Isuzu D-Max 2012
Teknisk kurs RSA 2012
Modell varianter RT56
Regular cab
Ikke til Norge
Crew cab
Extend cab
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
2
Nyheter RT56
Modeller : TFR,TFS
AY6 (M/T) Nyhet
Girkasse
Motor
4JK1-TC HiHi (Euro5)
TB-50LS (A/T)
Nyhet
Transfer
Motor
TM
Extend
Crew
T/F
ESC (Electronic stability control)
Nyhet
Bremser
EBD (Electronic brake-force distribution)
TCS (Traction control system)
20.10.2012
T150
ABS (Anti-lock brake system)
Regular
CAB
Nyhet
Kurs Isuzu D-Max 2012 rev. A
Nyhet
3
Mål Extended cab
SAP (Side Access Panel), bakhengslet dør.
Større plass bak setene
Cargo bed size
Total length Total width
1830
1530
12MY
Svart: Utgående modell
Curret model
1831
12MY
Current
model
1460
1720
1800 1635 1730
(mm)
(mm)
≦1800
-1(1830)
10
30
11
+128 ( 898)
5045
+45 (3095)
+146 (5191)
-27 (1198)
4x2: +54(1689)/4x4:+60(1790)
Blå: 2012 modell
Total width Overall height
Total length 2WD 4WD 2WD 4WD
5191
1766 1860 1689 1790
+70(1530)
4 x 2:+46 (1766)
4 x 4:+60 (1860)
Bakhengslet dør (SAP)
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
4
Mål Crew cab
• Større plass bak setene
• Større døråpning bak
• Større lasteplan(lengde & bredde)
Blå linje : RT56
Større lasteplan
21°
+104(1483)
25
20
30
11
+128( 898)
Større døråpning bak
20.10.2012
+45 (3095)
+266(5191)
12MY
Current
model
4x2: +52(1692)/4x4:+59(1794)
12MY
Current
model
Seat angle
24°
Svart linje TF190
Større plass bak
Setevinkel: + 3°
+70(1530)
4x2:+46(1766)
4x4:+60(1860)
+93(1198)
494
458
12MY
Current
model
Kurs Isuzu D-Max 2012 rev. A
Total width Overall height
Total length 2WD 4WD 2WD 4WD
5191
1766 1860 1692 1794
4925
1720
1800 1640 1735
5
Lys
Projector type
(4-LIGHT SYSTEM HEADLAMP)
Retningslys
Parklys
Fjernlys
Nærlys - Projector
Kjørelys (DRL) finnes på alle biler.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
6
Baklamper
Baklampene finnes i to utgaver. Våre modeller har LED for baklys og bremselys .
Baklys/bremselys
LED
Retningslys
Tåkebaklys
Ryggelys (tåkebaklys)
Refleks
LED type
Høytmontert bremselys er endret. Har nå vanlige lyspærer og ikke LED.
RT56
TF190
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
7
INTERIØR
MID/IP
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
8
MID
OUTLINE OF MULTI-INFORMATION DISPLAY (MID)
Operation &
maintenance
information
Shift indicator
Coolant temp.
gauge
Fuel gauge
Ambient air
temp.
Driving mode
Cruise control
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 internal
processing, and it is integrated within the IP-Cluster.
The MID mainly informs following items;
•Warnings and indicators
•Operation related information
•Maintenance information
Clock
Notice!
Regardless of model with MID or without MID, the
replacement of the IP-Cluster must be programmed
with a scan tool.
CAN
communication bus
20.10.2012
Analog inputs
& other inputs
Kurs Isuzu D-Max 2012 rev. A
9
MID
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:
ECM
EGR valve
Yaw rate G
sensor
TCM
TCCM
Steering angle
sensor
EHCU
ICU
IP cluster
20.10.2012
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)
12V
SRS
From TCCM to IP-Cluster
•Lamp request (check 4WD, 4WD and 4WD low)
BCM
From EHCU to IP-Cluster
•Lamp request (ABS, EBD, TSC and ESC)
Auto A/C
From IP-Cluster to BCM
•Vehicle speed (for vehicle speed linked door lock)
CAN communication
EHCU local CAN communication
From IP-Cluster to automatic air conditioner
•Ambient air temperature
Kurs Isuzu D-Max 2012 rev. A
10
MID
CONTENTS OF MULTI-INFORMATION DISPLAY (MID)
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.
