ABS ISUZU TROOPER 1995 Workshop Manual

DRIVEABILITY AND EMISSIONS 6E2-151
SECTION C-7
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
CONTENTS
GENERAL DESCRIPTION ................. 6E2-151
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-151
Exhaust Gas
Recirculation (EGR) Valve
Check . .

. . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-152
Exhaust Gas
Recirculation (EGR)
Backpressure Transducer (BPT) Check 6E2-152
Exhaust Gas
Recirculation (EGR)
Vacuum Switch Valve (VSV) Solenoid
Check . .

. . . . . . . . . . . . . . . . . . . . . . . . . . 6E2-152
DIAGNOSIS ........................... 6E2-153
ON-VEHICLE SERVICE .................... 6E2-153
Exhaust Gas
Recirculation (EGR)
Manifold Passage ................... 6E2-153
Exhaust Gas
Recirculation (EGR)
Valve Replacement .................. 6E2-153
Exhaust
Gas Recirculation (EGR)
Backpressure Transducer (BPT)
Replacement ....................... 6E2-153
Exhaust Gas
Recirculation (EGR)
Vacuum Switch Valve (VSV) Replacement . 6E2-153
CHART C-7A Exhaust Gas
Recirculation (EGR)
System Check ...................... 6E2-154
GENERAL DESCRIPTION
The Exhaust Gas Recirculation (EGR) System controls
the formation of NOx (Oxides of Nitrogen) Emissions
by
recirculating the exhaust gases into the combustion
chamber. This is done through the intake
manifold.
OPERATION (Fig. 6E2-93)
The EGR is controlled by the engine control module
(ECM) through an EGR Vacuum Switch Valve (VSV)
and Back Pressure Transducer (BPT). Vacuum is
allowed to the EGR Valve at acceleration and shut
"OFF" upon deceleration.
The diaphragm mounted in the EGR BPT is operated by
back pressure
of the exhaust gas to open and close the
valve. By this opening and closing action of the valve,
the EGR BPT controls the vacuum transmitted to the
EGR valve.
Under
a low load condition such as low speed driving,
the exhaust pressure is
low. In this state, the BPTvalve
opens to allow the air into the vacuum passage from
the outside.
As a
result, the vacuum transmitted to the EGR valve
becomes smaller and so does the opening of the EGR
valve.
Thus, less amount of exhaust gas is recirculated to the
intake
manifold.
Under
a high load condition such as high speed
driving, on the
other hand, the exhaust pressure is
high. By the high exhaust pressure, the diaphragm in
the
BPT is pushed up and closes its valve. As the air
does
not enter the vacuum passage in this state, the
vacuum transmitted
to the EGR valve grows larger and
so does the opening
of the EGR valve.
Thus, larger amount of exhaust gas is recirculated to
the intake manifold.
Under
any one ofthe following conditions, ECM closes
the vacuum passage of VSV. In this state, as the
vacuum is not transmitted
to the EGR valve, it remains
closed.
•
When engine coolant temperature is low.
•
When throttle body is at idle position.
• When engine is running under high load.
•
When intake manifold absolute pressure is low.
Other
than the above, EGR valve opens and closes in
accordance
with EGR BPT operation.
Fig. 6E2-93
i
.
,::·)I)' t
/
..f-l

