2007 ISUZU KB P190 Harness

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–31

Keep the control valve body level when
lowering it to prevent the loss of the
checkballs located in the body passages.
5 Carefully lower the control valve body (1) from the transmission case. As the valve body is being lowered,
rotate it slightly to disconnect the manual valve link (2)
from the manual valve (3) and remove the control
valve body.
6 Remove the manual valve link from the inner detent lever (4).
Figure 7C4 – 39
Reinstall
Different bolt sizes are used to attach the control valve body and components, Figure 7C4 – 40 shows the location of the
attachment bolts with the letters referring to their dimensions.
NOTE
For clarity, the control valve body harness is not
shown in the illustration.

Figure 7C4 – 40
Legend
1 Control Valve Body
2 Torque Converter Clutch (TCC) Solenoid
3 Transmission Fluid Pressure (TFP) Manual Valve Position Switch
4 Manual Detent Spring
5 1 – 2 Accumulator Cover A Bolt M6 x 1.00 x 65.0
B Bolt M6 x 1.00 x 54.4
C Bolt M6 x 1.00 x 47.5
D Bolt M6 x 1.00 x 18.0
E Bolt M6 x 1.00 x 35.0
F Bolt M6 x 1.25 x 20.0
G Bolt M6 x 1.00 x 12.0
1 Ensure the spacer plate gasket is in a satisfactory condition, replace as required, refer to 3.15 Spacer Plate, Check Balls, Filter Screens and 3 – 4 Accumulator.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–34
9 Fit a new shield (1) to the transmission fluid pressure
(TFP) manual valve position switch (2) and reinstall to
the control valve body.
NOTE
Refer to Figure 7C4 – 40 for bolt dimension and
corresponding location.
10 Reinstall the three long bolts (3) and the two short bolts (4) hand tight only.
11 Reinstall the manual detent spring (5) and the attaching bolt (6) hand tight only.
Figure 7C4 – 45

The control valve body bolts must be
tightened in an outward spiral starting from
the centre. Failure to follow this pattern may
distort the valve body causing the valves to
jam in their bores.
12 Follow the sequence starting from the centre as shown by the arrows to tighten the following bolts to the
correct torque specification:
• fourteen bolts (1) attaching the control valve
body,
• five bolts (2) attaching the transmission fluid
pressure (TFP) manual valve position switch and
• one bolt (3) attaching the manual detent spring.
Control valve body attaching bolt
torque specification ............................................ 12.0 Nm
Transmission fluid pressure (TFP) manual valve position switch attaching bolt torque specification ..................................... 12.0 Nm
Manual detent spring attaching bolt torque specification ............................................ 23.0 Nm
13 Reinstall the control valve body harness , refer to 3.13 Control Valve Body Harness.
Figure 7C4 – 46

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–40
5 Remove the filler tube from the engine compartment.
6 Remove the filler tube seal from the transmission case and discard.
7 If the breather hose needs to be replaced proceed as follows: a unclip the breather hose (4) from the harness channel (5).
b Remove the transmission support and lower the rear of the transmission sufficiently to get access to the breather hose, refer to 3.7 Transmission Support and Mount.
c Disconnect the breather hose from the T-joint (6) and the top of the transmission case and remove.
d If required, remove the two bolts (7) attaching the brackets of the vent pipe (8) to the chassis, disconnect from the T-joint and remove the vent pipe.

Figure 7C4 – 57
Reinstall
Reinstallation of the transmission filler tube and/or the breather hose is the reverse of the removal procedure, noting the
following:
1 Smear a new filler tube seal with clean transmission fluid and fit it to the transmission case.
2 Ensure the transmission breather hose and the harness are secured to the filler tube lower bracket.
3 Tighten the bolt attaching the filler tube bracket to the correct torque specification.
Filler tube bracket attaching bolt
torque specification ................................. 20.0 – 35.0 Nm
4 If required, tighten the two bolts attaching the vent pipe bracket to the chassis to the correct torque specification.
Vent pipe attaching bolt
torque specification ..............................................6.0 Nm

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–43

If the verifier disc does not clip into place, the
quick-connect fitting is not engaged, rectify
as required.
10 As a security check, push and clip each verification disc into place over the quick-connect fittings. If difficulty is experienced, repeat the installation process until the verification disc can be clipped into place over the radiator
quick-connect fitting.
11 Snap the outlet cooler line (4) in the clip (5) of the radiator fan shroud.
12 Ensure the routeing of the cooler lines is correct and there is no fouling of the lines.
13 Tighten the screw attaching the cooler lines bracket to the correct torque specifications.
Transmission cooler lines bracket
attaching screw torque specification .................. 23.0 Nm
14 If required, top up the transmission fluid level (cold).
15 Start the engine and check for any fluid leak at the fittings. If a leak is found, stop the engine and rectify the leak.
16 Check and top up the transmission fluid to the correct level as required, refer to 2.1 Transmission Fluid.
3.18 Transmission Assembly
Remove