Press and hold (long apply)
Tap (short apply)
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Kurs Isuzu D-Max 2012 rev. A
11
MID
SELECT 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.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
12
MID
Service
Distance remaining until the next engine oil replacement,
air cleaner element replacement and any maintenance
can be selected with a MID switch.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
13
MID
OTHER DISPLAYS
Coolant Temperature Gauge
The IP-Cluster receives a temperature signal from the
ECM via the CAN communication bus.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
14
MID
Shift Indicator
The IP-Cluster receives a position or current gear signal
from the TCM via the CAN communication bus.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
15
MID
4WD Mode Status
The IP-Cluster receives a lamp request signal from the
TCCM via the CAN communication bus.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
16
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.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
17
MID
WARNINGS
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 Off
This 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
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
18
MID
SUMMARY OF MID CONTROL
5,000 to
20,000km with
2,500 km
increments or
OFF
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
19
MID
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
20
MID
IP CLUSTER SELF DIAGNOSTIC FUNCTION
The IP-Cluster has ability to test internal components with
following procedures.
Turn ON ignition
while pressing
●
●
●
Longer than
0.6 seconds
●
●
●
Within 7
seconds
Once release
●
●
●
Repeat 3 times
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.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
21
MID
SCAN TOOL MENU ON THE IDSS
Menu
Functions
Programmig
Upload Vehicle Configuration
Data
To upload the current setting at the original IPCluster 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
20.10.2012
To read current option contents or setting.
Kurs Isuzu D-Max 2012 rev. A
22
MID
SCAN TOOL MENU ON THE IDSS
Items for Individual Setting with Scan Tool
Parameter
Selection
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
PESS Information Display
Available/ Not Available
Back Shift Warning
20.10.2012
Notice
Choose Number whenever setting.
Choose Not Available whenever setting.
Available/ Not Available
Choose Available if 6 speed manual transmission.
Kurs Isuzu D-Max 2012 rev. A
23
Varsellamper 1/3
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 oil
pressure 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.
This warning light should come on when the starter switch is turned to the
Fuel filter warning "ON" position, and then should go out after approximately 3 seconds.
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 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 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.
This warning light should come on when the starter switch is turned to the
Generator warning "ON" position, and then should go out after the engine is started.
light
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
20.10.2012
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.
Kurs Isuzu D-Max 2012 rev. A
24
Varsellamper 2/3
Lamp display Display name
Operation condition
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.
ABS warning light
This warning light comes on whenever there is a problem in the anti-lock
brake system (ABS).
When the starter switch is turned to the "ON" position, the ESC warning
light turns on before going out after approximately 3 seconds. This
ESC warning light warning light comes on whenever there is a problem in the electronic
stability control (ESC). When the ESC is operating, the ESC warning light
flashes.
When the ignition switch is turned ON for the first time, the SRS airbag
warning light blinks 7 times to confirm the operation of the SRS airbag
SRS airbag
warning light and SRS control unit.
warning light
This warning light comes on whenever there is a problem in the SRS
airbag system.
Seat belt warning
light (driver seat)
This warning light comes on when the driver is not wearing the seat belt
while the starter switch is in the "ON" position.
2
20.10.2012
Seat belt warning
light (Passenger
seat)
Door open
warning light
The door open warning light comes on if any door is not fully closed when
the starter switch is turned to the "ON" position.
Automatic
transmission fluid
temperature
warning light
This warning light should remain on for approximately 3 seconds after the
starter switch is turned to the "ON" position, 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 turned
to the "ON" position and should then go out after approximately 3
seconds. When this warning light stays on, the 4WD system has a
malfunction.
