battery ISUZU TF SERIES 2004 Workshop Manual

ON-VEHICLE SERVICE (AW30 –40LE) 7A3-49


Tighten transmission transfer bolts as shown in
the figure.(4WD only)

261R300002
20. Connect transfer harness connectors and
clips.(4WD only)

Speed sensor
 2W-4W shift actuator
21. Install the middle exhaust pipe.



RTW37ASH0001
22. Install the rear propeller shaft.
Torque: 63 N 


m (6.4 kg 


m/46 lb ft)
NOTE: Align alignment marks on the flange.
23. Install the center bearing on crossmember.
Torque: 69 N 


m (7.0 kg 


m/51 lb ft)


24.Install the front propeller shaft.(4WD only)
Torque: 63 N 


m (6.4 kg 


m/46 lb ft)
NOTE: Align alignment marks on the flange.


401RS023
25. Connect battery ground cable.

7A1-6 CONSTRUCTION AND FUNCTION
ELECTRONIC CONTROL COMPONENTS LOCATION

4WD Only 4WD Only
Instrument panel (Meter)







Speed meter (2WD Only)
Shift position indicator lamp
POWER DRIVE, 3rd START
indicator lamp
A/T OIL TEMP indicator lamp
CHECK TRANS indicator lam
p

Brake pedal





Brake Switch
Select lever








Power Drive
, 3rd Start select switch
Transmission Control Module (TCM)
Electrical source






Ignition
Battery voltage
Speed sensor
Turbine sensor
Inhibitor switch
ATF thermo sensor
High clutch oil pressure switch
2-4 brake oil pressure switch
Low & Reverse brake oil pressure
switch
Line pressure solenoid
Low clutch solenoid
High clutch solenoid
2-4 brake solenoid
Low & Reverse brake solenoid
Lock-up solenoid
Transmission
Transfer Control Module
Transfer




4L mode switch
Engine




Engine speed sensor
Throttle Position Sensor


Engine Control Module (ECM)
Data link connector

CONSTRUCTION AND FUNCTION 7A1-25
TRANSMISSION CONTROL MODULE (TCM)

The TCM is fitted side of brake pedal by means of two stud bolts.

The TCM judges necessary line pressure, gear shifting point and lock-up operation based on electrical
signals from switches and sensors and sends appropriate signals to solenoids.















        




















 
 
 
 
 
 
 












      
  

Connect to White Connector Connect to Grey Connector


Figure 49. Pin Assignment

Pin No. Pin Assignment Pin No.Pin Assignment
B1 2-4 Brake Oil Pressure Switch A1 V BATT (Battery Back-up Power Supply)
B2 2 Range Switch A2 P Range Switch
B3 Turbine Sensor A3 Brake Switch
B4 ATF Thermo Sensor A4 3rd Start Indicator Lamp
B5 Ground A5 K-Line Signal (Tech 2 Serial Communication)
B6 Low & Reverse Brake Duty Solenoid A6 No Connection
B7 2-4 Brake Duty Solenoid A7 Engine Speed Sensor
B8 High Clutch Duty Solenoid A8 No Connection
B9 Low Clutch Duty Solenoid A9 No Connection
B10 N Range Switch A10 Vehicle Speed Sensor Out (2WD Only)
B11 D Range Switch A11 3rd START Select Switch
B12 Low & Reverse Brake Oil Pressure Switch A12 4L Mode Switch (4WD Only)
B13 Vehicle Speed Sensor A13 No Connection
B14 ATF Thermo Sensor Ground A14 No Connection
B15 Ground A15 No Connection
B16 No Connection A16 Throttle Position Sensor
B17 Lock-up Duty Solenoid A17 3 Range Switch
B18 Vign
Ignition Power Supply) A18 DIAG Switch (Test Switch)
B19 R Range Switch A19 A/T OIL TEMP Indicator Lamp
B20 High Clutch Oil Pressure Switch A20 CHECK TRANS Indicator Lamp
B21 L Range Switch A21 POWER DRIVE Indicator Lamp
B22 Ground (Shift Solenoid) A22 No Connection
B23 Line Pressure Solenoid A23 No Connection
B24 Vign (Ignition Power Supply) A24 POWER DRIVE Select Switch

CONSTRUCTION AND FUNCTION 7A1-33
LEARNING CONTROL

Oil pressure control timing is optimally corrected at the time of clutch engagement and disengagement
and controlled to bring the speed-change time to the value preset to the TCM and compensate the
changes of the engine performance and changes of the transmission with time.

