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Teknisk kurs RSA 2012

Isuzu D-Max 2012

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20.10.2012 Kurs Isuzu D-Max 2012 rev. A 2

Modell varianter RT56

Crew cab

Regular cab

Extend cab

Ikke til Norge

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Motor

Crew

4JK1-TC HiHi (Euro5)

Girkasse

Motor

CAB

Modeller : TFR,TFS

AY6 (M/T)

TM T/F

TB-50LS (A/T)

Transfer T150

Extend

Regular

Bremser

ABS (Anti-lock brake system)

ESC (Electronic stability control)

EBD (Electronic brake-force distribution)

TCS (Traction control system)

Nyhet

Nyhet

Nyhet

Nyhet

Nyhet

Nyheter RT56

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+45 (3095)

+146 (5191)

+128 ( 898) -27 (1198)

-1(1830)

+70(1530)

4 x 2:+46 (1766)

4 x 4:+60 (1860)

4 x 2 : + 5 4 ( 1

6 8 9 ) / 4 x 4 : + 6 0 ( 1 7 9 0 )

10

30

11

SAP (Side Access Panel), bakhengslet dør.

Større plass bak setene

Bakhengslet dør (SAP)

≦1800

Blå: 2012 modell

Svart: Utgående modell

(mm)(mm)

Total length Total width12MY 1830 1530

Curret model 1831 1460

Cargo bed sizeTotal length 2WD 4WD 2WD 4WD

12MY 5191 1766 1860 1689 1790

Current

model5045 1720 1800 1635 1730

Total width Overall height

Mål Extended cab

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+45 (3095)

+266(5191)

+128( 898) +93(1198)

+104(1483)

+70(1530)

25

30

11

20

4x2:+46(1766)

4x4:+60(1860)

4 x

2 : + 5 2 ( 1 6 9 2 ) / 4 x 4 : + 5 9 ( 1 7 9

4 )

• Større plass bak setene

• Større døråpning bak

• Større lasteplan(lengde & bredde)

Større døråpning bak

Større plass bak

Setevinkel: + 3 Større lasteplan

Blå linje : RT56

Svart linje TF190

Seat angle12MY 24°Current

model21°

Total length 2WD 4WD 2WD 4WD

12MY 5191 1766 1860 1692 1794

Current

model4925 1720 1800 1640 1735

Total width Overall height

12MY 494

Current

model458

Mål Crew cab

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Projector type(4-LIGHT SYSTEM HEADLAMP)

Parklys

Retningslys

Nærlys - ProjectorFjernlys

Kjørelys (DRL) finnes på alle biler.

Lys

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Tåkebaklys

LED type

LEDBaklys/bremselys

Retningslys

Ryggelys (tåkebaklys)

Refleks

Baklampene finnes i to utgaver. Våre modeller har LED for baklys og bremselys .

Høytmontert bremselys er endret. Har nå vanlige lyspærer og ikke LED.

RT56TF190

Baklamper

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INTERIØRMID/IP

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MID

20.10.2012 9Kurs Isuzu D-Max 2012 rev. A

CANcommunication bus

Analog inputs& other inputs

OUTLINE OF MULTI-INFORMATION DISPLAY (MID)

The multi-information display (MID) has been newly

adopted to for driver’s information such as operation

related information and maintenance information along

with the inputs from other control module or internalprocessing, and it is integrated within the IP-Cluster.

The MID mainly informs following items;

ClockDriving mode

Coolant temp.gauge Fuel gauge

Shift indicator

Ambient airtemp.

Operation &maintenanceinformation

•Warnings and indicators

•Operation related information•Maintenance information

Notice!

Regardless of model with MID or without MID, the

replacement of the IP-Cluster must be programmed

with a scan tool.

Cruise control

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MID

Yaw rate Gsensor

ECM

IP cluster

12V

SRS

ICU

Auto A/C

BCM

TCCM

EHCU

TCM

EGR valve

Steering anglesensor

CAN communication

EHCU local CAN communication

IP-CLUSTER COMMUNICATION

The IP-Cluster communicates with the scan tool over the controller

area network (CAN) link.

The IP -Cluster communicates with other modules via the same

CAN link. Following signals are communicated via a CAN

communication bus:

From ECM to IP-Cluster

•Engine speed (for tachometer)

•Vehicle speed (for speedometer)

•Engine coolant temperature (for temp. gauge)

•Lamp request (service vehicle soon, DPD regeneration

request, fuel filter and cruise control)

•Fuel consumption data

From TCM to IP -Cluster

•Selector lever position or current gear position

•Shift inhibit status (for alarm operation)

•Lamp request (ATF temperature)

From TCCM to IP-Cluster

•Lamp request (check 4WD, 4WD and 4WD low)

From EHCU to IP-Cluster•Lamp request (ABS, EBD, TSC and ESC)

From IP-Cluster to BCM

•Vehicle speed (for vehicle speed linked door lock)

From IP-Cluster to automatic air conditioner

•Ambient air temperature

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MAIN ROUTINE

Basic operation and the screens of the MID are shown

below. Use the MID switch on the combination switch to

select the desired screen.

Tap (short apply)

Press and hold (long apply)

CONTENTS OF MULTI-INFORMATION DISPLAY (MID)

MID

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MIDSELECT MODE

Unit, maintenance distance, customize setting and clock

(only for a vehicle without factory-equipped audio

system) can be changed on the select mode.

This mode runs only while the vehicle is stationary.

Unit

Unit displaying on the fuel consumption data and

ambient air temperature can be selected with a MID

switch.

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Service

Distance remaining until the next engine oil replacement,

air cleaner element replacement and any maintenance

can be selected with a MID switch.

MID

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MIDOTHER DISPLAYS

Coolant Temperature Gauge

The IP-Cluster receives a temperature signal from the

ECM via the CAN communication bus.

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MID

Shift Indicator

The IP-Cluster receives a position or current gear signal

from the TCM via the CAN communication bus.

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4WD Mode Status

The IP-Cluster receives a lamp request signal from the

TCCM via the CAN communication bus.

MID

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MID

Ambient Air Temperature

Ambient air temperatures between -40 to 50 ゜C (-40 to

122゜F) are displayed on the MID.This temperature signal is shared with the automatic air

conditioner and it is sent from the IP-Cluster via the CAN

communication bus.

Unit displaying on the ambient air temperature can be

selected. Available unit setting is “゜C” or “゜F”.

If the ambient air temperature is less than -1

C (30

F),

icy road warning is turned ON.

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MIDWARNINGS

MID indicates some warning if conditions are met, and

desired display may be interrupted. Warning alarm also

rings.

Release Park Brake

This warning appears if following conditions are met:

• Vehicle speed is higher than 5 km/h (3 MPH)

• Park brake is applied

Light OffThis warning appears if following conditions are met:

• Key is removed from the key lock

• Driver’s door is opened

• Headlight switch in ON

Key Remain

This warning appears if following conditions are met:

• Ignition switch is positioned at ACC or OFF

• Driver’s door is opened

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SUMMARY OF MID CONTROL

5,000 to

20,000km with2,500 kmincrements orOFF

MID

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MID

MID

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MID

IP CLUSTER SELF DIAGNOSTIC FUNCTION

The IP-Cluster has ability to test internal components with

following procedures.

During the self diagnostic mode;

1. All segments of the odometer, trip meter, clock, shift

indicator, ambient air temperature, coolant

temperature gauge and fuel gauge turns ON

sequentially.

2. While the MID switch is pressed, tachometer and the

speedometer indicates a certain value.

Within 7

seconds

Repeat 3 times

Longer than0.6 seconds

Once release

Turn ON ignitionwhile pressing

● ●

●

● ● ●

● ● ●

MID

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MID

Menu Functions

Programmig

Upload Vehicle Configuration

Data

To upload the current setting at the original IP-

Cluster before replacement.

Download Vehicle Configuration

Data

To download the uploaded setting at the

replaced IP-Cluster after replacement.

Vehicle Configuration Setting To change current option contents or setting

individually. This will be used if an original IP

cluster cannot be communicated with a scan

tool

Module Information To read current option contents or setting.

SCAN TOOL MENU ON THE IDSS

MID

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MIDSCAN TOOL MENU ON THE IDSS

Parameter Selection Notice

Opening Message Display Available/ Not Available Choose Available whenever setting.

Clock Display Available/ Not Available With MID: Choose Not Available if factory equipped audio

system is equipped.