6E2-154 DRIVEABILITY AND EMISSIONS
CHART C-7A
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK
Circuit Description:
A properly operating Exhaust Gas Recirculation (EGR) system will directly affect the air/fuel requirements of the
engine. Since the exhaust gas introduced into the air/fuel mixture is
an inert gas (contains very little or no oxygen),
less fuel is required
to maintain a correct air/fuel ratio. If the EGR system were to become inoperative, the inert
exhaust gas
would be replaced with air and the air/fuel mixture would be leaner. The Engine Control Module
(ECM) would compensate for the lean condition by adding fuel, resulting in higher block learn values.
The engine control system operates within
two block learn cells, a closed throttle cell and an open throttle cell.
Since EGR is not used at idle, the closed throttle cell would not be affected by EGR system operation. The open
throttle
cell is affected by EGR operation and when the EGR system is operating properly, the block learn values in
both
cells should be close to being the same. If the EGR system was inoperative, the block learn value in the open
throttle
cell would change (become higher) to compensate for the resulting lean system, but the block learn value
in the closed throttle
cell would not change.
This change or difference in block learn values is used to monitor
EGR system performance.
Diagnostic Aids:
The EGR valve chart is a check of the EGR system. If the EGR system works properly, check other items that could
result in high block learn values in the open throttle
cell, but not in the closed throttle cell.
CHECK:
EGR Passages
Restricted
or blocked
Manifold Absolute Pressure Sensor
A manifold absolute pressure sensor may shift in calibration enough to affect fuel delivery. Use CHART
C-1 0,
manifold absolute pressure output check.
EGR VALVE
EGRV
+
BACK
PRESSURE
TRANSDUCER
vsv
+ EGRVALVE VACUUM SWITCHING
VALVE (VSV)
ENGINE HARNESS
CONNECTOR
'+--+-' ( BLU)
GRN AB
t tt BL~L ---+ TO IGN
PORTED VACUUM
Fig. 6E2-98
ENGINE HARNESS
CONNECTOR
(BLU)
ENGINE CONTROL
MODULE(ECM)
EGR VALVE VSV DRIVER
•

•
"'Tl c3' -..J )> I "'
~ )
DASH
BOARD
DISPLA
V
*
*
*
*
ATF
WARNING
LAMP
CHECK
TRANS
LAMP
POWER DRIVE MODE LAMP WINTER DRIVE MODE LAMP
~----------------
SHIFT INDICATOR
LAMP
COMPENSATION
FOR
ENGINE
LOAD
AIR CONDITIONING SWITCH
TI
DRIVER'S
INPUT
liJ
MANUAL
SELECTOR
~
KICK-DOWN SWITCH
" ~
BRAKE
SWITCH
*
(AfT
SHIFT INDICATOR)
CONTROL
UNIT
---
' ---
I-------------,
il
PUSH BUTTON
FOR
NORMALJPOWER
DRIVE MODE
ON-BOARD DIAGNOSTIC
j4
.. ,
..
l__l--1 L_-$-L_g
ENGINE CONTROL
MODULE
(ECM)
_ IGNITION
CONTROL
I
MODULE
i
THROTTLE POSITION
SENSOR
ENGINE SPEED SENSOR
l
I
I -
ENGINE COOLANT TEMPERATU~,_.TCH
)
I +12 IGNITION
• •
TRANSMISSION
CONTROL MODULE
(TCM)
j
L I
BATTERY
)
--
~
'
5SOLENOID VALVES
il
-·----·
___.
u
PUSH BUTTON
FOR
WINTER DRIVE MODE
OTHERS
OVERDRIVE
OFF
SIGNAL
(CRUISE CONTROLLER)
ABS
SIGNAL
(ABS CONTROLLER)
f.-
n_
VEHICLE SPEED
SENSOR
f-
/
ATF TEMPERATURE SENSOR
L__ L__
[PRNDJ2L
I MODE SWITCH
-
m
.....
r-
)>
m
I
(")
..;=...
-t
)>
;::g 0
c:
2
-1
-
0
(")
s:
(")
~
0
-
2
n
-t
-1
;::g
:a
0
)> z
r-
en
c
s:
:;
(i)
C)
en
~
0 z
3:
-..;=... r-w 0 I !!!
)