Check trans
warning light
This warning light should remain on for approximately 3 seconds after the
starter switch is turned to the "ON" position, and then should go out.
If this light comes on after the engine has started, there is something
wrong with the transmission electronic control system.
Kurs Isuzu D-Max 2012 rev. A
25
Varsellamper 3/3
Lamp display Display name
Operation condition
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 light
This indicator light comes on when the light switch is in the "ON" position.
Turn signal
indicator light – left
Turn signal
indicator light –
right
Either of these indicator lights flashes when the turn signal switch is
operated with the starter switch in the "ON" or "ACC" position.
Both indicator lights flash when the hazard warning flasher switch is
operated irrespective of the position of the starter switch.
Front fog light
indicator light
This 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 OFF
indicator 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 The 4WD low indicator light comes on when the 4WD switch is used to
light
select "4L (4WD low)".
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
26
INTERIØR
BCM
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
27
BCM
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)
For high grade
D-MAX only
•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
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
28
BCM inn-/utsignaler
Relay controls
 Door lock/ unlock relay
Switch 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
 Door lock/ unlock actuator
Actuator controls
 Answer back flasher
 Anti-theft horn
Relay control
BCM
 Super lock relay (with super lock)
 Rear defogger relay
Other inputs
Lamp controls
 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)
 Room light (map light & dome light)
 Anti-theft indicator lamp
 Door open indicator lamp
Other control
 Power window control
Communication with scan tool
 Controller area network (CAN)
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
29
BCM kommunikasjon
CAN communication
EHCU local CAN communication
ECM
EGR valve
The BCM communicates with the scan tool via the CANBus.
The BCM receives the vehicle speed signal from the
IP-Cluster also via the CAN-Bus.
Yaw rate
G sensor
TCM
TCCM
Why does the BCM needs the information vehicle speed?
Steering
angle sensor
The BCM needs this information for the vehicle speed
linked door lock control.
EHCU
ICU
BCM COMMUNICATION
12V
SRS
BCM
Auto A/C
IP cluster
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
30
BCM pinout
A
A: B19 (20 pins connector)
Pin
Pin function
B
C
B: B20 (18 pins connector)
Pin
Pin function
C: B21 (25 pins connector)
Pin
Pin function
1
Ground
1
Not used
1
Not used
2
Door switch 2 (with super lock)
2
Not used
2
Not used
3
Not used
3
3
Not used
4
Not used
Door unlock switch signal (door lock)
(without super lock)
4
Anti-theft indicator lamp control
4
Not used
5
Not used
5
Not used
6
Door open indicator lamp control
6
Door unlock switch signal (central
door lock switch)
7
Not used
7
Not used
8
Not used
8
Not used
9
Rear defogger relay control
9
Power ground
10
Not used
10
Door unlock actuator control
11
Rear defogger switch signal
11
Door lock actuator control
12
Not used
Door lock switch signal (door lock)
(without super lock)
13
Anti-theft horn control
14
Battery voltage feed
5
6
Not used
Keyless entry signal from receiver
unit
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
12
14
Keyless entry receiver unit ground
13
Not used
15
Battery voltage feed
15
Not used
14
Disarm signal from immobilizer
control unit (with super lock)
16
Not used
Door lock switch signal (central door
lock switch)
17
Power window control
15
18
Not used
16
Keyless entry receiver unit 5V
reference
17
Not used
18
CAN low signal
16
Room light control low side
19
Answer back flasher control
19
Accessory voltage
17
Not used
20
Not used
20
Battery voltage
18
Power ground
21
Super lock relay control (with super
lock)
20.10.2012
22
Airbag
Kurs Isuzu D-Max 2012
rev. Adeployment signal
Pin
Pin function
23
Not used
24
Door lock/ unlock position switch
signal
25
Room light control high side
31
BCM Sentrallås Keyless
KEYLESS ENTRY FUNCTION (RADIO REMOTE CONTROL
DOOR LOCK)
The BCM controls a remote keyless entry system with
following functions:
Lock/
unlock
signal
BCM
Receiver
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.