Without MID: Choose Not Available whenever setting.

Glow Plug Indicator Light Available/ Not Available Choose Available whenever setting.

SVS Indicator Light Available/ Not Available Choose Available whenever setting.

ESC Indicator Light Available/ Not Available Choose Available whenever setting.

ABS Warning Light Available/ Not Available Choose Available whenever setting.

Cruise Control Indicator

Light

Available/ Not Available Choose Available if cruise control is equipped.

4WD Indicator Light Available/ Not Available Choose Available if 4WD vehicle.

Key Remind Warning Available/ Not Available Choose Available whenever setting.

Language Setting Available/ Not Available Choose Not Available whenever setting.

Seat Belt Warning Available/ Not Available Choose Available if roof rail airbag is equipped.

DPD Indicator Light Available/ Not Available Choose Available whenever setting.

Over Speed Warning Available/ Not Available Choose Not Available whenever setting.

Fuel Economy Display Number/ Graphics Choose Number whenever setting.

PESS Information Display Available/ Not Available Choose Not Available whenever setting.

Back Shift Warning Available/ Not Available Choose Available if 6 speed manual transmission.

Items for Individual Setting with Scan Tool

V ll 1/3

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Lamp display Display name Operation condition

Check engine

warning light

Turn on the lamp untill starting the engine. After starting, turn off the lamp.

Turn on the lamp at the malfunction.

Engine oilpressure warning

light

After starting the engine, this lamp turn off.

Engine overheat

warning light

This warning light should come on when the starter switch is turned to the

"ON" position, and then should go out after approximately 3 seconds.

Fuel filter warning

light



The fuel filter warning light comes on when the fuel filter element clogged

with dust and others.

Water separator

warning light



This warning light comes on when water in the water separator needs

draining.

Low fuel warning

light

This warning light comes on when the fuel level in the tank becomes low

while the engine is running.

Generator warning

light


"ON" position, and then should go out after the engine is started.

This warning light comes on when, while the engine is running, there is a

problem with the charging system (such as a loose or broken fan belt).

Brake

system/parking

brake warning

light

This warning light comes on when the parking brake lever is pulled up.

And also, this warning light will come on when the starter switch is turned

to the "ON" position with the parking brake released, and if there is no

malfunction will then go out after the engine is started.

Varsellamper 1/3

V ll 2/3

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ABS wa rning light

This warning light should come on when the starter switch is turned to the"ON" position, and then should go out after approximately 3 seconds.This warning light comes on whenever there is a problem in the anti-lockbrake system (ABS).

ESC warning light

When the starter switch is turned to the "ON" position, the ESC warninglight turns on before going out after approximately 3 seconds. This

warning light comes on whenever there is a problem in the electronicstability control (ESC). When the ESC is operating, the ESC warning lightflashes.

SRS airbagwarning light

When the ignition switch is turned ON for the first time, the SRS airbagwarning light blinks 7 times to confirm the operation of the SRS airbagwarning light and SRS control unit.

This warning light comes on whenever there is a problem in the SRSairbag system.

Seat belt warninglight (driver seat)

Seat belt warninglight (Passenger seat)

Door openwarning light

The door open warning light comes on if any door is not fully closed whenthe starter switch is turned to the "ON" position.

Automatictransmission fluidtemperature

warning light

This warning light should remain on for approximately 3 seconds after thestarter switch is turned to the "ON" pos ition, and then should go out.This warning light comes on when the temperature of the automatic

transmission becomes high while driving.

Check 4WD

warning light

The check 4WD warning light comes on when the starter switch is turnedto the "ON" position and should then go out after approximately 3

seconds. When this warning light stays on, the 4WD system has amalfunction.

Check trans

warning light

This warning light should remain on for approximately 3 seconds after thestarter switch is turned to the "ON" pos ition, and then should go out.

If this light comes on after the engine has s tarted, there is somethingwrong with the transmission electronic control system.

This warning light comes on when the driver is not wearing the seat beltwhile the starter switch is in the "ON" position.

Varsellamper 2/3

V ll 3/3

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Icy road warning

light (model with

MID)

This illuminates when the outside temperature is low and the road surface

may be frozen. Since this is based on the outside temperature detected

by the outside air temperature sensor and not the actual road surface

temperature, it does not accurately display frozen road surface conditions.

High beam

indicator light

This indicator light comes on when high beam is selected or the

headlights are cycled between high and low beams (passing signal).

Light position

indicator lightThis indicator light comes on when the light switch is in the "ON" position.

Turn signal

indicator light – left

Turn signal

indicator light –

right

Front fog light

indicator lightThis indicator light stays on while the front fog lights are on.

TCS OFF

indicator light

When the starter switch is turned to the "ON" position, the TCS OFF

indicator light turns on before going out after approximately 3 seconds.

The TCS OFF function is normal if the indicator light goes out.

ESC OFF

indicator light

When the starter switch is turned to the "ON" position, the ESC OFFindicator light turns on before going out after approximately 3 seconds.

The ESC OFF function is normal if the indicator light goes out.

4WD indicator

light

The 4WD indicator light comes on when the 4WD switch is used to select

"4H (4WD high)" or "4L (4WD low)".

4WD low indicator

light

The 4WD low indicator light comes on when the 4WD switch is used to

select "4L (4WD low)".

Either of these indicator lights flashes when the turn signal switch is

operated with the starter switch in the "ON" or "ACC" posi tion.

Both indicator lights flash when the hazard warning flasher switch is

operated irrespective of the position of the starter switch.

Varsellamper 3/3

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INTERIØRBCM

BCM

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The BCM integrates some body control functions

Location:

The BCM is attached to the driver’s side dash panel.

Supplier:Panasonic Electronic Devices Japan Co. Ltd.

The BCM controls following functions:

•Power door lock function (central door locking)

•Vehicle speed linked door lock function

(model with SRS)

•Keyless entry function

(radio remote control door locking)

•Anti-theft control function

•Super lock function (optional: model with super locking)

•Room light control function

•Rear defogger timer function

•Power window timer function

•Diagnostic information for BCM

For high gradeD-MAX only

BCM

BCM inn /utsignaler

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Remote key lock/ unlock signal

SRS airbag deployment signal (PWM)

Vehicle speed signal (CAN) Anti-theft disarm signal from immobilizer control

unit (with super lock)

Other inputs

Ignition switch

Accessory position switch

Door switch (driver’s side and other doors)

Door lock/ unlock switch (central door lock switch)

Door lock/ unlock switch (door lock) (without super

lock)

Door lock/ unlock position switch

Key reminder switch switch Engine hood switch

Rear defogger switch

Switch inputs

Door lock/ unlock actuator

Controller area network (CAN)

Communication with scan tool

Door lock/ unlock relay

Relay controls

Room light (map light & dome light)

Anti-theft indicator lamp

Door open indicator lamp

Lamp controls

BCM Super lock relay (with super lock)

Rear defogger relay

Relay control

Power window control

Other control

Answer back flasher

Anti-theft horn

Actuator controls

BCM inn-/utsignaler

BCM kommunikasjon

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20.10.2012 30

CAN communication


Yaw rateG sensor

ECM

IP cluster

12V

SRS

ICU

Auto A/C

BCM

TCCM

EHCU

TCM

EGR valve

Steeringangle sensor

BCM kommunikasjonBCM COMMUNICATION

The BCM communicates with the scan tool via the CAN-

Bus.

The BCM receives the vehicle speed signal from theIP-Cluster also via the CAN-Bus.

Why does the BCM needs the information vehicle speed?

The BCM needs this information for the vehicle speed

linked door lock control.