AUTOMATIC TRANSMISSION (4l30-E) 7A-5
TRANSMISSION CONTROL MODULE (TCM)
ENGINE
ENGINE SPEED
ECM ENGINE
COOLANT
TEMPSW
;--J
---
SERIAL DATA
TORQUE
t MANAGEMENT TPS +
.L OUT
I -
4L30E
.J:
X a MODE SWA
Xb MODE SWB
Xc MODE SWC
Xg MODE SWG
A Ac OIL TEMP
Ad ANALOG GND
~~x OUTPUT SPEED HI
1 X1 OUTPUT SPEED LO
II A a TCCHI
Me SHIFT SOL. HI
~Md SHIFT SOL. 1-2/3-4
~Ma SHIFT SOL. 2-3
~Mb BAND APPLY SOL.
~Ab FORCE MOTOR HI
Ac FORCE MOTOR LO
ECM: Engine Control Module
TPS: Throttle Position Sensor
TCC: Torque Converter Clutch
ABS:
Anti-Lock Brake System
-
1
·-c
IGN BATT GND
h+ri A7 AS A4 C1 01
D12 VEHICLE
IGN
BRAKE SW ~ D14 D9 ~
DB AJC REQUEST /o---
CB BB POWER SW
=~
WINTERSW B6
C5 KICK DOWN SW C6 B5
-=
D7 IGN
D16 DIAG INIT. D6
~
D5 C10 CHECK TRANS LAMP
D4 TCM 89 POWER LAMP
A10 ATF WARNING LAMP ~
¥ 83 A11 WINTER LAMP
C14
A12
OD OFF SIGNAL CRUISE 812 84 CONTROLLER
811
C7 ABSSIGNAL ABS
810 CONTROLLER
C12
A2
A3
AS
C15
C16
Fig. 7A-3

7A-6 AUTOMATIC TRANSMISSION (4L30-E)
CONTROL SYSTEM DIAGRAM
L1J ~ (!) z L1J
I
I
lr
t:··
~ .. I I
I
I
AUTOMATIC TRANSMISSION ASSEMBLY
O.:a: :Eo LLJ(J) t-z --' L1J oVl
ENGINE COOLANT TEMPERATURE
ffio ~---a:O wz >LLJ z--' oo uCJ> w::C :::>u at-a:=> ~d
0 0 z ... w, --'"' o-.. (J)N t-.!-u.. J: CJ)
IGNITION
CONTROL .
MODULE
~==PO=W==ER==M=O=D=E=L=A=M=P~r.-------
r-------CHECK TRANS. LAMP
~=W=IN=T=E=R=M=O=D=E=LA=M=P~~--J---
::c u L1J a: 1-:.:: ::c <( :::> <( u L1J --' a: 1-(!) u al :::> >-L1J L1J 0 --' 1-~ z u a: :5 <( ~ ~ --' al Cl.
Cl. L1J i=
i= L1J ~ z :.:: --' --' <( L1J :5 :::> :::> a: z Cl. ::!: ::!: al 0
0 a: L1J 0 >-0 > --'o --' z (l._ 1-<( L1J Cl.Q 0 > __,..., "' 0--' L1J 1-zo u :::> u.. <(Vl a: z J: 0 <( al u.. ::!: CJ)
SHIFT
CONTROL
BAND APPLY CONTROL
TORQUE CONVERTER CLUTCH CONTROL
LINE PRESSURE CONTROL
SAFETY MODE
ON-BOARD DIAGNOSTIC
SYSTEM
TORQUE MANAGEMENT
ATF WARNING CONTROL
r-ABS CONTROL
L--A-T_F_w_A_R_N_I_N_G_L_A_M_P_...Jr---_l 1---------------'
0 L1J "'a: Bio wVl __,z uw J:Vl L1J >
POWER c): TRANSMIT
.... : OIL PRESSURE
CONTROL
MECHANICAL
...• : SIGNAL
LLJJ: ou ELECTRONIC ot:: -•: ::!:~ SIGNAL
KICK DOWN SWITCH
BRAKE SWITCH
POWER MODE SWITCH
WINTER MODE SWITCH
AIR CONDITIONING
SWITCH
ABS
SIGNAL (ASS CONTROLLER)
ABS: Anti-Lock Brake System
Fig. 7A-4
..

