occurs at
the specified point shown on the automatic shift
diagram.
RUW 37ASH000601
2. W hile running in the “L" position, check to see that
there is no upshift to 2nd gear.
3. W hile running in the “L" position, release the accelerator pedal and check the engine braking
effect.
4. Check for abnormal noise during acceleration and deceleration.
RUW 37ASH000701
“R" Position Test
Select into the “R" position and, while starting at full
throttle, check for slipping.
RUW 37ASH000801
“P" Position Test
Stop the vehicle on a grade (more than 9%) and afte
r
shifting into the “P" position, release the parking brake.
Then check to see that the parking lock pawl holds the
vehicle in place.
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Page 4102 of 6020
ON-VEHICLE SERVICE (AW30–40LE) 7A3-17
“POWER" mode
Upshift km/h (mph)
Position Throttle Opening 1 →
→→
→
2 2 →
→→
→
3 3 →
→→
→
4
Fully opened 40 - 46 (25 - 29) 79 - 85 (49 - 53) 122 - 128 (76 - 80) D
Half throttle 28 - 34 (17 - 21) 63 - 69 (39 - 43) 100 - 106 (62 - 66)
Fully opened 40 - 46 (25 - 29) 79 - 85 (49 - 53)
— 3
Half throttle 28 - 34 (17 - 21) 63 - 69 (39 - 43)
—
Fully opened 40 - 46 (25 - 29)
— — 2
Half throttle 28 - 34 (17 - 21)
— —
Downshift km/h (mph)
Position Throttle Opening 1 ←
←←
←
2 2 ←
←←
←
3 3 ←
←←
←
4
Fully opened 33 - 39 (21 - 24) 70 - 76 (43 - 47) 115 - 121 (71 - 75)
Half throttle 11 - 17 (7 - 11) 36 - 42 (22 - 26) 66 - 72 (41 - 45) D
Fully closed 5 - 11 (3 - 7) 12 - 18 (8 - 11) 22 - 28 (14 - 17)
Fully opened 33 - 39 (21 - 24) 70 - 76 (43 - 47)
—
Half throttle 11 - 17 (7 - 11) 36 - 42 (22 - 26)
— 3
Fully closed 5 - 11 (3 - 7) 12 - 18 (8 - 11)
—
Fully opened 33 - 39 (21 - 24) 83 - 89 (52 - 55)
—
Half throttle 11 - 17 (7 - 11) 83 - 89 (52 - 55)
— 2
Fully closed 5 - 11 (3 - 7) 83 - 89 (52 - 55)
—
L Fully
opened 42 - 48 (26 - 30)
— —
“3rd START" mode
km/h (mph)
D position, 3rd START mode ON
→OFF 32 – 38 (20 – 24)
Lock-Up Point Chart
(H2, H4)
(REAR AXLE RATIO: 4.100 / 3.909)
(RADIUS OF TIRE: 0.368 / 0.349m) km/h (mph)
Throttle Opening: 20 %
Lock-up ON Lock-up OFF
Position
A/T Mode
3rd 4th 3rd 4th
NORMAL 64 - 70 (40 - 43) 64 - 70 (40 - 43) 41 - 47 (25 - 29) 59 -65 (37 - 40)
D POW ER — 71 - 77 (44 - 48) — 59 - 65 (37 - 40)
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