Kurs Isuzu D-Max 2012 rev. A

BCM pinout

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20.10.2012 31

A: B19 (20 pins connector)

Pin Pin function

1 Ground

2 Door switch 2 (with super lock)

3 Not used

4 Not used

5 Not used

6 Keyless entry signal from receiverunit

7 Not used

8 CAN high signal

9 Key reminder switch signal

10 Ignition voltage

11 Engine hood switch signal

12 Door switch signal

13 Not used

14 Keyless entry receiver unit ground

15 Not used

16 Keyless entry receiver unit 5Vreference

17 Not used

18 CAN low signal

19 Accessory voltage

20 Battery voltage

B: B20 (18 pins connector)

Pin Pin function

1 Not used

2 Not used

3 Door unlock switch signal (door lock)(without super lock)

4 Not used

5 Not used

6 Door unlock switch signal (centraldoor lock switch)

7 Not used

8 Not used

9 Power ground

10 Door unlock actuator control

11 Door lock actuator control

12 Door lock switch signal (door lock)(without super lock)

13 Not used

14 Disarm signal from immobilizercontrol unit (with super lock)

15 Door lock switch signal (central doorlock switch)

16 Room light control low side

17 Not used

18 Power ground

C: B21 (25 pins connector)

Pin Pin function

1 Not used

2 Not used

3 Not used

4 Anti-theft indicator lamp control

5 Not used

6 Door open indicator lamp control

7 Not used

8 Not used

9 Rear defogger relay control

10 Not used

11 Rear defogger switch signal

12 Not used

13 Anti-theft horn control

14 Battery voltage feed

15 Battery voltage feed

16 Not used

17 Power window control

18 Not used

19 Answer back flasher control

20 Not used

21 Super lock relay control (with superlock)

22 Airbag deployment signal

Pin Pin function

23 Not used

24 Door lock/ unlock position switchsignal

25 Room light control high side

A B C

BCM pinout

Kurs Isuzu D-Max 2012 rev. A

BCM Sentrallås Keyless

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32

BCM

Flasherunit

Keyless entryreceiver unit

A6

Lock/unlocksignal

A14C19

Answerbackflashercontrol

Antenna

Hazardwarningswitch

Keyreminderswitch(closed @key in)

Keyremainedswitchsignal

Room(10A)

Battery voltage

A9

Hazard(15A)

Battery voltage

Turnsignallamps

Engine compartment

Cabin

BCMReceiver

Lock/unlocksignal

Transmitter

KEYLESS ENTRY FUNCTION (RADIO REMOTE CONTROL

DOOR LOCK)

The BCM controls a remote keyless entry system with

following functions:

Lock, Unlock and Relock Function •When the remote key is operated, all doors are

operated.

•When no door is opened within 30 seconds after

unlocking, it automatically relocks.

If any of the following conditions are met, remote key

operation is ignored.

- Battery voltage is not supplied to the BCM

- Ignition switch is ON position

- Key is inserted in the key lock

- Any door open (without super lock)

- Doors opened other than driver’s door (with super lock)

5V

A16

Where is the receiver unit located?

The receiver unit is located behind the radio.

How can you check if the receiver unit is sending asignal?

We can measure the lock/ unlock signal.


Kurs Isuzu D-Max 2012 rev. A20.10.2012


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BCMReceiver

Lock/unlocksignal

Transmitter

KEYLESS ENTRY FUNCTION (RADIO REMOTE CONTROL

DOOR LOCK)

Remote Key Registration Function

Remote key registration is carried out manually or with the

scan tool. Maximum of five remote keys can be providedby additional programming.

How to do the key registration manually:

1. Close the driver’s door

2. Open the driver’s door 3. Switch the ignition on and off three times

4. Close the door twice

5. Switch the ignition on and off twice

6. Press the keyless entry button 6 times.

7. Continue to press the keyless entry button of the next

remote key also 6 times

How to check the amount of installed remote controls

for the keyless entry:

Put the key into the ignition switch three times in a

row (no turning of the key)



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Receiver unit

Location: attached to the dash panel reinforcement.

Supplier: Panasonic Electronic Devices Japan Co. Ltd.

While all doors are closed (without super lock) or whiledoors other than driver’s door are closed (with super lock),

the receiver unit is continuously sending pulse signals.

Once the receiver unit receives the unlock command from

the transmitter, the receiver unit sends unlock signal (A) to

the BCM. The BCM operates door lock/ unlock actuator in

0.5 s (B) to unlock all doors.

A

A

Section A-A

Antenna

Scale: CH1 2V/div

CH2 5V/div

500ms/div

CH10V

CH20V

Receiver unitsignal @ A6

Door unlockcontrol @ B10

Door close Door open

A

B



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Once the receiver unit receives the lock command from the

transmitter, the receiver unit sends lock signal (C) to the

BCM. The BCM operates door lock/ unlock actuator in 0.5 s

(D) to lock all doors.

The remote control works within approximately 10 m (33ft)

radius from the vehicle center.

A CR 1620 type lithium battery (DC 3 volts) is used for the

remote key transmitter.

CH10V

Receiver unitsignal @ A6

Door lock control@ B11

C

D

Door open Door close

Scale: CH1 2V/div

CH2 5V/div

500ms/div

CH20V

CR1620 lithium battery

Transmitter

Battery cover



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-Scan Tool Data List-•Vehicle Speed: Inputted vehicle speed from the IP-Cluster

•Vehicle Speed Signal (via CAN): Vehicle speed signal input state from the IP-Cluster

via CAN communication bus

VEHICLE SPEED LINKED DOOR LOCK FUNCTION (MODEL

WITH SRS AIRBAG)

The BCM locks all doors automatically when the vehicle

speed exceeds 20 km/h (12 MPH) even if door lock is not

operated.

All doors are unlocked if the key is removed from the key

lock. (Key linked door unlocking function)

-Scan Tool Programming-

•The vehicle speed linked door lock function can be enabled or disabled with a

scan tool function BCM Data Setting/ Change. (Defaulted setting: Disabled)

•Door unlocking timing (key linked door unlocking function) can be changed at the

ignition switch OFF position with a scan tool function BCM Data/ Setting Change.

(Default setting: Key is pulled out from key lock)

BCM

SRScontrolunit

C22

Deploymentsignal (PWM)

IPcluster

A8

CAN highsignal

A18

CAN lowsignal



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-Scan Tool Data List-

•SRS Airbag Deployment Signal: SRS airbag deployment state from the SRS control

unit

SRS Airbag Linked Door Unlock Function

The BCM receives the 20 Hz duty ratio signal from the SRS

control unit. During un-deployed state, the SRS control

unit outputs 20% duty ratio to the BCM.

In case of deployment of SRS airbag, the SRS control unitoutputs 80% duty ratio signal and the BCM unlocks all

door lock regardless of door lock by vehicle speed linked or

by switch. Simultaneously, the BCM blinks the hazard

warning lamps with 2 Hz to alert conditions to the

surrounding area.

The hazard warning lamps are canceled if once the

ignition switch is turned OFF and ON.


BCM Alarm

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•Door Lock Actuator Position Switch: Door lock/

unlock position feedback switch input state from

the door lock

•Anti-theft Indicator Lamp: Anti-theft indicatorlamp command state

•Anti-theft Horn: Anti-theft horn command state

•Engine Hood Switch: Engine food switch input

state

Activating the anti-theft system

1. Turn OFF the ignition and remove the key from the key

lock.

2. Close all doors and engine hood. Lock all doors with the

remote key.3. After approximately 10 seconds, the anti-theft indicator

lamp will blink. The anti-theft system is now in operation

(armed state).

If the super lock is engaged, this standby time is not

applied.

Anti-theft system alarm operation conditionThe alarm will be operated if the door or the engine hood is

opened without using the remote key.

Deactivating the anti-theft system and alarm

When the anti-theft is triggered, the alarm will be canceled

(disarmed) under any of the following condition.

•Press the door unlock button on the remote key.•Insert the key in the key lock and turn ON the ignition.

First 10 seconds

After 10seconds

Slow brinks (armed)

Fast brinksStay ON(standby)

Goes OFF

Normal operation Engine hood openTime since door lockingwith remote key

BCM Alarm

BCM Belysning

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The BCM controls the dome light and map lights.

If the dome light and/ or map lights are left at the ON position while

the ignition switch is other than ON position and all doors are closed,

the BCM automatically shuts off the high side driver after 20 minuteselapsed to prevent battery discharge.


•Door Switch 1: Door switch input state

•Door Switch 2: Door switch input state other than

driver’s door (with super lock)

•Door Open Indicator Lamp: Door open indicator lampcommand state on the IP cluster

•Room Light Battery Side Control: Room light high side

driver command state

•Room Light GND Side Control: Room light low side

driver command state

BCM

Maplights

C25

Low sidecontrol

Meter(10A)

Battery voltage

Dooropenindicatorlamp (IPcluster)

C19

Dooropenindicatorlampcontrol

Domelight

+B (via room lamp10A fuse)

B16

High sidecontrol

Keyreminderswitch(closed @key in)

Keyremainedswitchsignal

Room(10A)

Battery voltage

A9

Cabin

Door switch (closed @ door open)

Doorswitchsignal

A12

Door switchsignal (withsuper lock)

A2

Driver’s door

BCM Belysning

BCM

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SUMMARIZED TABLE FOR PROGRAMMING ON THE BCM

Relating to When replacing to new one or transferred (swapped) Notice

BCM Before replacement

1. Upload current setting by BCM Data Upload.

After replacement

1. Download uploaded data by BCM Data Download.

2. Remote key registration by Remote Keyless Entry Transmitter

Registration.