Transmitter
Engine compartment
Cabin
Battery voltage
Battery voltage
Hazard
(15A)
If any of the following conditions are met, remote key
operation is ignored.
Room
(10A)
Turn
signal
lamps
Keyless entry
receiver unit
Flasher
unit
Key
reminder
switch
(closed @
key in)
- 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)
Antenna
Where is the receiver unit located?
Hazard
warning
switch
C19
BCM
Answer
back
flasher
control
20.10.2012
The receiver unit is located behind the radio.
A9
Key
remained
switch
signal
A14
Lock/
unlock
signal
A6
A16
5V
How can you check if the receiver unit is sending a
signal?
We can measure the lock/ unlock signal.
Kurs Isuzu D-Max 2012 rev. A
32
BCM Sentrallås Keyless
KEYLESS ENTRY FUNCTION (RADIO REMOTE CONTROL
DOOR LOCK)
Lock/
unlock
signal
Receiver
BCM
Remote Key Registration Function
Remote key registration is carried out manually or with the
scan tool. Maximum of five remote keys can be provided
by additional programming.
Transmitter
How to do the key registration manually:
1.
2.
3.
4.
5.
6.
7.
Close the driver’s door
Open the driver’s door
Switch the ignition on and off three times
Close the door twice
Switch the ignition on and off twice
Press the keyless entry button 6 times.
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)
20.10.2012
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33
BCM Sentrallås Keyless
Receiver unit
Location: attached to the dash panel reinforcement.
Supplier: Panasonic Electronic Devices Japan Co. Ltd.
A
A
Section A-A
While all doors are closed (without super lock) or while
doors 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.
Door close
Door open
A
Receiver unit
signal @ A6
CH1
0V
Antenna
B
Door unlock
control @ B10
CH2
0V
Scale: CH1 2V/div
CH2 5V/div
500ms/div
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34
BCM Sentrallås Keyless
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.
Door open
Door close
C
Receiver unit
signal @ A6
CH1
0V
D
Door lock control
@ B11
Battery cover
CH2
0V
CR1620 lithium battery
Scale: CH1 2V/div
CH2 5V/div
500ms/div
Transmitter
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.
20.10.2012
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35
BCM Sentrallås Keyless
SRS
control
unit
C22
BCM
Deployment
signal (PWM)
VEHICLE SPEED LINKED DOOR LOCK FUNCTION (MODEL
WITH SRS AIRBAG)
IP
cluster
A8
CAN high
signal
A18
CAN low
signal
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 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
-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)
20.10.2012
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36
BCM Sentrallås Keyless
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 unit
outputs 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.
-Scan Tool Data List•SRS Airbag Deployment Signal: SRS airbag deployment state from the SRS control
unit
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
37
BCM Alarm
Time since door locking
with remote key
Normal operation
Stay ON
(standby)
Engine hood open
Fast brinks
First 10 seconds
Slow brinks (armed)
Goes OFF
After 10
seconds
-Scan Tool Data List•Door Lock Actuator Position Switch: Door lock/
unlock position feedback switch input state from
the door lock
•Anti-theft Indicator Lamp: Anti-theft indicator
lamp command state
•Anti-theft Horn: Anti-theft horn command state
•Engine Hood Switch: Engine food switch input
state
20.10.2012
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 condition
The 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.
Kurs Isuzu D-Max 2012 rev. A
38
BCM Belysning
-Scan Tool Data List•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 lamp
command 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
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 minutes
elapsed to prevent battery discharge.