1. SHIFT CONTROL
The transmission gear is shifted according to the
shift pattern selected by the driver.
~ In shifting gears, the gear ratio is controlled by the
ON/ OFF signal using the 1-2/3-4 shift solenoids and
the 2-3 shift solenoid.
2. BAND APPLY CONTROL
The band apply is controlled when in the 3-2
downshift (engine overrun prevention) and the
garage shift (shock control).
The band
apply solenoid is controlled by the signal
from the Pulse Width Modulation (PWM) to regulate
the
flow of the oil.
3. TORQUE CONVERTER CLUTCH CONTROL
The clutch ON/OFF is controlled by moving the
converter clutch valve through shifting Torque
Converter Clutch
(TCC) solenoid using the ON/OFF
signal.
4. LINE PRESSURE CONTROL
The throttle signal allows the current signal to be
sent
to the force motor. After receiving the current
signal, the force motor activates the pressure
regulator valve to regulate the line pressure.
5. ON-BOARD DIAGNOSTIC SYSTEM
Several malfunction displays can be stored in the
Transmission Control Module (TCM) memory, and
read
out of it afterward.
The serial data lines, which are required for the
testing of the final assembly and the coupling to
other electronic modules, can be regulated by this
function.
6 FAIL-SAFE MECHANISM
If there is a problem in the transmission system, the
TCM will go into a "backup" mode. The vehicle can
still be driven, but the driver must use the gear
lever to shift gears.
7. TORQUE MANAGEMENT CONTROL
The TCM sends the absolute spark advance signal
to the Engine Control Module (ECM) while the
transmission is being shifted, to control the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the
change of speed.
8. ATF WARNING CONTROL
The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning,
TCC and the winter mode.
9. ABS CONTROL
When the select lever is at "L" or "R" range, a
signal is sent
to the ABS controller as one of the
ABS control conditions.
AUTOMATIC TRANSMISSION (4L30-E) 7A-7

AUTOMATIC TRANSMISSION (4L30-E) 7 A-11
FUNCTIONS OF INPUT /OUTPUT COMPONENTS
Components Function
Speed sensor
Senses rotation
of output shaft and feeds the data to Transmission
(fixed
to transmission (T/M)) Control Module (TCM)
Throttle Senses the extent of throttle valve opening and the speed of the throttle
position sensor (TPS) valve lever motion to open the valve and feeds the data to TCM (fed to
(fixed to engine)
Engine Control Module (ECM) also)
I
Brake Switch (SW) Senses whether the driver has pressed the brake pedal or not and feeds
N (fixed
to brake pedal) the
information to TCM
p Kick-down SW (fixed to Senses whether the driver has pushed the accelerator pedal fully or not
u accelerator pedal) and feeds the information to TCM
T Mode
SW (fixed to T/M) Senses the select lever position and feeds the information to TCM
s Power drive SW Senses whether the driver has selected the power mode and feeds the
I (fixed to front console) information to TCM
G T/M
oil temp. sensor
Senses the T/M oil temperature and feeds the data to TCM
N Engine
coolant Senses the engine cooling water temperature and feeds the data to TCM
A temperature
SW (feeds the signal from ECM)
L
Engine speed
signal Feeds the signals monitoring engine speed to TCM from Ignition Control
Module
(fed to ECM also)
Air conditioning Senses whether the air conditioner has been switched on or not and
information feeds the information
to TCM
On-board diagnostic
input By monitoring the Ground (GND), the location of failure is shown on the
T/M
monitor lamp ("CHECK TRANS") by flashing the diagnostic trouble
code
Winter switch
Senses whether the driver has selected the winter mode, and feeds the
(fixed
to front console) information to TCM
Cruise
controller Downshift takes place when Overdrive OFF signal is received from auto
(Overdrive
OFF signal) cruise control unit
Shift
solenoid Selects shift point and gear position suited to the vehicle running con-s 1-2/3-4, 2-3
dition on the basis of TCM output 0 Band apply solenoid
Controls oil flow suited to the vehicle running condition on the basis of L
E TCM output
0 N
Torque
Converter Controls clutch engagement/disengagement suited to the vehicle
u 0 Clutch solenoid running condition on the basis of TCM output
T I Force motor Adjusts the oil pump delivery pressure to line pressure suited to the p D
(Pressure regulator vehicle running condition on the basis of TCM output u valve) T
Power drive mode lamp
Informs the driver whether the vehicle is in power mode or not
s Winter drive mode lamp Informs the driver whether the vehicle is in winter mode or not
I T/M monitor lamp Informs the driver of failure in the system. It also displays the self diagnosis
G
("CHECK TRANS") code.
N Data Link Connector
(DLC) When connected with TECH 1 or tester, can communicate the data for A
L function
check, etc. (fed to ECM also). When TECH 1 is not connected, can
communicate the
signal for torque management with ECM.
Self-diagnosis connector
When short-circuited with the bipolar connector, the T/M monitor lamp
displays
a failure by code.
ATF warning
lamp Lights when ATF oil temperature rises.
ABS signal When the select lever is at "Reverse" or "L" range, sends a signal to the
ABS controller as one of the ABS control conditions.