Original BCM can be communicated

with scan tool

After replacement

1. Program current vehicle option contents or setting by BCM Data Setting/

Change. Note that the Write Completion Flag must be changed to“Written” if “Initial”.

2. Remote key registration by Remote Keyless Entry Transmitter

Registration.

Original BCM cannot be

communicated with scan tool

Remote Key 1. Remote key registration by Remote Keyless Entry Transmitter

Registration.

2. Transponder key programming must be performed separately at the

Immobilizer menu.

-

BCM

Notice!

Non-programmed BCM will cause: _________________DTC B1001 to set.

IMMOBILISER

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IMMOBILISER

• Immobiliser kontrollmodul med antennering

sitter der den satt på forrige modell.

• 5 transponderkoder kan lagres.

• 4 sifret kode må fås fra teknisk avdeling som tidligere.

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ANDRE NYHETER

Elektriske vinduer

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Automatisk lukking/åpning av vindu i førerdør.

Note: Hvis batteriet frakobles slettes lagrede verdier for vindu. En

initialisering må gjøres før automatisk lukking/åpning fungerer.

Metode for initialisering:

1.) Slå på tenning.

2.) Åpne vindu halveis.

3.) Trekk bryteren til AUTO UP posisjon til vinduet er helt lukket og hold

bryteren i minst 2 sekunder. (Skal høre et klikk).

4.) Slå av tenning.

Elektriske vinduer

Gasspedalsensor

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Gasspedalsensor er endret fra kontakt-type (potentiometer) til kontaktløs (hallsensor) for å gi bedret nøyaktighet.

RT56TF190

APP sensor

Accelerator pedalbracket

only twoconnectors

sensor

+ pedal =one unit

Gasspedalsensor

Aircondition

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Condenser

RT56

Compressor

+109 mm

+ 8 5 m m

- 0.8kg

Følgende er endret (for å redusere drivstofforbruk):

• Ny kondenser som krever lavere effekt fra kompressor.

• Økt kjølekapasitet i kondenser, samtidig som den er 4 mm tynnere og lettere.

• Elektrisk kjølevifte er tatt bort.

TF190

Refrigerant: 134a Mengde: 480-580 gram

Aircondition

Kondenser

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•Kondenseren kjøler gass med høyt trykk og temperatursom kommer fra kompressoren slik at gassenkondenserer til flytende væske.

•Modulatoren sepparerer kjølemediet i gass og flytende formog sender flytende kjølemedium til “subcooler”.

•Ved å bruke tørkemiddel og et filter, fjerner modulatorenfuktighet og fremmedpartikler fra kjølemediet.

•“Subcooler” kjøler ned væsken ytterligere for å øke kjølemediets entalpi.

The fan was deletedfrom 12 MY

The drier/ filter is now inculdudedin the condenser

Drivstoffforbruk:

ca 0,25 -1,0 liter pr time.

Kondenser

Aircondition

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Manuell type Auto type

RT56TF190

Interiør temperatur sensor plassert under rattetSol sensor plassert midt oppe på dashbordet

Aircondition

SRS

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SRS


The new SRS newly adopts:

• Roof rail airbag

• Side airbag

The roof rail airbag protects:

The passenger's head and neck,

The side airbag protects:

The passenger’s hips and the upper body

These SRS equipments are developed to achieve a

good rating in the EURO-NCAP.

Roof rail airbag(RRAB)

Side airbag(SAB)

SRS

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The system consists of:

1. Front G-Sensor2. Combination switch with SRS coil

3. Driver airbag4. SRS control unit5. Passenger airbag6. Door pressure sensor7. Side airbag8. Pretensioner seat belt9. Roof airbag10. Side G-Sensor

Compared with the current model , the following senors are new:

• Front G-Sensor (detection accuracy)

• Side G-Sensor

• Door pressure sensor (detection

accuracy)

The last two sensors are needed to trigger the

roof rail airbag and the side airbag.

11

2

3

4

5

6

6

7

7

8

8

9

9

10

10

SRS

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The front G-Sensors are installed in the front

bumper.

The side G-Sensors are installed under the

pretensioners / seat belt symmetrically.

The side G-Sensor is fitted only with the Extend

cab and the Crew cab.

The same sensor type is used for the front G-

Sensor and the side G-Sensor.

These sensors send signals to the SRS control

unit.

1. Right side FrontG-Sensor

2. Left side FrontG-Sensor

Side G-Sensor

1

2

SRS

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The door pressure sensors are installed inside

the right and left door.

Door pressure sensor detects any change in

pressure between the door outer panel and door

inner panel.

Important:

If replacing the water proof, you have to attach

the water proof completely to obtain optimalpressure conditions for the door pressure sensor.

11. The pressure between the door

outer panel and door inside panel,

2. Door pressure sensor

3. Water proof

3

2

Scan Tool data

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Seter

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For å tilfredstille Euro-NCAP (New Car Assessment Program)

Anti whiplash nakkestøtte

Bevegelse forover og opp.(opp: 30 mm, forover: 25 mm)

• Hodet presses mot nakkestøtten ved kollisjon bakfra.• For å redusere skader (whiplash), blir nakkestøtten pressetmot hodet.

Beltevarsler passasjersete

Når sensoren i setet detekterer vekt over 15 kg, varsles det med lys oglyd fra 20 km/t.

Starting speed: 20 km/hStrarting weight: 15 kg

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MOTOR4JK1-TCY

Motor

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(Kw/Nm)

(Kw/Nm)

Effekt: 120 kW @ 3600 rpmMoment: 400 Nm @ 1400 – 2000 rpm

Motor

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1400 rpm – 3600 rpm = område på 2200 rpm

2000 rpm

Hastighetsbegrenser på 180 km/h, kan ikke slås av.

Motor 4JK1 Hi Hi Euro 5

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• Motor

– Nyheter

Større

Katalysator

DPD (Diesel ParticulateDefuser)

Større EGR kjøler,

EGR Bypass System

Endret designav forbrenningskammer

Økt innsprøytningstrykk(200 MPa)

To-Steg Turbo System

Frontmontertog større Intercooler

Oljefilter

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RT564JJ1, Euro 4 (gjeldende modell)

Oljetrau

Plasseringen av oljefilteret er endret, fra å sitte nede på motoren, til øverst foran på motoren.

Det er da enkelt å skifte filteret. Det er også et trau under filteret som skal samle opp olje.

Trauet skal samle opp olje ved filterskift.

EGR kjøler

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EGR-kjøler for å øke EGR volum:

- EGR bypass ventil:

Lav motorbelastning Varm EGR

Høy motorbelastning Kald EGR

EGR cooler

EGR pipe

EGR valve

Adapter

EGR bypass valve

Varm EGR

Kald EGR

RT56Layer type

TF190Tube type

Veksler fra varm til kald EGR ved:35° C

Inlet manifold

EGR ventil

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Magnet

Rotor

Stator

Motor shaft

Valve rod

Hall IC

Bearing

Return Spring

Operation control part

Pin Number Pin name

1 CAN_H

2 CAN_L

3 GND

4 Power

Magnet

Stator

Hall IC

Control unit

Rotor

Børsteløs type EGR-Valve

Kommuniserer med ECM via CAN-Bus

Dobbel Turbo

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B o o s t p r e s s u r e

Engine revolution

Current model

12 MY


Turboaggregatet er bygget opp av en lavhastighetsturbo og en høyhastighetsturbo. Ved å kombinere

egenskapene til disse to turboene kan oppnås bedre kompresjon i hele turtallsområdet. Dette medfører bl.a. at

mengden EGR kan økes.

Ved å øke mengde EGR reduseres utslippene av NOx.

High pressure turbo

Low pressure turbo

Normalflow

Bypass

valve open

Fresh air

Fresh air compression

Dobbel Turbo

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Høytrykksturbo

Lavtrykksturbo Lavtrykksturbo

Høytrykksturbo

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Turbo (lavt turtall)

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“Compressor bypass”, “turbine bypass” (og wastegate) er lukket. Begge turboer lader i serie.