Cabin
Battery voltage
Battery voltage
Door switch (closed @ door open)
Dome
light
Map
lights
Room
(10A)
Meter
(10A)
Door
open
indicator
lamp (IP
cluster)
C25
BCM
20.10.2012
High side
control
+B (via room lamp
10A fuse)
B16
Low side
control
Driver’s door
Key
reminder
switch
(closed @
key in)
C19
Door
open
indicator
lamp
control
Kurs Isuzu D-Max 2012 rev. A
A9
Key
remained
switch
signal
A12
Door
switch
signal
A2
Door switch
signal (with
super lock)
39
BCM
SUMMARIZED TABLE FOR PROGRAMMING ON THE BCM
Relating to
BCM
Remote Key
When replacing to new one or transferred (swapped)
Notice
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
1. Remote key registration by Remote Keyless Entry Transmitter
Registration.
2. Transponder key programming must be performed separately at the
Immobilizer menu.
-
Notice!
Non-programmed BCM will cause: _________________
DTC B1001 to set.
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Kurs Isuzu D-Max 2012 rev. A
40
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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41
ANDRE NYHETER
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42
Elektriske vinduer
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.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
43
Gasspedalsensor
Gasspedalsensor er endret fra kontakt-type (potentiometer) til kontaktløs (hallsensor) for å gi bedret nøyaktighet.
RT56
TF190
APP sensor
Accelerator pedal
bracket
only two
connectors
sensor
+ pedal =
one unit
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44
Aircondition
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
RT56
+85 mm
Condenser
+109 mm
Refrigerant: 134a
Mengde: 480-580 gram
Compressor
- 0.8kg
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45
Kondenser
•Kondenseren kjøler gass med høyt trykk og temperatur
som kommer fra kompressoren slik at gassen
kondenserer til flytende væske.
•Modulatoren sepparerer kjølemediet i gass og flytende form
og sender flytende kjølemedium til “subcooler”.
•Ved å bruke tørkemiddel og et filter, fjerner modulatoren
fuktighet og fremmedpartikler fra kjølemediet.
•“Subcooler” kjøler ned væsken ytterligere for å øke kjølemediets entalpi.
Drivstoffforbruk:
The drier/ filter is now inculduded
in the condenser
The fan was deleted
from 12 MY
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
ca 0,25 -1,0 liter pr time.
46
Aircondition
RT56
TF190
Manuell type
Auto type
Interiør temperatur sensor plassert under rattet
Sol sensor plassert midt oppe på dashbordet
20.10.2012
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47
SRS
Roof rail airbag
(RRAB)
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.
Side airbag
(SAB)
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48
SRS
The system consists of:
1
1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
2
6
4
5
3
6
Front G-Sensor
Combination switch with SRS coil
Driver airbag
SRS control unit
Passenger airbag
Door pressure sensor
Side airbag
Pretensioner seat belt
Roof airbag
Side G-Sensor
Compared with the current model, the
following senors are new:
7
7
8
8
9
• 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.
9
10
10
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49
SRS
1. Right side Front
G-Sensor
2. Left side Front
G-Sensor
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.
1
The same sensor type is used for the front GSensor and the side G-Sensor.
2
These sensors send signals to the SRS control
unit.
Side G-Sensor
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50
SRS
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 optimal
pressure conditions for the door pressure sensor.
1
1. The pressure between the door
outer panel and door inside panel,
2. Door pressure sensor
3. Water proof
2
20.10.2012
3
Kurs Isuzu D-Max 2012 rev. A
51
Scan Tool data
20.10.2012
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52
Seter
For å tilfredstille Euro-NCAP (New Car Assessment Program)
Anti whiplash nakkestøtte
• Hodet presses mot nakkestøtten ved kollisjon bakfra.
• For å redusere skader (whiplash), blir nakkestøtten presset
mot hodet.
Bevegelse forover og opp.
(opp: 30 mm, forover: 25 mm)
Beltevarsler passasjersete
Når sensoren i setet detekterer vekt over 15 kg, varsles det med lys og
lyd fra 20 km/t.
Starting speed: 20 km/h
Strarting weight: 15 kg
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53
MOTOR
4JK1-TCY
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54
Motor
(Kw/Nm)
(Kw/Nm)
Effekt: 120 kW @ 3600 rpm
Moment: 400 Nm @ 1400 – 2000 rpm
20.10.2012
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55
Motor
Hastighetsbegrenser på 180 km/h, kan ikke slås av.
