air condition ISUZU TROOPER 1995 Workshop Manual

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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__
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I MODE SWITCH
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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
..

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.

7 A-20 AUTOMATIC TRANSMISSION (4L30-E)
CHECKING TRANSMISSION FLUID
LEVEL AND CONDITION
Checking fluid level and condition (color and odor)
at
regular intervals will provide early diagnosis
information about the transmission. This inform­
ation may be used to correct a condition that, if not
detected early, could result in major transmission
repairs.
IMPORTANT: When new, automatic transmission
fluid is red in color. As the vehicle is driven, the
transmission
fluid will begin to look darker in color.
The
color may eventually appear light brown.
A DARK
brown color with burnt odor may indicate
excessive
fluid deterioration and signal a need for
fluid change.
FLUID LEVEL
When adding
or changing fluid, use only DEXRON
®-Ill.
Refer to the Maintenance and Lubrication (Section 0
of this manual) for maintenance information and
servicing
interval.
\f CAUTION: DO NOT OVERFILL
Overfilling will cause foaming, loss ~f fluid,
abnormal shifting and possible damage to
the transmission.
1. Start engine and drive vehicle until normal AfT
oil operating temperature is reached:
NOTE: The automatic transmission fluid level
must be checked with the vehicle at normal
A/T oil operating temperature: 75 TO 85°C
(167 TO 185°F) MEASURED WITH TECH1 SCAN
TOOL.
Temperature will greatly affect transmission
fluid level.
If the vehicle is not at normal AfT oil operating
temperature and the proper checking
procedures are
not followed, the result could
be a false reading of the fluid level indicator
and
an incorrect adjustment of the fluid level.
2. Park vehicle on level ground.
3. Move gear selector to "Park".
4. Apply parking brake and block wheels.
5. Allow vehicle to idle for 3 minutes with all
accessories turned off.
6. Check fluid level with engine running at idle:
Fluid should
be in "HOT" area on AfT dipstick
(Fig. 7A-6).
Check also color and condition (Refer to next
page.)
Hot
Cold ---IIU 0
0
Min
Dipstick
Fig. 7A-6
\f CAUTION:
DO NOT CHECK FLUID LEVEL UNDER THESE
CONDITIONS: •
At high ambient temperature above 30°C
(86°F).
Immediately after driving at sustained highway
speeds.
• In heavy city traffic during hot weather.
If vehicle is towing a trailer.
If the vehicle has been operated under these
conditions,
shut the engine off and allow the
vehicle to "cool" for thirty (30) minutes. After the
cool-down period, restart the vehicle and continue
from step 2 above.
'~I
......

AUTOMATIC TRANSMISSION (4L30-E) 7A-21
FLUID CONDITION
FLUID CONDITION
NORMAL* CONTAMINATED
COLOR
RED BROWN NON-TRANSPARENT BROWN OR LIGHT BROWN
/PINK
DRAIN NO
YES YES YES
REQUIRED?
CO NT AMI- NONE Very small amount Contamination by Large pieces of
NATION of foreign material coolant or other metal or other
in bottom of pan
source foreign material in
bottom of pan
1. LOW LEVEL:
A. Add fluid to -
Remove both pans -Repair/replace
obtain
proper radiator cooler
level
& check -Change filter -Transmission -Transmission
CORRECT for external overhaul required overhaul required
LEVEL leaks. See -Flush cooler -Check for:
& chart 16..811 • Damaged plates -Flush cooler and
CONDITION ~· -Add new fluid and seals cooler
lines
B. Correct cause • Contaminated -Add new fluid
of leak. -Check level solenoids
2. HIGH LEVEL: -Flush cooler -Check level
-Remove excess -Add new fluid
fluid -Check level
* Fluid should be changed according to maintenance schedule.