Turbo (mellom turtall)

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I mellomturtalls-/mellomlastområdet jobber begge turboer fortsatt, men her begynner “turbin bypass” å

regulerer.

Turbo (høyt turtall 1/3)

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Når utgangstrykket på lavtrykksturboen overstiger forespurt trykk vil “compressor bypass” åpne. Samtidig er

“turbine bypass” fullt åpen.



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For å beskytte turboen ved høy hastighet og belastning, regulerer wastegate.


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Low rotation area Middle rotation area High rotation areaTurbine bypass

valveLukk et Regulerer Åpen

Compressor

bypass valveLukk et Luk ket Åpen

Wastegate

valveLukk et Luk ket Regulerer

Dyser og stempel

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Materialet i stempelring nr. 2 er endret for å gi bedre driftsikkerhet.2. stempelring

Endringer på dyser:

・Antall åpninger er økt fra 6 til 8.

・Diameter på åpningene er redusert.

・Karakteristikken til solenoidventilen er endret, denne har blitt raskere.

Engine Nozzle hole diameter

4JK1-HiHi 0.112 mm

Stempelring

(Solenoid)injektor

Glødeplugger

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Keramiske glødeplugger.

Årsak: Euro 5, lavere utslipp, redusert kompresjon.

Batteri

Glødepluggstyreenhet

・Produsert av Bosch・Spenningsnivå: 7V

Glødeplugger

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Keramiske glødeplugger

Glødeplugger

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Glødeplugger

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1.) Når tenning settes på starter for-gløding. Tiden glødepluggene er på avhenger av ECT(Engine Coolant Temperature).

2.) Etter at motoren er startet, vil ettergløding fortsette, også dette avhengig avkjølevæsketemperatur.


Glødeplugger

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Andre endringer motor

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2

3

Drivstoffilter

Radiator/Intercooler

Endringer:

• ECM

• Drivstoffilter

• Radiator/

Intercooler

• Luftfilter

• DPD

Plassering ECM

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DRM

TCCM

TCM (AT)

ECMRT56

ECM er nå flyttet inn i bilen (bak hanskerommet til høyre).

TF190

DRM er en delav ECM

Dieselfilter

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Drivstoffilteret er flyttet for å lette vedlikeholdet.Drivstoffilter

Håndpumpe Drivstofftrykkbryter

Vann-sensor

Element

Drivstoffilteret er utviklet av Denso og har nå fått håndpumpe.

Hva må gjøres om det kjøres til tanken er tom?

Etter å ha fylt opp tanken, må håndpumpen brukes for å “lufte”

systemet.

Kjølesystem

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Intercooleren er flyttet. Den har også blitt større.

+ 51 mm

2.5 & 3.0 L Hi engine: + 30 mm

Motorstyring 1/2

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INLET

MAF & IAT SENSOR

INTER COOLER

EGR VALVE

INTAKE

THROTTLE W/TPS

ECM (Engine Control Module)

BOOST SENSOR

HIGH PRESSURE

TURBO

LOW PRESSURE

TURBO

EXH PRESSURE SENSOR

IN&OUT

TO VAC.PUMP

EXH TEMP

SENSOR 2

EXH TEMP SENSOR 1

TO VAC.PUMP

EXH.TEMP SENSOR

BARO SENSOR

EGR COOLER

TO RADIATOR

THERMOSTAT

TO METER

WATER TEMP SENSOR

CRANK ANGLE

SENSOR

OIL PRESSURE SW

EVRV

# 1 # 2 # 3 # 4

SCV

SENSOR

FUEL PRESS. SENSOR

SENSOR

INJECTOR

EXH.GAS

PRE FUEL FILTER

GLOW PLUG

CSF

CAM ANGLE SENSOR

GLOW RELAY

FUEL FILTER&

SEDIMENTOR

AIR CLEANER

VSV

VSV

VSV

GLOW CONTROLLER

BATTERY

BATTERY

DOC

SUPPLY PUMP

FUEL

PRESS.SW

WATER.SW

TO METER

FUEL COOLER

FUEL LEVEL

FUEL TANK

FILTER

VSS

COMMON RAIL

TO VAC.PUMP

EGR GAS TEMP SENSOR

TO VAC.PUMP

PRESS. RELIEF VLV

EXHAUST

THROTTLE

TO VAC.PUMP

VSV

EVRV

TO VAC.PUMP

TEMP SENSOR

EXH TEMP

SENSOR 3

Motorstyring 2/2

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INTER COOLER

EGR VALVE

INTAKE

THROTTLE W/TPS

T SENSOR

TO VAC.PUMP

TO VAC.PUMP

EXH.TEMP SENSOR

EGR COOLER

TO RADIATOR

THERMOSTAT

ATER TEMP SENSOR

EVRV

VSV

VSV

VSS

EGR GAS TEMP SENSOR

TO VAC.PUMP

TEMP SENSOR

1

2

3

1. TEMP SENSOR.Tempsensor for luft fra turbo sitter nær ekspansjonstanken for kjølevæske. Denne måler temperaturen før intercooler ogkontrollerer trykket for turboaggregat.

2. EGR TEMP SENSOR 2EGR temperatursensor sitter mellom EGR ventilen EGR-kjøler/bypass-ventil (etter kjøler) og måler temperaturen på eksosgassen forå regulere bypass-ventilen.

3. EGR TEMP SENSOR 1Eksostemperatursensor på eksosmanifold overvåker temperaturen før turbo og EGR ventil.

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Systemoversikt

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The DPD is a system that uses an oxidation

catalyst to clean the CO and HC and a filter to

collect PM from the engine.

When particulates are accumulated in the filter,

regeneration is performed.

The ECM detects the condition of PM

accumulation from the exhaust differential

pressure sensor or from the distance traveled.

When PM are accumulated to reach a certain

amount, or mileage reach a certain distance, the

automatic regeneration starts.

If the automatic regeneration cannot be

completed for some reasons, the runningregeneration is requested to the driver by the

blinking DPD-Lamp on the instrument panel

cluster.

Systemoversikt

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During regeneration, the temperature inside the

filter rises, and the accumulated PM burn off.

In order to have the optimum temperature, the

ECM detects exhaust temperature using theexhaust temperature sensors, and then increase

the temperature by controlling fuel injection to

burn off the accumulated PM.

Once the regeneration starts, it must be finished

within a certain time. After regeneration is

finished, filter purification level is checked

according to the exhaust differential pressure.

In case of excessive PM accumulation detected,

regeneration operation will not be activated

again, as it could lead to “out of control” burning.

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The exhaust differential pressure sensor detects

Komponenter

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The exhaust differential pressure sensor detects

exhaust gas differential pressure between front and

rear of the filter.

The ECM uses this value to monitor the actual

clogging condition of the filter.The exhaust differential pressure sensor provides

signal to the ECM. When the differential pressure is

low indicating small PM accumulation, the ECM

detects low voltage on the signal circuit.

If you replace the exhaust differential pressure

sensor , “sensor learning” procedures is necessary asfollows:

1. Turn ignition ON and keep it for 120 seconds. DO

NOT start the engine!

2. Turn ignition OFF and keep it for 30 seconds.

21

1. Differential pressure hose front

port

2. Differential pressure hose

rear port

-Scan Tool Data Displays-

Following data can be observed on the scan tool.

• Exhaust Differential Pressure (kPa/ psi)

• Exhaust Differential Pressure Sensor (V)

O u t p u t ( V o l t s )

1.0

4.5

Exhaust Differential Pressure (kPa)0 100

●

●

DPD varsellampe

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The DPD lamp is located on the instrument panel

cluster (IPC). When the ignition switch is turned ON

with the engine OFF, the DPD lamp illuminates for a

bulb test.

Under normal driving conditions, the DPD-lamp

informs the driver of the following messages:

• The DPD amber lamp blinking slowly (1.3 Hz) : Calls

to perform a “running regeneration”.

• The DPD amber lamp blinking fast (2.0 Hz) Calls you

to perform “running regeneration” immediately as

the accumulated PM is at high level.

• The DPD lamp is kept on once the “running

regeneration” is started.

The MID shows the amount of particulate matter

(PM) accumulated in the DPD, with five bars in total.

During the regeneration, regeneration state is

displayed on the MID.

Message Display indication

DPD PM level

DPD regenerationstate

Name Symbol

DPD lamp

Oljefortynning

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MIN

(Hole)

Refill MAX

(Hole)

Inspection

MAX(Stamp on

X)

Oil level gauge

HOW to inspect the engine oil

1. Remove the oil dipstick and wipe off any

oil of the dipstick.