2000 rpm
1400 rpm – 3600 rpm = område på 2200 rpm
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56
Motor 4JK1 Hi Hi Euro 5
• Motor
Større EGR kjøler,
EGR Bypass System
– Nyheter
To-Steg Turbo System
Økt innsprøytningstrykk
(200 MPa)
Større
Katalysator
Endret design
av forbrenningskammer
DPD (Diesel Particulate
Defuser)
20.10.2012
Frontmontert
og større Intercooler
Kurs Isuzu D-Max 2012 rev. A
57
Oljefilter
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.
RT56
4JJ1, Euro 4 (gjeldende modell)
Oljetrau
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58
EGR kjøler
EGR-kjøler for å øke EGR volum:
- EGR bypass ventil:
Lav motorbelastning  Varm EGR
Høy motorbelastning  Kald EGR
TF190
Tube type
RT56
Layer type
EGR cooler
EGR pipe
EGR valve
EGR bypass valve
Inlet manifold
Varm EGR
Kald EGR
Veksler fra varm til kald EGR ved:
35° C
20.10.2012
Adapter
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59
EGR ventil
Børsteløs type EGR-Valve
Kommuniserer med ECM via CAN-Bus
Control unit
Magnet
Hall IC
Rotor
Operation control part
Hall IC
Bearing
Stator
Motor shaft
Return Spring
Magnet
Stator
Valve rod
Rotor
Pin Number
1
2
3
4
20.10.2012
Pin name
CAN_H
CAN_L
GND
Power
Kurs Isuzu D-Max 2012 rev. A
60
Dobbel Turbo
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.
Boost pressure
High pressure turbo
12 MY
Current model
Engine revolution
Ved å øke mengde EGR reduseres utslippene av NOx.
Normal
flow
Bypass
valve open
Low pressure turbo
Fresh air
Fresh air
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Kurs Isuzu D-Max 2012 rev. A
compression
61
Dobbel Turbo
Høytrykksturbo
Høytrykksturbo
Lavtrykksturbo
20.10.2012
Lavtrykksturbo
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62
Dobbel Turbo
Systemoversikt
20.10.2012
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63
Turbo (lavt turtall)
“Compressor bypass”, “turbine bypass” (og wastegate) er lukket. Begge turboer lader i serie.
20.10.2012
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64
Turbo (mellom turtall)
I mellomturtalls-/mellomlastområdet jobber begge turboer fortsatt, men her begynner “turbin bypass” å
regulerer.
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65
Turbo (høyt turtall 1/3)
Når utgangstrykket på lavtrykksturboen overstiger forespurt trykk vil “compressor bypass” åpne. Samtidig er
“turbine bypass” fullt åpen.
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66
Turbo (høyt turtall 2/3)
For å beskytte turboen ved høy hastighet og belastning, regulerer wastegate.
20.10.2012
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67
Turbo (høyt turtall 3/3)
Low rotation area
Middle rotation area
High rotation area
Turbine bypass
valve
Lukket
Regulerer
Åpen
Compressor
bypass valve
Lukket
Lukket
Åpen
Wastegate
valve
Lukket
Lukket
Regulerer
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68
Dyser og stempel
(Solenoid)injektor
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
4JK1-HiHi
Nozzle hole diameter
0.112 mm
Stempelring
Materialet i stempelring nr. 2 er endret for å gi bedre driftsikkerhet.
2. stempelring
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69
Glødeplugger
Keramiske glødeplugger.
Årsak: Euro 5, lavere utslipp, redusert kompresjon.
Batteri
Glødeplugg
styreenhet
・Produsert av Bosch
・Spenningsnivå: 7V
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70
Glødeplugger
Keramiske glødeplugger
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71
Glødeplugger
Keramiske glødeplugger
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72
Glødeplugger
Keramiske glødeplugger
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 av
kjølevæsketemperatur.
