engine mechanical ISUZU TF SERIES 2004 Workshop Manual

IMMOBILIZER SYSTEM 11A-5

Diesel Engine With Engine Immobilizer Unit (4JA1-T Mechanical Control Engine)






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IMMOBILIZER SYSTEM 11A-9

Diesel Engine With Engine Immobilizer Unit (4JA1-T Mechanical Control Engine)






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IMMOBILIZER SYSTEM 11A-13

Immobilizer control unit (ICU);
Mechanical Control Engine (4JA1-T)
Immobilizer control unit (ICU) permits engine starting,
when the security code which compares the securit
y
code registered into the transponder (key) and the
security code registered into ICU, and is similarl
y
registered into ICU and engine immobilizer unit (DDS-1)
is compared and it is judged that it is normal. When the
code registered into the key is unusual, and when not
recognizing a security code, engine immobilizer unit
does not permit starting of engine by the fuel cut valve
on the fuel pump.
The engine immobilizer unit is located with fuel cut
valve on fuel pump 4JA1-T engine.
The immobilizer control unit decides whether there is an
abnormality the security code based on the engine
immobilizer unit security code.
When the problem found, the engine immobilizer unit
stops fuel fupply by the fuel cut valve.




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11A-16 IMMOBILIZER SYSTEM

Car Pass Card
Each vehicle has a car pass, which is issued to the
customer on delivery of the vehicle along with the othe
r
papers.


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Notes:

This car pass is an important document and must be
treated with the same care as the vehicle papers.
It must not be kept in the vehicle. The customer must
present the car pass for operations involving the
immobilizer or the engine control unit.

Loss of car pass card
If the car pass is lost, the data can be requested from
your proper organization name. This request will only be
processed if accompanied by the enclosed form and
proof of ownership. Once the data is received, it can be
entered in a blank car pass and given to the customer.
The unused car pass should be destroyed.

Instructions on Filling Out the form "Data
request, car pass"
To be provided by the dealership.
The data requested under items 1-10 must be provided
completely, including the authorized dealership number,
the vehicle Identification number (VIN) and engine
type/number (Engine type/No).

Mark missing data / desired data with a cross:


Security code (for diagnosis and programming with
Tech-2)


Mechanical key Number
Complete the form by entering the data and
signature/authorized dealership stamp and send it along
with proof of ownership (Vehicle lD or invoice) to
address provided in the form. The requested data will
be sent by Fax to the dealership that made the request
after your organization has confirmed that the info is
corrected.

IMMOBILIZER SYSTEM 11A-19

lmportant information on Programming
Security code
The security code protects the immobilizer control unit
against unauthorized programming and data access
from Tech-2. The security code consists of a 4 digit
code number and is programmed into the immobilize
r
control unit and Engine Control Module (ECM).
New control units are not programmed with a securit
y
code.
If the control units are replaced, the security code
entered in the car pass, transponder lD, etc.
Must be programmed into the new control unit with
Tech-2.
The security code can only be programmed with Tech-2
once and must therefore be performed with great care.
Once programmed, the security code cannot be
overwritten. An already used immobilizer can be reused
in a different car by initializing the immobilizer. After that
you can program the security code again. For initializing
command you need the current security code.
If the immobilizer control unit is returned, always
enclosed the security code that is allocated to that
control unit. If this is not done, we can not process the
case and the warranty will not be recognized.
Entering a code
If the Tech-2 display requests that the

security code


mechanical key number


Vehicle Identification No.
be entered, process as follows;
To input a digit you need to use the up and down
buttons of the Tech-2. By using the numeric buttons the
according digit will be displayed at the current position
and the cursor will move to the next position.
For letters you need to use the up and down buttons o
f
the Tech-2. The up and down key might be used for
digits as well. By using the up and down buttons the
displayed digit or letter will be increased or decreased.
To move to the next position you need to use the move-
to-right-button.
With the two buttons, move-to-right and move-to-left
you can select the position of number you want to
change.
This will allow you to correct a wrong number.
After the number is completed you need to press the
Enter button to accept the number. Correction is now no
longer possible.
Use the OKAY soft key to program the number and the
NOT OKAY soft key to abort the programming.
Transponder (Key)





If a transponder key is lost:
If a transponder key is lost, all transponder keys in the
immobilizer control system must be erased.
Transponder keys can be ordered via the "Your prope
r
organization name such as part and accessor
y
department" as previously by providing the mechanical
key number.
The mechanical key number is provided on the ca
r
pass.
Thereafter, existing and new transponder keys are
programmed consecutively using Tech-2. The vehicle
can then no longer be started using lost key.