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 6D1-3
Battery, before disconnecting the battery.
1 Disconnect the battery ground lead.
2 Raise the vehicle and support in a safe manner, refer to 0A General Information for the location of support points.
3 Remove the heat shield from the neutral start and back-up lamp switch, gently prise the selector cable from the transmission external manual shaft linkage and remove the selector cable from the bracket, refer to
3.3 Selector Cable Assembly.
4 Disconnect the harness connectors from the following:
a Vehicle speed sensor, refer to 3.5 Vehicle Speed Sensor.
b Neutral start and back-up switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
c For the following on four wheel drive vehicles (4W D), refer to 7D Transfer Case and Adaptor Housing:
• neutral switch,
• 2WD – 4WD shift actuator switch,
• speed sensor.
NOTE
If the battery is connected, avoid turning the
ignition switch to the ON position, as the transfer
case control module (TTCM) must first be
removed (memory to be cleared as Check 4W D
Indicator will light).
5 Remove the following components: a Front and centre exhaust assemblies, refer to 6F Exhaust System.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–44
b Starter motor, refer to 6D1-2 Starting System.
b Rear propeller shaft and for 4WD front propeller shaft, refer to 4A Propeller Shaft.
6 On 4WD vehicle, disconnect the harness two clips from the upper side of the transfer case.
7 From within the starter motor access hole, remove the three bolts (2) attaching the torque converter to the flexplate and discard, refer to Figure 7C4 – 62.
8 Remove the transmission support, refer to 3.7 Transmission Support and Mount.
9 Disconnect the fuel and EVAP pipes three brackets and clips, refer to 6C Fuel System – V6.

Before lowering the transmission take care of
the following:
• Do not strain the harness and connector
as the connector pins could be
permanently damaged.
• Ensure the inlet manifold does not hit the
firewall.
10 Carefully lower the transmission to provide enough clearance to disconnect the harness connector (1).

Do not wiggle the connector from side to side
during removal as the connector pins could
be permanently damaged.
11 Disconnect the harness connector from the transmission as follows:
a Roll back the dust boot to access the connector.
b Squeeze the widest side of the connector (A) inward and pull it directly upward.
Figure 7C4 – 61
12 Remove the screws attaching the harness clips to the right-hand and left-hand sides of the transmission case, refer to 12O Fuses, Relays and W iring Harnesses.
13 Place a suitable sized drip tray underneath the transmission.
14 Remove the transmission cooler lines, refer to 3.17 Transmission Cooler Line/Hose Assemblies.
15 Disconnect the breather hose from the top of the transmission case.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–46
Reinstall
1 If required on 4W D vehicle, reinstall the transfer case, refer to 7D Transfer Case and Adaptor Housing.
2 Ensure the transmission and the engine mating surfaces are clean and free of burrs.
3 Lubricate the torque converter spigot (7) with a small amount of high temperature wheel bearing grease, refer to Figure 7C4 – 62.
4 Install a new filler tube seal into the transmission case.

Support the transmission while installing the
attaching bolts to avoid damage to the torque
converter and flexplate. Do not have the
transmission hanging.
5 Bring the transmission up to the engine, inserting the filler tube and ensuring the locating dowels completely enter the torque converter housing.
6 Reconnect the breather hose to the top of the transmission case.
NOTE
The bolts attaching the torque converter housing
are facing forward except for the bolt in position ℑ

which is facing rearward.
7 With the transmission supported, install the bolt (1), nine places, attaching the torque converter housing to the engine and tighten to the correct torque specification following the sequence shown in
within Figure 7C4 – 62.
Torque converter housing attaching
bolt torque specification .......................... 52.0 – 66.0 Nm
8 Remove the access hole cover plate from the lower surface of the housing and push the torque converter forward to meet the flexplate, then hand start three new bolts (2) before tightening to the correct torque specification.
Reinstall the access hole cover plate.
Torque converter to flexplate attaching
bolt torque specification .......................... 60.0 – 70.0 Nm
9 Reinstall the bolt (3) and torque converter cover (4) on the transmission right-hand side and the bolt (5) and torque converter cover (6) on the transmission left-hand side, tighten the bolts to the correct torque specification.
Torque converter cover attaching
bolt torque specification .......................... 12.0 – 16.0 Nm
10 Reinstall the transmission fluid lines, refer to 3.17 Transmission Cooler Line/Hose Assemblies.