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73
Glødeplugger
Keramiske glødeplugger
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74
Andre endringer motor
Drivstoffilter
2
Endringer:
• ECM
• Drivstoffilter
• Radiator/
Intercooler
• Luftfilter
• DPD
20.10.2012
3
Radiator/
Intercooler
Kurs Isuzu D-Max 2012 rev. A
75
Plassering ECM
ECM er nå flyttet inn i bilen (bak hanskerommet til høyre).
TF190
RT56
ECM
TCCM
TCM (AT)
DRM er en del
av ECM
DRM
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76
Dieselfilter
Drivstoffilteret er flyttet for å lette vedlikeholdet.
Drivstoffilter
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.
Håndpumpe
Drivstoff
trykkbryter
Vann-sensor
Element
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77
Kjølesystem
Intercooleren er flyttet. Den har også blitt større.
2.5 & 3.0 L Hi engine: + 30 mm
+ 51 mm
20.10.2012
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78
Motorstyring 1/2
AIR
INLET
AIR CLEANER
MAF & IAT SENSOR
TEMP SENSOR
INJECTOR
INTER COOLER
GLOW RELAY
GLOW CONTROLLER
THERMOSTAT
BATTERY
WATER TEMP SENSOR
EGR GAS TEMP SENSOR
GLOW PLUG
BATTERY
TO RADIATOR
BOOST SENSOR
#1
VSV
EGR VALVE
INTAKE
THROTTLE W/TPS
#2
#3
#4
TO VAC.PUMP
PRESS. RELIEF VLV
EGR COOLER
COMMON RAIL
FUEL PRESS. SENSOR
VSS
VSV
FUEL COOLER
TO VAC.PUMP
EXH.TEMP SENSOR
TO VAC.PUMP
FUEL
PRESS.SW
SUPPLY PUMP
EVRV
CAM ANGLE SENSOR
VSV
TO VAC.PUMP
SCV
HIGH PRESSURE
TURBO
TO METER
OIL PRESSURE SW
CRANK ANGLE
SENSOR
FUEL FILTER&
SEDIMENTOR
WATER.SW
PRE FUEL FILTER
EVRV
FUEL TEMP.
SENSOR
TO VAC.PUMP
FUEL TANK
TO METER
FUEL LEVEL
LOW PRESSURE
TURBO
EXH TEMP
SENSOR 2
EXH PRESSURE SENSOR
IN&OUT
VSV★
DOC
FILTER
FUEL LEVEL
SENSOR
EXH TEMP
SENSOR 3
CSF
BARO SENSOR
EXHAUST
THROTTLE★
EXH TEMP SENSOR 1
EXH.GAS
TO VAC.PUMP
ECM
(Engine Control Module)
ACCEL SENSOR 1&2
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79
Motorstyring 2/2
1. TEMP SENSOR.
Tempsensor for luft fra turbo sitter nær ekspansjonstanken for kjølevæske. Denne måler temperaturen før intercooler og
kontrollerer trykket for turboaggregat.
2. EGR TEMP SENSOR 2
EGR temperatursensor sitter mellom EGR ventilen EGR-kjøler/bypass-ventil (etter kjøler) og måler temperaturen på eksosgassen for
å regulere bypass-ventilen.
3. EGR TEMP SENSOR 1
Eksostemperatursensor på eksosmanifold overvåker temperaturen før turbo og EGR ventil.
1
TEMP SENSOR
INTER COOLER
THERMOSTAT
2
WATER TEMP SENSOR
EGR GAS TEMP SENSOR
TO RADIATOR
BOOST SENSOR
VSV
TO VAC.PUMP
EGR VALVE
INTAKE
THROTTLE W/TPS
EGR COOLER
VSS
3
VSV
EXH.TEMP SENSOR
TO VAC.PUMP
TO VAC.PUMP
EVRV
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80
Partikkelfilter DPD
Ny modell D-Max har fått partikkelfilter, DPD (Diesel Particulate Defuser). Katalysator og DPD er separate
komponenter.