When the gear is shifted, the clutch pressure 2 is optimally corrected so that the speed-change time is as
near as the target value
1 preset to the TCM and the changes in the engine performance and the
changes of the transmission with time can be compensated based on the past speed-change results.

When the clutch is operated to shift the gear, the time of the clutch oil pressure release timing 4 on the
disengagement side is optimally corrected so that the changes of the engine rpm
3 is optimum.


Note:

When the battery terminal is disconnected, contents of learning are cleared and resultantly the speed
change shock may increase. After the vehicle has traveled, learning is repeated and the shock
decreases gradually.





Figure 53. Learning Control

DIAGNOSIS (JR405E) 7A2-21
SERVICE PROGRAMMING SYSTEM (SPS)
The procedure to program the control unit by using Service Programming System (SPS) software contained in TIS
2000 is explained in steps below.

Important: Perform the following checks before attempting to program the control unit:







The Tech 2 PCMCIA card is programmed with the latest software release.







The latest release of TIS2000 is located on the PC.







The vehicle battery is fully charged.







The control unit to be programmed is connected to the vehicle.

1. Preparations of TIS 2000
1. Connect Tech 2 to P/C.
2. Check to see if Hardware Key is plugged into Port.
3. Activate TIS 2000 by P/C.
4. On the activating screen of TIS2000, choose "Service Programming System"



5. On the screen of "Diagnostic Tester and Processing Program Selection", choose the one that will comply with
the following.

Diagnostic Tech2 in use

New programming by the existing module or new programming by the replaced/new module.

Fixing position of the control unit.
6. Upon completion of the selection, push the button of "Next".


2. Demand of Data
1. Connect Tech-2 to the vehicle. When activated by turning on the power of Tech-2, push the "Enter" switch.
2. Turn on the ignition switch (without starting the engine).
3. In the main menu of Diagnostic Tester, push "F1: Service Programming System (SPS)".
4. Push "F0: Request Info" of Tech-2.
5. Where vehicle data has been already saved in Tech 2, the existing data come on display. In this instance, as Tech-2 starts asking whether to keep the data or to continue obtaining anew data from the control unit,
choose either of them.

7A2-32 DIAGNOSIS (JR405E)

No. Connector face No. Connector face
E-30
(4JH1-TC)
Gray A/T speed sensor H-23
(6VE1)
(4JH1-TC)
WhiteEngine ~ Engine room B
E-31
(4JH1-TC)
Gray Turbine sensor P-1
SilverBattery (+)
E-44
Gray
Vehicle speed sensor P-2
SilverRelay & Fuse box
E-51
(4JH1-TC)
Black Inhibiter switch P-5
SilverBattery (-)
E-54
(4JH1-TC)
Black A/T term ASM P-6
SilverBody earth (Ground)
H-4
(6VE1)
(4JH1-TC)
White Engine ~ Engine room P-10
SilverEngine ground
H-6
White
Engine room ~ INST R-15
Black2-4 WD control unit
H-7
White
Engine room ~ INST


H-18
(RHD)
White Engine room ~ INST


H-22
(6VE1)
(4JH1-TC)
White Engine ~ Engine room C

7A2-36 DIAGNOSIS (JR405E)
DTC P0722 (Flash Code 11) Vehicle Speed Sensor No Signal


Speed
Sensor
TCM



B13
H23
(4)C95
(13)E30
(2)
(1)
(3)
E10
Key SW
YEL/RED
BLK YEL/RED

Speed Sensor Turbine Sensor

Setting Condition:

When the vehicle speed exceeds 5 km/h with the turbine speed over 1000 rpm for 5 seconds, after 25.5
seconds elapsed in D, 3, 2 or L range.

Fail Safe:

When the vehicle is running, the gear position selected at the trouble detection is held and the lock-up is
inhibited.

After the vehicle stopped, all solenoid operations stop (OFF) and the gear is fixed to the 3rd.

Possible Cause:

Speed sensor malfunction.

Sensor wheel (parking gear) malfunction.

Large sensing gap between speed sensor and sensor wheel (parking gear).

Sensor wire open circuit, short circuit to battery or short circuit to ground between speed sensor terminal 1 and
TCM terminal B13 (C95).