2. Reinsert the oil dipstick fully and then

gently remove it. If the oil surface is

between the "Inspection MAX" and "MIN"

marks, the oil is at the correct level.

3. If the oil level is too low, add oil to the

refill to

"MAX" mark. If the oil level is over the

"Inspection MAX" level, then the oil needs tobe changed.

4. After checking the oil level, put the oil dipstick

back to the original position.

TB50LS

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AISIN AW TB50-LS

Automatic Transmission

TB50LS

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The AISIN AW TB50LS automatic transmission is electrically

controlled by the transmission control module (TCM).

Five forward speeds and one reverse speed.

This transmission has a learning function and constantly

checks the time of each clutch and brake required for theshift in order to match this time with the target value for the

optimum shift.

The TCM will automatically selects the most appropriate

shift points and lock-up points depending on the accelerator

pedal opening, the vehicle speed and the vehicle load.

The driver can select the gear in the manual mode.

The TB50LS AT consists of:

Torque converter, oil pump, input shaft, output shaft,planetary gears and valve body.

The gear train consists of:

three planetary gear sets, three multiple plate clutches,

four multiple plate brakes and three one-way clutch.

12

3 4

1. Torque converter housing

2. Torque converter

3. C2 clutch

4. C3 clutch

5. C1 clutch

6. One way clutch 2

7. B3 brake

8. One way clutch 1

9. B1 brake

5 6

78

910

14

1516

10. B2 brake

11. One way clutch 3

12. B4 brake

13. Output shaft

14. Input shaft

15. Oil pump

16. Valve body

17. Extension housing

11 12 13

17

4WD

2WD

TB50LS Time Lag Test

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4. Let idle and record the time lag from when the selectorlever is moved from N to D or N to R range until theshock has felt.

Selector lever position Time lag

N to D range Less than 0.7 seconds

N to R range Less than 1.2 seconds

Standard Value

< CAUTION >

1. Make sure to take 3 measurements and take the

average value.

2. Make sure to keep interval for more than 1 minbetween time lag tests (That purpose is to remove

clutch / brake pressure left unfinished.)

Time lag test can inspect hydraulic condition and clutch / brake condition.

1. Fully apply the parking brake and chock all wheels.

2. Check the level of engine oil, coolant and transmission fluid.

Refill them if necessary.

3. Start the engine and warm up

(let engine coolant temperature reach at least 50 - 80 degree C (122 -176

degree F ))

Diagnosis

1. If the stall speed is longer than the standard value

when shift to N-D, the possible cause can be:

• Lower line pressure

• C1 failure (slipping)

• F3 failure

2. If the stall speed is longer than the standard value

when shift to N-R, the possible cause can be:

• Lower line pressure

• C3 failure (slipping)

• B4 failure (slipping)

• F1 failure

TB50LS Måle operasjonstrykk

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1. Fil ler Test hole for l ine pressure.

Hydraulic test can inspect working condition inside automatic transmission

by measuring line pressure in "D" / "R" range and "idle" condition.

1. Chock 4 wheels and apply parking brake fully, lock vehicle completely.

2. Install oil pressure gage to test hole for line pressure.

3. Fully press on foot brake pedal with left foot, shift into “D” and “R” range

and measure the line pressure in "idle“ condition.

Line

pressure"D" "R"

Engine

idle

357 kPa

(3.640 to 4.354

kgf/cm2)

454 to 662 kPa

(4.629 to 6.750 kgf/

cm2 )

< CAUTION >

Make sure to check no oil leak after installing oil

pressure gage.

Diagnosis

1.If the line pressure is higher than standards for both "D" and

"R“ the possible cause can be:

• Pressure control solenoid C (SLT) failure

• Primary regulator valve failure

2. If the line pressure is lower than standards for both "D"

and "R“ the possible cause can be:

• Pressure control solenoid C (SLT) failure

• Primary regulator valve failure

• Oil pump failure

3. If the line pressure is lower than standards only for Dthe possible cause can be:

• “D" hydraulic circuit failure

• C1 failure

4. If the line pressure is lower than standards only for R

“R" hydraulic circuit failure, the possible cause can be:

• C3 failure

• B4 failure

TB50LS Kontroll av oljenivå 1/4

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(1) Parker bilen på flatt gulv, og sett girvelger i posisjon “P”.

(Kontrollprosedyre startes med kald ATF olje).

(2) Sjekk oljetemperatur med diagnoseverktøy (hvis

tilgjengelig), hvis temperaturen er lavere enn følgende,

fortsett til neste punkt.- 4JK1 HI HI : Mindre enn 42℃ (108 F).

*Hvis temperaturen er høyere, vent til den er under

nevnte verdi.

(3) Fyll på 500 ml ATF olje på girkassen gjennom

påfyllingshull (se bilde).

(4) Kortslutt terminalene 12 (terminal for

diagnoseforespørsel) og 4 eller 5 (4 og 5 er jord) i DLC

kontakten (diagnosekontakten).”Check Trans” varsellampe lyser.

(5) Start motoren.

(1)

(3)4WD2WD

(4)

Påfyllingsplugg

4

12

5

DLC terminal


TB50LS Kontroll av oljenivå 2/4Utfør følgende punkter (punkt 6 og 7) for å bekrefte at

oljetemperaturen er i området merket blått (se under) hvor

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(6)

(7)

℃ 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

F 95 97 99 100 102 104 106 108 109 111 113 115 117 118 120 122 124 126 127 129 131 133 135 136 138 140 142 144 145 147 149 151 153 154 156 158

4JJ1-HiHi

ATF Temperature

Blue range: Turn off the AT

warning indicator light

Green range: Turn on the AT warning indicator

light

Red range: Blink the AT warning indicator light

Engine

j p ( )

oljetemperaturen kan justeres.

(6) Flytt girvelgeren innom alle posisjoner, fra "P” til "D”, for å

sirkulere ATF oljen i alle trykk-kretser.

La girvelgeren stå i hver posisjon i mer enn 2 sekunder.

Gjør dette 2 ganger, og sett så girvelgeren i ”P”.

(7) Flytt girvelgeren mellom N-D-N på under 1,5 sekunder og

fortsett med dette i 6 sekunder. Varsellampe for ATF temperatur

tenner i 2 sekunder, deretter hvis varsellampen:

(Blått område)

ATF er i området hvor temperaturen kan justeres.

GÅ TIL NESTE PUNKT

(Grønt område)

ATF er i området der temperaturen ikke kan justeres.

KAN IKKE GÅ TIL NESTE PUNKT

Vent til ATF oljen er kald og start deretter fra punkt 5.

(Rødt område)

ATF er i området der temperaturen ikke kan justeres.

KAN IKKE GÅ TIL NESTE PUNKT

Vent til ATF oljen er kald og start deretter fra punkt 5.

Varsellampe for ATF temperatur

(8) Etter å ha bekreftet at temperaturen er i riktig område (blått),hvor temperaturen kan justeres, kan temperaturøknings-

d åk ll


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prosedyre og nivåkontroll starte.For å få ATF temperaturen i området for nivåkontroll, utførfølgende punkt (a – d):

a) Dra på håndbrems og trå inn bremsepedal.

b) Flytt girvelgeren til "D" og øk motorturtallet til 1000 rpm og hold

turtallet der i 5 sekunder.

c) Sett girvelgeren i ”N”. d) Sjekk varsellampe for ATF temperatur.

(Blått område)ATF er under temperatur for nivåkontroll.KAN IKKE GÅ TIL NESTE PUNKTStart igjen fra punkt b.

(Grønt område)

ATF temperatur er i området for nivåkontroll.Om lampen fortsetter å lyse i 1 minutt, fortsett til neste punkt.

Om lampen lyser mindre enn 1 minutt, start igjen fra punkt b.

(Rødt område)ATF olje for varm.KAN IKKE GÅ TIL NESTE PUNKTVent til ATF oljen er kald og start deretter fra punkt 5

Hold i 5 sekunder

og sett girvelger i ”N”

Varsellampe for ATF temperatur

℃ 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

F 95 97 99 100 102 104 106 108 109 111 113 115 117 118 120 122 124 126 127 129 131 133 135 136 138 140 142 144 145 147 149 151 153 154 156 158

4JJ1-HiHi

ATF Temperature

Engine

Blue range: Turn off the AT

warning indicator light

Green range: Turn on the AT warning indicator

light

Red range: Blink the AT warning indicator light


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(9) Fjern nivå (overflow) pluggen og kontroller om ATF olje

kommer ut.