5 transponder keys can be provided:

Each transponder has different Identifications. If a
customer wants more than 2 transponder keys,
maximum 5 transponder keys can be provided b
y
additional programming by Tech-2.






lf a new ignition key with different mechanical key
number needs to be installed:
If installation of an ignition lock with a different
mechanism key number is necessary (an ignition lock
which belongs to the mechanical key number has to be
ordered first), all transponder keys must first be erased
and the two transponder keys which belong to the
ignition lock that is now installed must be programmed.
The new mechanical key number must be programmed
now into the immobilizer. The mechanical key numbe
r
in the car pass is to be changed as well.
Important:
After successful programming, the engine control can
only be used for vehicles with immobilizer and
transponder.
Faults that occur in connection with the immobilize
r
control unit are recognized by the engine control unit
and as long as "IMMOBILOZER" is not programmed,
are indicated by a flashing of the check engine lamp.
If the immobilizer and engine control unit are replaced
at the same time, the immobilizer control unit must be
programmed first before the "IMMOBILIZER" function in
the engine control unit can be activated.

IMMOBILIZER SYSTEM 11A-27

4.
Input the security code, then press the soft key of
"Okay" or "Not Okay".

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5.
Enter VIN.
6.
Enter Mechanical key number.
7.
Turn ON ignition.
8.
Select an engine system.
9.
See the programming result.

Tech-2 displays the result of programming as the
following.

Follow those instructions

Selected Programming is not possible due to
wrong System Status!


Immobilizer Not Programmed!


Immobilizer Already Programmed!


ECM Not Programmed!


ECM Already Programmed!
10.
Transponder key must be reprogrammed,
because all transponder information is erased.

When ICU is programmed. See Transponde
r
programming.

Programming ECM
1.
Follow Programming Immobilizer Function steps 1
through 14.
2.
Input a program option, by moving the cursor on
the selection, then pres "Enter" key.

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3.
Enter the security code.
4.
Input the security code, then press the soft key o
f
"Okay" or "Not Okay".

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5.
Turn on the Ignition.
6.
Select an Engine system.

7A3-12 ON-VEHICLE SERVICE (AW30 –40LE)

Manual Shifting Test
NOTE: With this test, it can be determined whether the
trouble lies within the electrical circuit or is a mechanical
problem in the transmission.
1. Disconnect TCM connector
Inspect manual driving operation
2. Inspect manual driving operation
Check that the shift and gear positions correspond
with the table.
If the “L", “2", “3" and “D" range gear positions are
difficult to distinguish, do perform the following road
test.
While driving, shift through the “L", “2", “3" and “D"
ranges. Check that the gear change corresponds to
the gear position.
If any abnormality is found in the above test, do
perform the stall, time lag or gear change tests.



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3. Connect TCM connector
With the engine off, connect the TCM connector.


Stall Test



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The object of this test is to check the overall
performance of the transmission and engine b
y
measuring the maximum engine speeds at the “D" and
“ R" ranges.
NOTE:
1. Perform the test at normal operation fluid
temperature (50 – 80 
C or 122 – 176 
F).
2. Do not continuously run this test longer than 5 seconds.

7A1-10 CONSTRUCTION AND FUNCTION
INPUT SHAFT

The input shaft has some oil holes, through which lubricating ATF is supplied to the torque converter,
bearings, etc.

The input shaft is fitted the turbine runner in the torque converter, reverse & high clutch drum and rear sun
gear by means of the spline. Therefore, the engine driving force received by the torque converter is
transmitted to the reverse & high clutch drum and rear sun gear.

OUTPUT SHAFT

The output shaft has some oil holes, through which the lubricating ATF is supplied to the bearings,
planetary gear unit, etc.

The output shaft transmits the engine driving force from the planetary gear to the propeller shaft.

The front internal gear is fitted with the rear carrier assembly by spline. The parking gear is also fitted by
spline. By fixing this gear mechanically, the output shaft is fixed as required when parking the vehicle.

GEAR SHIFTING MECHANISM

The JR405E consists of two sets of planetary gears, three multiple plate clutches, two multiple plate
brakes and a one-way clutch. They are activated in different combinations in any of four forward and one
reverse gear positions.