AUTOMATIC TRANSMISSION (4L30-E) 7 A-63
F5: ACTUATOR TEST
The purpose
of F5: ACTUATOR TEST mode is to check for correct operation of electronic system actuators.
By means of the TECH 1 you can command the actuators ON and OFF. Then you can check the actuators for
correct operation.
Select the actuator by pushing the "i" or".!." key. (The* mark moves.)
For some actuator tests the TECH 1
can automatically determine the correct function of the actuators.
W CAUTION
Always put the parking brake on and block the wheels when using this test mode.
The engine
should be OFF and the ignition is ON. Refer to page 7A-73.
TEST ABORTED! ENGINE MUST NOT BE RUNNING
If engine running
SELECT MODE FO: DATA LIST
F1:NOT USED F2:TROUBLE CODE
(T,.J..)
SELECT MODE
F3:SNAPSHOT F4:CLEAR CODES
F5:ACTUATOR TEST
(F5)
SELECT ACTUATOR *SOLEN. 1-2/3-4 SOLENOID 2-3
SHIFT SOLENOID TCC SOLENOID TCC HIGH CD)
ATF LAMP POWER LAMP WINTER LAMP
CHK. TRN. LAMP ABS OFF LAMP
(i,.!.+ENTER)
SOLENOID 1-2/3-4
*1 i: ON .j,: OFF
CYESJ
(YES)
SOLENOID 1-2/3-4 * INACTIVE SOLENOID 2-3 INACTIVE ON/OFF
* 1 (i,.!.)
*:Flashing
*1: The
"i" key is ON and the".!." key is OFF.
(EXIT)
SELECT ACTUATOR *SOLEN. 1-2/3-4 SOLENOID 2-3 SHIFT SOLENOID

AUTOMATIC TRANSMISSION (4L30-E) 7A-73
CHART 5: F5: ACTUATOR TEST QUICK CHECK
Before carrying out the Actuator Test, the selector lever should be placed in selector position "N ".
The ignition should be switched ON, engine not running.
TECH 1 DISPLAY
NOTES CORRECT RESULT FOR
DIAGNOSIS
SEE*1
SOLEN. 1-2/3-4 Press arrow up (ON)
"Click" heard from DTC31
Press
arrow down (OFF) transmission or 41
SOLENOID 2-3 Press arrow up (ON) "Click" heard from DTC 32
Press arrow down (OFF) transmission or 42
SHIFT SOLENOID Press arrow up (ON)
"Click" heard from DTC 82
Press arrow down (OFF) transmission
TCC SOLENOID Not used --
TCC HIGH (D) Press arrow up (ON)
"Click" heard from DTC33
Press
arrow down (OFF) transmission or 43
ATF LAMP Press arrow up (ON) A/TOIL TEMP lamp A/TOIL TEMPERA-
Press
arrow down (OFF) ON TURE INDICATOR
TEST (PAGE
~ 41)
POWER LAMP
Press arrow up (ON) POWER lamp ON TRANSMISSION Press arrow down (OFF) OPERATING
WINTER
LAMP Press arrow up (ON)
WINTER lamp ON MODE
TEST
Press arrow down (OFF) (P1'\(3E 1 42)
CHK. TRN. LAMP Press arrow up (ON) CHECK TRANS lamp CHECK TRANS
Press arrow down (OFF) ON CHECK (12AGE .11:8)
ABS OFF LAMP Not used - -
NOTE:
(*1) FOR DIAGNOSIS OF A DTC SEE CHART 2: DIAGNOSTIC
TROUBLE CODES (DTC) (~)