< Hvis ATF olje drypper >:

Vent til det ikke kommer mer olje, mens varsellampe for

ATF temperatur lyser.< Hvi ATF olje ikke drypper ut>:

Fyll på med ATF olje til det drypper ut.

(10) Bruk ny pakning og skru til nivåplugg til riktig moment

(20 Nm). Tørk vekk utenpåliggende ATF olje.

Vær oppmerksom på pakningen, at denne monteres riktig

vei. Se figur.

(9)

(10)

Nivå (overflow) plugg

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GIRKASSEAY6

AY62WD model

The new manual transmission AY6 is adopted

from 2012 model year Due to its new structure

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2WD model

4WD model

from 2012 model year. Due to its new structure,

maximum allowable input torque is strongly

increased. A compact manual transmission with

high power performance for the 4Jk HiHi engine

has been developed.In order to achieve high torque, the “output

reduction structure” which comes from the

ISUZU manual transmission (MUX) was adopted.

AY6

AISIN AI CI.,LTD

56,2Fully synchronized forward

and reverese gear

Direct control with gear shift lever

Gear ratio 1st 5,232

2nd 2,644

3rd 1,606

4th 1,219

5th 1,000

6th 0,728

Reverse 4,525

75W-90 GL5

(1.8L)

Ф275

Shift patterm

Clutch size

Dry weight (kg)

Model

Supplier

Oil

Transmission type

Control type

AY6

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1. Revers gear lamp switch2. Clutch housing3. Clutch housing bolt4. Clutch housing hole plug5. Breather6. Reverse idler gear7. Reverse idler gear bearing8. Reverse idler gear shaft9. Intermediate case10. Oil separater11. Drain plug12. Oil trough

13. Oil seal14. Tapered bearing race15. Rear case housing16. Fill plug17. Shift shaft detent plug & spring & pin18. Rear output shaft seal19. Oil trough20. Extension housing21. Neutral switch

1 2

3

4

5

6 7

8

9 1011

1213

14 1516

17

18

1920 21

Input reduction type manual transmission

AY6

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The AY6 model employs “output reduction system

(speed)” that is completely different from “input

reduction type manual transmission”.

With the input reduction type, reduction point islocated in front of the transmission. Most of the

parts (=red parts) will see approximately 1.6 times

of engine torque.

With the output reduction type, reduction point

located in the rear of the transmission. Most of

the parts (=green parts) will see only the engine

torque.

In this way, the output reduction type realizes

“low weight”, “compact design” and “high output

torque”.

Output reduction

41R 3 5

AY6 : Output reduction type manual transmission

Input reduction

4 1 R 23 5

Approx. 1.6times

62

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TRANSFERKASSE

Transferkasse

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Transfer:

Transferkassen overfører trekkraft til

forakselen.

Transferkassen har også et reduksjonsgir.

4WD bryteren er nå plassert i

midtkonsollen og styrer transferkassen.

Transferkasse, fra 2H til 4H

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2H

4H

Transferkasse, fra 4H til 4L

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4H

4L

Drive type 2WD 4WD

Transferkasse, operasjonsbryter

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2H 4H (4WD high) 4L (4WD low)

Indicator light OFF

Model with MID

Driving conditions

During normal

driving on an

ordinary road or

highway.

Wet roads,

snowcovered

roads, icy roads,

and other roads

where the vehicle

needs more

traction than

2WD.

Steep slopes,

rough roads,

sand, mud or

deep snow, and

other roads where

the vehicle needs

significant

traction.

4WD switch

Transferkasse, operasjonsbryter

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Posisjonen N (Nøytral) finnes ikke lenger, det er ikke mulig å sette

transferkassen i fri.

Det er derfor viktig at det ved tauing av kjøretøyet med alle hjul på bakken,skal bryteren stå i “2H” posisjon og at det sjekkes at 4WD indikatoren er

slukket!

4H kan legges inn/det kan kobles ut fra 2WD i hastigheter opp til100 km/h.

For å velge 4L, stopp bilen, sett girkassen i fri, trykk ned og vri 4WDbryteren med klokken.

For å koble ut 4L igjen, stopp bilen og trykk og vri 4WD bryteren motklokka.

Tauehastighet i 2H er: 30 km/hTauedistanse er: 80 km

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ESC

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TireTire

TireTire

Scan tool

CAN LINE for scan tool

Switch ESC OFF

Fluidline

Electricalline

Wheel speed sensor

New wheelspeed sensor

Brake wheel cylinder

EHCU

10 Solenoid

Wheel speed sensor

Warning lamp for ABS & EBD

& ESC

Indicator lamp for TCS & ESC

Meter

Sensor

Steering

angle

Sensor

Yaw rate

Mastervac

Mastercylinder

Master cylinderpressure sensor inEHCU

Rear brake right and leftindependence

Front left wheel hold valve

ESC

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Front left wheel speed sensor

Front right wheel speed sensorRear left wheel speed sensor

Rear right wheel speed sensor

Ignition switch

Brake pedal switch

ESC (TCS) cut off switch

Front left wheel hold valve

Front left wheel release valve

Front right wheel hold valve

Front right wheel release valve

Rear left wheel hold valve

Rear left wheel release valve

Rear right wheel hold valve

Rear right wheel release valve

Solenoid Master Cylinder Cut Valve 1

Solenoid Master Cylinder Cut Valve 2

Return pump

ABS warning lamp

Brake (EBD) system warning lamp

ESC system warning lamp

ESC cut off Illumination lamp

TCS cut off Illumination lamp

Vehicle speed pulse

CAN

EHCU

G sensor (4WD For ABS & EBD)YAW & G sensor (For ESC)

Steering Sensor

Master cylinder (M/C) pressure sensor

ESC

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(1) (2)

(3) (5) (6)(4)

For ABS / EBD / TCS/ESC

EHCU location

1. Front wheel fluid from master cylinder

2. Rear wheel fluid from master cylinder

3. To front left wheel cylinder

4. To front right wheel cylinder5. To rear right wheel cylinder

(Without ESC :Dummy hole)

6. To rear left wheel cylinder

(Without ESC : To rear wheel cylinder)

The EHCU is located near the air clearer. The

EHCU is made by ADVICS company. EHCU is

integrated with the modulator assembly. The

EHCU performs following

task:

・ Controls solenoid valves

・ Controls return pump

・ Performs “Self check”

・ Performs “On-board diagnostics”

hi l ith ESC

ESC

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Terminal

No. Terminal nameTerminal

No. Terminal name

1 Ground (solenoid valve) 18 Wheel speed sensor front left signal2 Brake switch signal 19 Wheel speed sensor front left 12 volts reference3 CAN low 2 signal (local) 20 Not used4 Wheel speed sensor rear left signal 21 Not used5 Wheel speed sensor rear left 12 volts reference 22 Not used6 Wheel speed sensor front right signal 23 Not used7 Wheel speed sensor front right 12 volts reference 24 Battery voltage (motor)8 Not used 25 CAN high signal9 Not used 26 Not used

10 Not used 27 Not used11 Vehicle speed signal output 28 Not used12 Battery voltage (solenoid valve) 29 Not used13 Ground (motor) 30 ESC OFF switch signal14 CAN low signal 31 Not used15 CAN high 2 signal (local) 32 Not used16 Wheel speed sensor rear right signal 33 Diagnostic request switch17 Wheel speed sensor rear right 12 volts reference 34 Ignition voltage

vehicles with ESC

ECM

C i ti ith S t l

ESC

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Yaw rateG sensor

ECM

IP cluster

12V

SRS

ICU

Auto A/C

BCM

TCCM

DRM

EHCU

TCM

EGR valve

Steeringangle sensor

CAN communication


Communication with Scan tool

The EHCU communicates with the scan tool over the controller area

network (CAN) link.

Communication with Other modules

The EHCU communicates with ECM,TCCM, and IP cluster over thecontroller area network (CAN) link. Following signals are communicated

via a CAN bus.

• Injection volume reduction signal (with ESC model)

(EHCU→ECM)

• Accelerator pedal position signal (with ESC model)

(ECM→EHCU)

• Transfer case range ( High / Low)

• ABS warning lamp request signal

• Brake warning lamp request signal

• ESC warning lamp request signal• TCS off indicator lamp request signal

• ESC off indicator lamp request signal

The wheel speed sensors use a hall IC type

sensor.