Prior to connecting the harness connector to
the transmission, check that all pins and
seals are in sound condition and the dust
boot is not torn or damaged.
11 Reconnect the transmission harness connector to the transmission as follows: a Push straight down on the connector body until a click is heard.
b Reinstall the dust boot ensuring it is correctly located.
12 Attach the harness clips to the right-hand and left-hand sides of the transmission case, refer to 12O Fuses, Relays and Wiring Harnesses.
13 On 4WD vehicle, connect the harness two clips from the upper side of the transfer case.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Automatic Transmission – 4L60E – On-vehicle Servicing Page 7C4–47
14 Reconnect the fuel and EVAP pipes three brackets and clips, refer to 6C Fuel System – V6.
15 Reinstall the following components:
a Starter motor, refer to 6D1-2 Starting System.
b Transmission support, refer to 3.7 Transmission Support and Mount.
c Front and centre exhaust assemblies, refer to 6F Exhaust System.
d Rear propeller shaft and for 4WD front propeller shaft, refer to 4A Propeller Shaft.
16 Reconnect the harness connectors to the following: a Vehicle speed sensor, refer to 3.5 Vehicle Speed Sensor.
b Neutral start and back-up switch, refer to 3.4 Neutral Start and Back-up Lamp Switch.
c For the following on 4W D vehicles, refer to 7D Transfer Case and Adaptor Housing:
• neutral switch,
• 2WD – 4WD shift actuator switch,
• speed sensor.
17 Reinstall the selector cable to the transmission external manual shaft linkage, secure the selector cable to the bracket and attach the heat shield to the neutral start and back-up lamp switch, refer to 3.3 Selector Cable
Assembly.
18 Perform a reverse flush of the cooler lines and a flow rate test, refer to 2.2 Reverse Flush and Flow Rate, if either of the following applies:
• the transmission fluid is contaminated,
• the transmission has been replaced,
• the torque converter has been replaced, or
• the transmission oil pump has been replaced.
19 Lower the vehicle to the ground.
20 If required, top up the transmission fluid level (cold).
21 Reconnect the battery ground lead.
22 Start the engine and check for any fluid leaking at the fittings. If a leak is found, stop the engine and rectify the leak.
23 Road test until the transmission has reached operating temperature. Re-check the fluid level and for any fluid leaks, refer to 2.1 Transmission Fluid.
3.19 Transmission Control Module
Remove
1 Ensure the ignition switch is in the OFF position.
2 Disconnect the connector (1) from the transmission control module (TCM) (2) as follows, refer to Figure 7C4 – 63: a remove the securing pin (3),
b press the locking tab and swing the lever (4) to free the connector,
c remove the connector.
3 Remove the four bolts (5) and nuts (6), then the TCM from the mounting bracket (7).
4 If required, remove the two nuts (8) and the mounting bracket from the firewall.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

TRANSMISSION CONTROL SYSTEM (AW30–40LE) 7A2-41

• All of the following conditions are met.
- Device Control is not operating
- Disable Normal Communication Service is receiving enable
- DTC Clear is not operating
Condition For Setting The DTC
W hen the TCM detects following conditions at 20 times
continuously.
• Ignition voltage is less than 9 volts for 1 second o
r
more continuously. (DTC P0562)
• Ignition voltage is more than 18 volts for 1 second o
r
more continuously. (DTC P0563)
Action Taken When The DTC Sets
• DTC stored.
Conditions For Clearing The DTC
• The DTC can be cleared from the TCM history by
using a scan tool.
• The DTC will be cleared from history when the
vehicle has achieved 40 warm-up cycles without a
failure reported.
•
After more than 1 second has elapsed after the
ignition key has been turned “ON”, short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
•
Inspect the wiring for poor electrical connection at the
TCM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.
• W hen diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.

Circuit/System Testing DTC P0562 or P0563
Step Action Value(s) YES NO
1
W as the On-Board Diagnostic (OBD) System Check
performed? — Go to
Step 2 Go to OBD
System Check
2 Using the 5-8840-0285-0 DMM, measure the battery voltage at the battery.

Is the battery voltage greater than the specified value? 11.5 V Go to
Step 3 Charge battery,
then go to Step 3
3 1. Install a scan tool.
2. Select “Ignition Volts” on a scan tool.
3. Start the engine and raise the engine speed to the specified value.
4. Load the electrical system by turning on the headlights, high blower, etc.

Is the ignition voltage approximately equal to the
specified value? More than
1000 rpm
9.0-18.0 V Go to
Step 4 Go to
Starting/
Charging

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007