7A-150 AUTOMATIC TRANSMISSION (4L30-E)
WIRING DIAGRAM
L--<~o-~~~~~~--~~~----~~~----~~--------------~G"IW~------------C«-9_0--iA4
D16
30A
D12
GfY ---~:at--B-'li BfY G(Y H-7 ,...-..~., 4,' ~ ~
RELAY ~' ~:iO 1 [my_ STOP LIGHT
2 3 I CRUISE MAIN '..BRAKES '' L------•CRUISE CONTROL (4) - ---vy UNIT (8) D1
~2
8-11+~---f4
~ 81~ Q._ ("'~2
~ IG1 18~ ~ ST ACC en 8-11
C-91 D9
C1
ECM MAIN RELAY
X-f~ ~X~~2 8 II• FENDER R/W : - : RiG H-42 C-90 '-----t--t------+-------!:!Lll----------< • ~( r fl A7 2 4 8 L....{+--AS
C-8
~A
H-13 BfY BfY 3 7 3
L-+-JB~~I,_IG __ __....,~4-B(Y ECM(A61 1 3 WARNING BOX TRANSMISSION
~T'~5'-'1:D----H-+~2~5 LfY ~~~ ~K TRANS 1-,17 Hr7 :~ C-~1 C10 C::
0 ~
"' <( u :!?
'----~
"' ":' 0'> J:
IXl ~ a: ~
I~ A10 AJT OIL TEMP 2
8
A
2
LfY 1-9~ ~1-9 GR/W H;9 BiG C-90 89 1~ POW. : 8 ~3 , A9
- -~· PiG c(-A11 WIN. 7 19 INDICATOR LIGHT (METER) POWER & WINTER SWITCH
_,. POW. 8-30 ViR H-,>,7:;-----'V"-'iR.!..,_ ___ c<-~9-0-l B8 C15 II-v 3, :7 • BODY of~~ ~-o-WIN. 1 ,' ViG -----.+.,.,176 __ ____;;V.:..;iG=-----<+'-----1 B
6 CONTROL C16 ,4 ILLUMINATION~' ~ '~RELAY: TAIL (4) CONTROLLER(3) 2 -~ 5
ABS ~c~4----------------__yV:J..:!:!._/W ______________ ___:C<-~9:..::0-l B 10 CONTROL UNIT 16 CRUISE CONTROL
RiB H-8 C-43
4 RiB 5(D)
UNIT Q;·>-9------"G,_,Ri_,L_~:+--;-----'G""R""iL::,_ ___ c,-+-9-0----j 84
MODE SWITCH
IT-MISSION)
C-43
2(F) ~ ' 8(A), '
BACKUP LAMP
RiL
t
PiL
p
C-91 ( D7 : D6
B3
C14
C7
MODULE D14
: D5 : C5 ( D4 C6
B5
7(B)'
X-17-l-~J,-~L -v-: 6((:1§': :
r! -v-u-3tGi'', STARTER H-~..._:4---4r::J-Mo~-_B~;~;8 LJR C;~434--o-_,_-o---+---<·' L ---1 8 1 [::::J 2 15 4(H) u---~< 1 '
CRUISE CONTROL UNIT RELAY;A/C (4)
DB
(TCM) 812
A12
811
C8
....
'
Fig.7A·11 I
------------------------~~
•