ISUZU TROOPER 1995 Workshop Manual

MOUNTING RUBBER
ENGINE EXHAUST (V6 3.2L) 6F-9
3

Removal steps 1. Center exhaust pipe mounting
rubber
2. Rear side mounting rubber
of exhaust silencer 3. Rear exhaust pipe mounting
rubber
Installation steps
To install, follow the removal steps in the reverse order.
Fig. 6F-12
E) REMOVAL
Preparation: • Battery negative cable.
• Raise the vehicle and support with
suitable safety stands.
1. Center exhaust pipe mounting rubber
• Disconnect center exhaust pipe mounting
rubber at center exhaust pipe mounting
bracket.
2. Rear side mounting rubber of exhaust silencer
• Disconnect exhaust silencer mounting rubber
at exhaust silencer mounting bracket.
3. Rear exhaust pipe mounting rubber
• Disconnect rear exhaust pipe mounting rubber
at rear exhaust pipe mounting bracket.
1••1 INSTALLATION
To install, follow the removal steps in the reverse
order.

6F-1 0 ENGINE EXHAUST (V6 3.2L)
MAIN DATA AND SPECIFICATIONS
TORQUE SPECIFICATIONS
Fig. 6F-13
N·m (lb·ft) ,-.
..

AUTOMATIC TRANSMISSION (4l30-E) 7 A-1
TRANSMISSION
CONTENTS
Automatic Transmission (4L30-E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 7 A
Manual Transmission . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section
78
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 7C
Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 70
SECTION 7A
AUTOMAT~ TRANSMISSION (4L30-E)
/' W CAUTION ./
When fasteners are r~movec;l, alway~reinstall them at the same location from which they were removed. If
a fastener needs to be repl£ed, use1'he correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound, will be called out. The correct torque
values must be used when installing fasteners that require torque. If the above conditions are not followed,
parts or system damage could result.
CONTENTS
General Description ............................................. 7 A-2 Flashing Codes ............................................... 7 A-50
Construction ..................................................... 7 A-3 TECH 1 Connection ........................................ 7 A-52
Electronic Control Diagram ............................. 7A-4 TECH 1 Operating Flow Chart ....................... 7 A-53
Transmission
Control Module Clear DTC ........................................................ 7 A-65
(TCM) ............................................................. 7A-5 DTC Check ...................................................... 7 A-66
Control System Diagram ................................. 7 A-6 FO: Data List Quick Check .............................. 7A-67
Functions
of Input/Output Chart 1: Diagnosis Connector and
Components ............................................... 7A-11 Voltage Supply Test .................................. 7A-69
Range Reference
Chart .................................. 7A-12 Chart 2: Diagnostic Trouble Code (DTC) ...... 7A-71
Normal Operation of 1994-95 4L30-E Chart 3: Transmission and
Transmission .............................................. 7 A-13
TCM Identification ..................................... 7 A-72
Diagnosis ............................................................ 7A-15
Chart 5: Actuator Test Quick Check ............. 7A-73
Introduction .................................................... 7A-15 Without DTC Set .......................................... 7 A-140
Driver Information ......................................... 7 A-16 TCM Precautions .......................................... 7A-145
General Diagnosis Procedure ....................... 7A-18 Intermittent Conditions ............................... 7A-146
Preliminary Inspection Chart ........................ 7 A-19 TCM MEM-CAL Replacement ..................... 7A-147
Checking Transmission Fluid Level Wiring Diagram ............................................ 7A-150
and
Condition ............................................. 7 A-20 Connector Location
..................................... 7A-152
Test Driving .................................................... 7 A-22
Mechanical/Hydraulic Diagnosis .................. 7 A-23
Connector List .............................................. 7A-153 •
On-Vehicle
Service ........................................... 7A-155
Check Trans Indicator Chart ......................... 7 A-23 Checking Transmission Fluid
Mechanical/Hydraulic
Diagnosis Level .......................................................... 7A-155
Symptoms Index ........................................ 7A-24 Changing Transmission Fluid ..................... 7A-155
Stall Test ......................................................... 7 A-41 Manual Linkage ............................................ 7A-155
Line Pressure Test .......................................... 7 A-42
Selector Lever .............................................. 7 A-156
Shift Speed Chart ........................................... 7 A-43 Mode Switch ................................................ 7A-157
Lock-up
Speed Chart ..................................... 7 A-44 Transmission
(With Transfer Case). ........... 7A-160
....._ Electronic Diagnosis ...................................... 7 A-45 Solenoid Valve (Main Case Valve Body) .... 7A-165
Check Trans Indicator .................................... 7 A-46 Solenoid Valve (Adapter Case Valve
Diagnostic Check ........................................... 7 A-47 Body)
......................................................... 7A-166
''Check Trans" Check ..................................... 7 A-48 Valve Body Assembly (Main Case) ............. 7A-167