Principle of gear shifting (Figure 12)

Planetary gears have the advantage of a compact configuration because of the way they are constructed
with a single central shaft.

Also, unlike the manual transmission gears that require changing of gear mesh, the gear ratio of the
planetary gears can be changed more easily by locking, releasing or rotating only some of their parts.

A planetary gear is made up of a sun gear (1) at its center and pinion gears (2) each of which rotates
about its own center and also along the sun gear, as shown. They are all called in the internal gear (3).

Also, since the pinion gears are further supported by the planetary carrier (4), they rotate as a unit in the
same direction and at the same rate.

As shown above, each planetary gears are constructed of three elements; a sun gear, pinion gears, and
internal gear and a planetary carrier. Gear shifting is achieved by conditioning two of the three elements
namely the sun gear, internal gear and the planetary carrier.

The planetary gears are locked by the clutch, brake and one-way clutch according to the gear shifting.
















1. Sun Gear
2. Pinion Gear
3. Internal Gear
4. Planetary Carrier

Figure 12. Planetary Gear

DIAGNOSIS (JR405E) 7A2-97
No. B2: Poor Acceleration at Starting

Description:

Starting acceleration is poor.

Diagnosis Hints:

In addition to the low engine output, faulty gear shifting of AT or fixing at the 3rd position may be possible.
Therefore, in case of such a trouble that "maximum speed is low, and acceleration is poor", it should be cleared
up whether the trouble is originated from the engine system of AT system by a running test, inspection of stall
revolution, etc.

Possible Cause:

Clogged air cleaner, out of injection timing, dropped compression pressure, etc.

Fixing at 3rd position (fail-safe activated).
Since the gear is fixed at the 3rd position because of the fail-safe function, a trouble that "Maximum
speed is low, and acceleration is poor" is resulted. In this case, the DTC is memorized.
When TCM stops operation because of faulty TCM ground, the gear is fixed at the 3rd position because
of a mechanical reason. In this case, no DTC is memorized.

Disordered inhibitor switch.

Incorrect properties of throttle opening signal (serial communication) of throttle position sensor.
Throttle opening signal (serial communication) of the throttle position sensor does not change in
proportion to the throttle opening. In this case, fixing at the high or low gear results in such a trouble
that "Maximum Speed is Low and Acceleration is Poor".

Slip of clutch (low clutch, high clutch).

If slip of clutch is caused, a DTC (gear ratio error) is stored.

Dropped line pressure.

Trouble in the torque converter system (faulty operation).

Step Action Yes No
1 Test Drive.
Is the gear smoothly shifted in the order of 1st to 2nd, 2nd to 3rd,
3rd to 4th gear and lock up?

Clogged air cleaner,
out of injection
timing, dropped
compression
pressure, etc.

Go to Step 2
2 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out)
Go to Step 3 Go to Step 3
3 Are any DTCs stored?
Go to DTC Chart Go to Step 4

DIAGNOSIS (JR405E) 7A2-101
Step Action Yes No
1 Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out)
Go to Step 2 Go to Step 2
2 Are any DTCs stored?
Go to DTC Chart Go to Step 3
3 Are the quantity, contamination and smell normal?
If the ATF level is
low, replenish up to
the specified level.

Go to Step 4

If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.
Overhaul the AT
unit.
4 Are the engine speed and other engine system correct?
Go to Step 5
Repair the defect or
replace.
5 Inspection of electrical or mechanical fault
Is the signal from each pressure switch changed synchronously?
Control Valve

TCM
B1
B12
B20 RED/YEL
WHT/BLK 2-4 Brake Pressure SW
Terminal
Assembly
YEL
E54
(7)
(12)
(1)H23
(12)
(10)C95
(1)
(12)
(20) RED/YEL
YEL
WHT/BLK
L&R Brake Pressure SW
High Clutch Pressure SWH22
(8)
Range TCM terminal
GearB20
(High clutch
pressure SW)B1
(2-4 brake pressure
SW)B12 (Low & reverse
brake pressu re SW)
P - More than 10V More than 10V More than 10VR Reverse More than 10V More than 10V -N - More than 10V More than 10V More than 10VD, 3, 2 1st More than 10V More than 10V More than 10V2nd More than 10V - More than 10V3rd - More than 10V More than 10V4th - - More than 10VL 1st More than 10V More than 10V -2nd More than 10V - More than 10V3rd - More than 10V More than 10V4th - - More than 10VGo to Step 6
Repair the defect or
replace.