7 A-22 AUTOMATIC TRANSMISSION (4l30-E)
TEST DRIVING
Some 4L30-E automatic transmission complaints
vehicles will require a test drive as a part of the
diagnostic procedure.
Some codes will not set
unless the vehicle is moving. The purpose of the
test
drive is to duplicate the customer's complaint
condition and set a current Transmission Control
Module (TCM) trouble code. Perform this
procedure before each 4L30-E automatic trans­
mission repair, and again after repairs are made.
IMPORTANT:
• Duplicate the condition under which the
customer's complaint was observed.
• Depending on the complaint, line pressure
gauge and the
TECH1 scan tool may be
required
during the test drive.
• During the test drive, it is important to record
all necessary data from the areas being
monitored, for use in diagnosis. Also listen for
and note any unusual noises.
The
following procedure should be used to test
drive 4L30-E automatic
transmission complaint
vehicles:
1. Turn the ignition ON without starting the
engine. Check
that the "CHECK TRANS" lamp
comes on for approximately 2 to 3 seconds
and then goes
out and remains out.
• If the lamp is flashing, GOTO CHECK
TRANS INDICATOR (on page 7A-46).
• If no serial data is present, see Chart 1:
DIAGNOSTIC CONNECTOR AND VOLTAGE
SUPPLY TEST (on page 7A-69 and 7A-70).
• If the lamp stays ON or stays OFF, GOTO
"CHECK TRANS"
CHECK (on page 7A-48).
NOTE:
Remember that, when TECH1 is connected,
line pressure will be at maximum during shifts.
2. Drive the vehicle. During the test drive be sure
that the transmission achieves normal
operating temperature (approx. 20 minutes) ..
Allow the transmission to go through all of 1ts
gear ranges, checking shift timing and
firmness.
Duplicate the owner's complaint
condition as closely as possible during the test
drive.
3. If, during the test drive, the "CHECK TRANS"
lamp comes on, use the TECH1 to check for
trouble codes.
4. If, during the test drive, a problem is felt, but
the "CHECK TRANS" lamp does not come on
and
no trouble codes are present, drive the
vehicle with the TCM disconnected (manually
shifting the vehicle).
•
In Manual L, the vehicle operates in first
gear.
• In Manual 2, the vehicle operates in third
gear.
• In Manual 3 or "D", the vehicle operates in
fourth gear.
If the problem still exists with the TCM
disconnected, refer
to the MECHANICAL/
HYDRAULIC DIAGNOSIS
in this Section.
5. If no problem has been found at this point,
check
all underhood connections that supply
power to the TCM and ignition fuses.
Physically and visually inspect all the TCM
harness connectors
for loose or corroded
terminals. Inspect the TCM ground points.
•

AUTOMATIC TRANSMISSION (4L30-E) 7 A-39
CHART 16: POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS
Before attempting to correct an oil leak, the actual source of the leak must be determined. In many cases,
the source
of the leak may be difficult to determine due to "wind flow" around the engine and
transmission.
The suspected area
should be wiped clean of all oil before inspecting for the source of the leak.
Oil leaks
around the engine and transmission are generally carried toward the rear of the car by the air
stream. For example, a transmission "OIL FILLER TUBE TO CASE" leak will sometimes appear as a leak at
the rear
of the transmission. In determining the source of an leak, the following two checks should be
made:
1. With the engine running, check for external line pressure leaks.
2. With the engine off, check for oil leaks due to the raised oil level caused by drainback of converter oil
into the transmission.
Overfill condition
Two possible causes of fluid
leaks
Sealing
malfunction
Check at POSSIBLE CAUSES OF FLUID LEAKS DUE TO SEALING
MALFUNCTION (See nex~

7 A-62 AUTOMATIC TRANSMISSION (4L30-E)
F4: CLEAR CODES
The purpose of the F4: CLEAR CODES mode is to command the clearing of stored Transmission Control ~
Module (TCM) trouble codes.
SELECT MODE FO:DATA LIST
F1:NOT USED F2:TROUBLE CODE
(i,J.)
'
SELECT MODE F3:SNAPSHOT
-F4:CLEAR CODES F5:ACTUATOR TEST
(F4)
' (NO) DO YOU REALLY WANT TO CLEAR THE CODES? (YES/NO)
(YES)
'
4L30E (DEl CLEARING CODES
'
4L30E (DE)
CODES CLEARED
'
SELECT MODE FO:DATA LIST F1:NOT USED
F2:TROUBLE CODE
..
-
4L30E (DEl
CODES NOT CLEARED (YES)
(YES)
'
4L30E (DEl TC PRESENT
15. 16 (YES)
(YES)
'
4L30E (DE)
TC NOT PRESENT
15. 16 (YESJ
(YES)
When a malfunction
remain
as is. (*1)
After clearing codes, confirm system operation by test driving the vehicle.
Allow the vehicle to shift through
all four forward gears in a manner which attempts to repeat the failure condition.
*1: When the trouble has not been repaired and the trouble code cannot
be erased, check the vehicle
again.