7A-2 AUTOMATIC TRANSMISSION (4L30-E)
Valve Body Assembly (Adapter Case) ....... 7A-168 Third Clutch and Sprag Unit ....................... 7A-195
Transmission Control
Module (TCM) ......... 7A-169 Third Clutch .................................................. 7A-196
Speed Sensor (Extension Housing) ............ 7A-169 Sprag
Unit ....................................................
7A-198
Transmission
Oil Temperature Sensor Second
Clutch .............................................. 7A-199
(Adapter Case) ..........................................
7A-170 3-4 Accumulator Piston ............................... 7A-200
Front Oil Seal (Converter Housing) ............ 7A-170 Reverse Clutch Piston and Center
Rear
Oil Seal (Extension Housing) ............. 7A-171 Support ..................................................... 7 A-202
Unit Repair ........................................................ 7A-173 Overrun Clutch and Turbine Shaft ............. 7A-204
Transmission (4L30-E) ................................. 7A-173 Main Data and Specifications ......................... 7 A-207
Converter Housing and Oil Pump General
Specifications ................................. 7 A-207
Assembly .................................................. 7 A-189 Torque
Specifications .................................. 7A-208
Oil
Pump ....................................................... 7A-190 Special Tools .................................................... 7A-211
Main Case Valve Body ................................. 7A-191 4L30-E Parts List.. ............................................. 7A-213
Adapter Case Valve Body ............................ 7A-193 Hydraulic
Circuit Diagram .......... End of This Manual
GENERAL DESCRIPTION
The 4L30-E is a 4-speed fully-automatic transmission.
It uses a microcomputer as a control unit to judge
running conditions
including throttle opening rate
and vehicle speed, then
it sets the shifting point in
the
optimum timing so that best driving performance
can be achieved.
In addition, the built-in shift mode select function can
select three shift modes according to the driver's
preference.
• Normal mode-Normal shift pattern.
• Winter mode-Starts in 3rd gear to reduce
slippage on ice
or snow.
• Power mode has a delayed upshift for when
more powerful acceleration is required.
Also, the built-in fail-safe
function ("backup mode")
assures driving performance even if the vehicle
speed sensor,
throttle signal or any solenoid fails.
Further, the self-diagnostic
function conducts diag­
nosis in a short time when the control system fails,
thus improving serviceability.
The major features of 4L30-E are as follows:
• A compact structure consisting of 2 sets of
planetary gears and flat torque converter.
• Electronic control selects the optimum shift
mode according
to the driving conditions.
• Electronic control maintains the optimum hy­
draulic pressure for clutch, band brake as well as
transmission so that shift feeling is improved.
• Two sets of planetary gears reduce friction of
power train.
Also, a lock-up mechanism in the torque con­
verter reduces fuel consumption.
• Wide gear ratio and high torque rate of torque
converter provide
excellent starting perform­
ance.
MODEL YEAR 1994-95 CHANGES
The Transmission Control Module (TCM) for ISUZU
TROOPER
models equipped with 4L30-E is changed
from "BOSCH" to "DELCO ELECTRONICS"
manufacture.
The main differences
which will be encountered
while servicing concerned vehicles are as follows:
Diagnostic Trouble Codes (DTC):
DTC's are changed: For example, DTC for
transmission gear error will be as follows depending
on the TCM unit:
-
On the "DELCO" unit (1994-95) ......... DTC 61
-On the "BOSCH" unit (1993-prior) ..... DTC 41
TCM Pin Connector:
The pin connector is changed. Therefore the
connections
to be made for troubleshooting also
change.
Shift Alteration when TECH 1 Tool is connected
toTCM:
SHIFTS WILL BE HARSH WHEN TECH 1 IS
CONNECTED.
Connection of TECH 1 automatically forces maximum
line pressure during shifts only.
Normal line pressure checks at idle and stall spe
can be carried out.
/
/
I J I
/
l
•

(
f
CROSS
SECTION
"'T1 ce· ~ .....
1. TORQUE CONVERTER-CLUTCH (TCC)
5.
REVERSE
CLUTCH (RC)
2.
FOURTH CLUTCH (C4)
6.
SECOND
CLUTCH (C2)
3.
OVERRUN CLUTCH
(OC)
7.
THIRD
CLUTCH (C3)
4. OVERDRIVE
UNIT
8.
RAVIGNEAUX
PLANETARY
GEARSET
9.
BRAKE
BAND (B)
10.
OVERDRIVE
FREE WHEEL
(ONE
WAY
CLUTCH) (OFW)
11.
SPRAG
FREE WHEEL
(ONE WAY
CLUTCH)
(PFW)
(
(') 0 2 CJ) -1 ::D c (') ::! 0 2
)> c: -f 0 s: )> -f n -f ::D )> 2 en s: c;; en s 2 -;; ,... w 0 I m -...... )> I w

•
"'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

7 A-8 AUTOMATIC TRANSMISSION (4l30-E)
SHIFT MODE CONTROL
CD Mode type
Mode type Select lever position
Normal drive mode (NOR) Entire range (excluding "R")
Power drive mode (PWR) Entire range (excluding "R")
Winter drive mode "D", "N", "R" and "P" range
® Mode selection
SWITCH
(SW) LAMP
Mode type POW/NOR. SW WINTER SW POWER DRIVE LAMP WINTER DRIVE LAMP
Normal drive mode (NOR) OFF OFF
OFF OFF
Power drive mode (PWR) ON OFF ON OFF
Winter drive mode ON/OFF
ON OFF ON
However, the winter switch prevails over
the PWR/NOR switch.
The
mode becomes normal drive mode when the winter switch is operated from ON to OFF.
@ Comparison of mode
(1) The normal drive mode is set at the normal shift points.
(2) The shift points of the power drive mode are shifted to the higher speed side, compared to the
normal drive mode.
(3) The winter drive mode is a special mode used exclusively for starting in third gear.
Amount of
throttle
opening
N: Normal drive mode P: Power drive mode
Shift diagram
Winter drive mode
Amount of Third Shift pattern
throttle gear of normal drive mode
opening
Speed mph(km/h) 21 1341 mph(km/h) Speed
Fig. 7A-5
..