3ESC

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The rear wheel sensor is newly introduced from

12MY. The supplier is Hitachi cable. The sensor

is covered by plastic.

The voltage is generated in the sensor by

turning the sensor rotor, which is firmly fitted

into the hubs of the front wheels. The

frequency of this voltage changes

proportionately to the rotor speed, by which

the wheel speed to cab be detected.

1

2

3

1. Front wheel speed sensor

2. Rear wheel speed sensor3. Connector

4. Wheel speed sensor5. Sensor rotor

4

4

5 5

The EHCU receives wheel speed signal and calculates the vehicle speed signal After that the EHCU send it to ECU

ESC

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The EHCU receives wheel speed signal and calculates the vehicle speed signal. After that, the EHCU send it to ECU.

And then the ECU sends it to the meter, TCM and so on in order to control various functions .

EHCU

ECM

4 pulseby hard wire

With ABS

Vehicle Speed Sensor

SRS

Without ABS

Four wheel speed sensors

Cluster TCM TCCM

100ms by CAN

Audio / DVD

4 pulseby hard wire

4 pulseby hard wire

The steering angle sensor is placed in the

l h d h

1ESC

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3

4

45

6

1. SRS coil assembly2. Steering angle sensor3. Large gear4. Detection gear5. Magnet6. Sensor

steering column part. This sensor detects the

sheering's angle and direction, and sends the

signal to EHCU by CAN (Local CAN).

when following actions are made, 0 point

learning for the steering angle sensor must be

performed:

• Disconnect the battery

• Disconnect the steering angle sensor

connector

• Replace the EHCU

If you don’t carry out the 0 point learning, it will

cause DTC “C0710 [4B] steering angle sensor

center position invalid malfunction” to set.

2

-Scan Tool Data Displays-

Following data can be observed on the scan

tool.

•Steering Sensor Centered Status

There are 2 ways to carry out 0 point learning:

ESC

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There are 2 ways to carry out 0 point learning:

1. Self learning during the driving

2. Scan tool (forced learning )

Self learning during the driving

The self learning is done by driving at the vehicle speed

at more than 40 km/h (25 mph) for about 10 seconds.

Scan tool:

1. Connect a scan tool to the DLC.

2. Select ABS/ESC.

3. Select Learning for Steering Central Position of

special function.

The yaw rate sensor and G sensor are integrated

ESC

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The yaw rate sensor and G sensor are integrated

and placed under the center of the dash panel.

The yaw rate sensor detects the rotating angular

speed of vehicle.

The G sensor detects the deceleration speed of

vertical direction and horizontal direction by using

the G sensors

When approaching the corner, the vehicle behavior

(which tends to be over-steering or under-steering

etc) is judged from :

• The rotating angular speed of vehicle and

deceleration (Yaw rate & G-Sensor)

• The steering wheel angle (Steering angle

sensor)

• The vehicle speed (Wheel speed sensor)

and ESC controls suitable brake force and engine

torque.

1. G sensor

2. Yaw rate sensor 3. Yaw rate sensorassembly

YAW rate

Rotating angular speed

G detection

Forward

Backward

Left Right

When Canceling the TCS:

ESC

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When the ESC is active after the engine is started,

press the ESC OFF switch for approximately 1

second to cancel and the TCS OFF indicator lamp

in the meter will go ON.

When Canceling the ESC:

When the ESC is active after the engine is started,

press the ESC OFF switch for approximately 5

seconds to cancel the ESC and the ESC OFF

indicator lamp in the meter will go ON.

The function can be returned by the following

actions:

• The ESC OFF switch is pressed again for

about 1 second

• Turn off the key switch

TCS OFF indicator lamp ESC OFF indicator lamp

ESC

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ESC

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ESC

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• After turning on key switch, the EHCU starts diagnosing the system.

• The following lamps are lit for approximately 3 seconds when the ignition switch is turned ON, with the engine

OFF.

ABS and ESC warning lamp

TCS and ESC off indicator lamp

• The EBD (brake) warning lamp remains ON when the ignition switch is turned ON, with the engine OFF.

TCS

OFF ABSW/L TCS OFF ESCOFF ESCW/L BRKW/L

ESC&TCS Disable Disable Disable ○

ABS&ESC&TCS Disable Disable Disable Disable ○ ○

ABS&EBD&ESC&TCS Disable Disable Disable Disable Disable ○ ○ ○

Initial check ○ ○ ○ ○ ○

CAN Communication Disable Disable Disable ○ ○ ○ ○ ○

ABS/ESC Mode

Control Disable ：Prohibition control

Lamps○：Lighting、 △：Blink

ABS E-TCS B-TCS ESC EBD

Failed

Failed

Failed

Failed

check

Diameter på bremseskivene foran på 4X2 Hi-ride og 4X4 er endret for å gjøre

Endringer bremser

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p p g gj

plass til større hjul og på grunn av økningen i totalvekt.

TF190: 280 mm

RT56: 300 mm

Bremsene bak er også redesignet, men størrelsen er som før.

Servoenhet og mastersylinder er endret på grunn av økningen i totalvekt.

Servo unit: 8+9 inch Twin → 10.5 inch Single

Master cylinder: Ф25.4 cylinder → Ф22.22 cylinder

Reservoartanken er den samme for bremser og clutch.

Bremsepedalen er endret for å øke sikkerheten.

12MYCurrent model

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RAMME/FJÆRER

Sterkere

Ramme

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Sterkere• Økt tverrsnitt/styrke på rammevanger

• Ekstra “bjelker” mhp kollisjonssikkerhet

• Deformasjonssone i front

Ny D-Max

90 x 173.6 mm

Tidligere D-Max89 x 138.9 mm

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4X4

Hjuloppheng foran

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Fjæringssystemet foran er endret fra torsjonsfjæring til spiralfjærer.

Følgende deler er skiftet ut:

(1) Øvre triangelarm(2) Nedre triangelarm

(3) Justering av vinkler er endret fra shims til “Kam”

Torsjonsfjæring Upper linkgas shockabsorber

Lower link

Stabilizer

RT56

TF190

Uavhengig dobbel wishbonemed spiralfjærer

TF190 U d l

Fjærene bak er endret for å øke kjørekomfort.Endringer hjuloppheng bak

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TF190: Under slung RT56: Over slung

(1) Ved å endre boltøyet er fjærene forlenget (nå: 1360 mm)

+ 160 mm

Front Rear Front Rear Soft type

Leaf suspentionBerlin eye Up turn eye

Hard type

Leaf suspentionBerlin eye Up turn eyeUp turn eye

urrent

shackle

t e

12MY shackle type

Berlin eye

4WD off-road egenskaper

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– Inngangsvinkel• 30o

– Utgangsvinkel• 22.7o

– Sidevinkel• 49o statisk

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STYRING

Servopumpe med variabel kapasitet er innført for 4JK1 (og 4JJ1).

Servopumpe

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Red : 12MYBlue : Current model

Drive type

Pulley drive

STD

Hi

Engine

4JA1/H1Current model

4JJ1/K1 Gear drive

Drive type Remark

Pulley drive

STD

Hi/Hi Hi Variable capacity

C/OCurrent model

Engine

4JA1/

4JJ1/K1 Gear drive

En konvensjonell pumpe gjør mye arbeid unødvendig. Områdetmerket A indikerer det unødvendige arbeidet.

En variabel pumpe reduserer belastningen på motoren og forebyggerøkning i servooljetemperatur.Følgen av dette er redusert drivstofforbruk.

A

Ved lave hastigheter:

Servopumpe

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(1) Kamringen presses mot venstre av fjæra.

(2) Åpningen C er stengt av kontrollventilfjæra.

(3) ATF-olje fra beholderen strømmer til “kamvolum” a og b.

(trykket er det samme i “kamvolum” a og b)

Valve chamber B

(Red room of control valve)

Valve chamber A

(Pink room of control valve)

Control valve

Control valve spring

ServopumpeVed høy hastighet:

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20.10.2012 133

(1) Trykket øker når rotasjonshastigheten går opp.

(2) Forskjellen i trykk mellom rødt og rosa er stort fordi åpningen D struper røret ut.

(3) Den grønne kontrollventilen trykkes mot høyre av trykket i ventilkammeret B, og åpner passas

1_Isuzu D-Max 2012

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Transcript of 1_Isuzu D-Max 2012