7A-68 AUTOMATIC TRANSMISSION (4l30-E)
FO: DATA LIST QUICK CHECK (continued)
TECH 1 DISPLAY
CONDITONS CORRECT VALUE FOR
DIAGNOSIS
SEE*1
SELECTOR PIN A Ignition ON ACTIVE DTC 53
Selector lever position: or 54
"P11, "R'', "311 or "211
SELECTOR PIN B Ignition ON ACTIVE DTC53
Selector lever position: or 54
"R11
, "N","D'' or "3''
SELECTOR PIN C Ignition ON ACTIVE DTC 53
Selector lever position: or 54
"D'', "311
, "211 or "L''
SELECTOR PIN P Ignition ON ACTIVE DTC 53
Selector lever position: or 54
"P11
, "N11, "311 or "Lu
TPS SIGNAL Ignition ON
Throttle body in idle speed position 0.1 V to 0.96 V (0%) DTC 21
Throttle body in full load position 4.9
V or less (99%) or 22
KICK DOWN SWITCH Ignition ON ACTIVE DTC 52
Depress accelerator pedal to stop
A!C REQUEST Engine running. Air conditioning ON. ACTIVE CHECK WIRE
Compressor
engaged. FROM TCM
CONNECTOR
C-91
TERMINAL
DB FOR
OPEN
CIRCUIT.
TRANSM. OIL
TEMP.
Engine running 70 -120°C/158 -248°F DTC 15
approx. 1.00 -3.10 V or16
COOLANT TEMP SW.
Ignition ON: Engine warm COLD (~ 63°C) DTC 51
WARM (> 70°C)
WINTER SW.
(-D-) Ignition ON ACTIVE TRANS
MIS-
Selector
lever position "D" SION
Press "WINTER" switch OPERATING
WINTER
LAMP Engine running ON MODE
TEST Sff-flAG£ Selector lever position "D" -,~ Press "WINTER" switch
POWER SWITCH Ignition ON ACTIVE TRANSMIS-
Press "POWER" switch SION
OPERATING
POWER LAMP Engine running ON MODE TEST
3!'Ef'AGE Press "POWER" switch l~·
• IF ALL VALUES ARE CORRECT, CONTINUE DIAGNOSIS WITH F5: ACTUATOR TEST QUICK CHECK.
NOTE:
*1
FOR DIAGNOSIS OF A DTC SEE CHART 2: DIAGNOSTIC TROUBLE CODES (DTC)
(PAGE Itt-
IIIII

AUTOMATIC TRANSMISSION (4L30·E) 7 A-75
DIAGNOSTIC TROUBLE CODE (DTC) 11
OUTPUT SPEED FAILURE
W CAUTION: If wire to connector C-90 terminal 812 is short to voltage, Transmission Control Module
(TCM) will be damaged.
IF the DTC 53 is set:
I I
~
GOTH ROUGH DTC 53 first J I IF you have a SCAN TOOL: TECH17 I and do a test drive. I
cf
$
• Raise drive wheels. • Ignition switch OFF.
• Connect the TECH1 GOTH ROUGH TECH1 • Disconnect TCM connector C-90 & C-91.
CONNECTION. • Connect ohmmeter between connector C-90 terminal
• Push "FO": DATALIST: DISPLAY. Read •AT OUTPUT A12 and terminal 812 . SPEED". IF: display is approx. 3K ohms: IF: Output Speed different from 0 RPM when the wheels are turning:
diJ
§J
$
T
Problem is intermittent. GOTO INTERMITTENT
CONDITIONS. • Connect ohmmeter between connector C-90 terminal A12 and ground connector C-91 terminal C1.
IF: display indicates an open circuit:
$ ~
Check for faulty TCM connection. IF OK GOTO TCM MEM-CAL
REPLACEMENT.
HINT: the wire between TCM terminal 812 and sensor connector M-15 terminal 1 can be shorted to ground or open without creating a problem because the TCM 812 pin is connected to the TCM ground internally and the signal is
detected only on the A 12 input.
• Check wire for a short to ground between terminal A 12 and sensor
connector M-15 terminal 2. IF: display indicates a short circuit:
I
A CONTINUED
ONNEX~
NO
• Disconnect transmission speed
sensor connector M-15.
• Connect ohmmeter between terminals 1 and 2 of the speed
sensor.
IF: display approx. 3K ohms:
$ ~
• Wires from Connector C-90 to sensor
connector are open or shorted together.
• Repair .
I Replace transmission
speed sensor.