Sensor wire open circuit or short circuit to ground of the harness between speed sensor terminal 2 and power
supply circuit.

Sensor wire open circuit or short circuit to battery between speed sensor terminal 3 and ground circuit.

Poor connection of each connector.

7A2-38 DIAGNOSIS (JR405E)
DTC P0727 (Flash Code 13) Engine Revolution Sensor No Signal



RED
TDC
Sensor TCM



A7
C94 (7)
BLK/RED
WHT
C56
(27)
E9
(1)

(2)
(3)

C57 (98)

(90)
(101)

ECM




C56 (ECM-A)

Setting Condition:

The engine speed becomes 0 rpm for 2 seconds while the vehicle is running at the over 40 km/h.

Fail Safe:

Lock-up is inhibited.

Possible Cause:

Crank position sensor malfunction.

Sensor wheel (flywheel) malfunction.

Large sensing gap between speed sensor and sensor wheel (flywheel).

Faulty input signal from crank position sensor to ECM.

Signal wire open circuit or short circuit to battery between ECM A24 and TCM terminal A7 (C94).

Poor connection of each connector.

Reference:
When the engine speed 2000rpm, following signal is outputted.
Measurement terminal: A7 (C94) and B5 (C95)
-AC range by circuit tester: Approximately 6.2V
-Oscilloscope: Following wave form can be found.

7A2-40 DIAGNOSIS (JR405E)
DTC P0717 (Flash Code 14) Turbine Speed Sensor No Signal

Turbine
Sensor TCM



B3
H23 (9)C95 (3) E31 (2)
(1)
(3)
E10
Key SW
BRN/RED
WHT
BLK BRN/RED


Speed Sensor Turbine Sensor

Setting Condition:

The turbine speed below 300 rpm for 2 seconds while the vehicle is running at the speed over 40 km/h with the
engine speed over 1500 rpm in the D, 3, 2, or L range.

Fail Safe:

When the vehicle is running, the gear position selected at the trouble detection is held and the lock-up is
inhibited.

After the vehicle stopped, all solenoid operations stop (OFF) and the gear is fixed to the 3rd.

Possible Cause:

Turbine speed sensor malfunction.

Sensor wheel (reverse & high clutch drum) malfunction.

Large sensing gap between speed sensor and sensor wheel (reverse & high clutch drum).

Sensor wire open circuit, short circuit to battery or short circuit to ground between turbine speed sensor terminal
1 and TCM terminal B3 (C95).

Sensor wire open circuit or short circuit to ground between turbine speed sensor terminal 2 and power supply
circuit.

Sensor wire open circuit or short circuit to battery between turbine speed sensor terminal 3 and ground circuit.

Poor connection of each connector.

7A2-42 DIAGNOSIS (JR405E)
DTC P0710 (Flash Code 15) ATF Temperature Sensor Failure

ATF
Temp.
Sensor
TCM


B4 (+)



B14 (-)

H23 (8)



(3)
C95 (4)



(14)
BLU
Terminal
Assembly
BLU/BLKE54 (2)



(8)
BLU
BLU/BLK


Setting Condition:

The condition in which the voltage of oil temperature sensor is below 0.1V (146 C) and ATF temperature
warning lamp ON in the P or N range lasts for more than 5 minutes.
Or

The vehicle speed exceeds 20 km/h and the voltage of oil temperature sensor exceeds 2.43V (-40 C) for more
than 10 seconds.

Fail Safe:

The lock-up is inhibited, and TCM is controlled ATF temperature 80 C condition as substitute.

When the engine speed is more than 470 rpm for 10 minuets, the lock-up and gear shift to 4th (over-drive) are
allowed.

Possible Cause:

Oil temperature sensor wire open circuit or short circuit.

Oil temperature sensor malfunction.

Power supply wire open circuit, short circuit to battery or short circuit to ground between oil temperature sensor
and TCM terminal B4 (C95).

Ground wire open circuit or short circuit to battery between oil temperature sensor terminal and TCM terminal
B14 (C95).

Poor connection of each connector.

Reference:
Following output voltage and resistance can be measured by circuit tester.
Measurement terminal: B4 (C95) and B14 (C95)

ATF Temperature Output Voltage Resistance ATF Temperature Output Voltage Resistance
20
C
1.55V 2,500  80
C
0.5V 320 
40
C 1.08V 1,160  100
C
0.3V 190 
60
C
0.7V 590  120
C
0.2V 120