TF190
RT56
DPD Produsent: TOKYO ROKI
Co., LTD
Produsent : NGK
SIZE : ф118.4 X 91.4 (quantity:2)
Materiale : Cordierite
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81
Systemoversikt
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 running
regeneration is requested to the driver by the
blinking DPD-Lamp on the instrument panel
cluster.
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82
Systemoversikt
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 the
exhaust 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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83
Komponenter
The exhaust temperature sensor 1 is installed to the
DPD housing.
Exhaust temperature sensor 2
The exhaust temperature sensor 2 and 3 are
installed to the converter housing.
The sensor 1 detects the temperature of the
exhaust gas in the DPD front to protect the DPD.
Exhaust temperature sensor 3
Exhaust temperature sensor 1
The sensor 2 and 3 are used to determine the post
injection start.
When the exhaust gas temperature is cold, the
sensor resistance is high and the ECM detects high
voltage (NTC).
-Scan Tool Data Displays-
Following data can be observed on the scan tool.
• Exhaust Temperature 1 2 3 ( °C / °F)
• Exhaust Temperature Sensor 1 2 3 (Volts)
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Komponenter
1
2
1. Differential pressure hose front
port
2. Differential pressure hose
rear port
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 as
follows:
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.
Output (Volts)
4.5
●
-Scan Tool Data Displays1.0
Following data can be observed on the scan tool.
• Exhaust Differential Pressure (kPa/ psi)
●
0
100
Exhaust Differential Pressure (kPa)
20.10.2012
• Exhaust Differential Pressure Sensor (V)
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85
DPD varsellampe
Name
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:
Symbol
DPD lamp
Message
DPD PM level
DPD regeneration
state
20.10.2012
Display indication
• 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.
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86
Oljefortynning
Oil level gauge
MIN
Refill MAX
(Hole)
(Hole)
Inspection
MAX
(Stamp on
X)
20.10.2012
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 to
be changed.
4. After checking the oil level, put the oil dipstick
back to the original position.
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87
TB50LS
AISIN AW TB50-LS
Automatic Transmission
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88
TB50LS
1
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 the
shift 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.
2
3 4
5
7
6
9
8
10
12
13
11
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.
4WD
14
15
16
17
2WD
20.10.2012
1.
2.
3.
4.
5.
6.
7.
8.
9.
Kurs Isuzu D-Max 2012 rev. A
Torque converter housing
Torque converter
C2 clutch
C3 clutch
C1 clutch
One way clutch 2
B3 brake
One way clutch 1
B1 brake
10.
11.
12.
13.
14.
15.
16.
17.
B2 brake
One way clutch 3
B4 brake
Output shaft
Input shaft
Oil pump
Valve body
Extension housing
89
TB50LS Time Lag Test
4. Let idle and record the time lag from when the selector
lever is moved from N to D or N to R range until the
shock has felt.
Standard Value
Selector lever position
Time lag
N to D range
Less than 0.7 seconds
N to R range
Less than 1.2 seconds
< CAUTION >
1. Make sure to take 3 measurements and take the
average value.
2. Make sure to keep interval for more than 1 min
between time lag tests (That purpose is to remove
clutch / brake pressure left unfinished.)
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
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 ))
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
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
90
TB50LS Måle operasjonstrykk
Line
pressure
Engine
idle
"D"
"R"
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
1.
Filler Test hole for line 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.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
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 D
the 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
91
TB50LS Kontroll av oljenivå 1/4
(1)
(1)
(2)
(3)
2WD
(3)
4WD
(4)
(5)
Parker bilen på flatt gulv, og sett girvelger i posisjon “P”.
(Kontrollprosedyre startes med kald ATF olje).
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.
Fyll på 500 ml ATF olje på girkassen gjennom
påfyllingshull (se bilde).
Kortslutt terminalene 12 (terminal for
diagnoseforespørsel) og 4 eller 5 (4 og 5 er jord) i DLC
kontakten (diagnosekontakten).
”Check Trans” varsellampe lyser.
Start motoren.
Påfyllingsplugg
(4)
DLC terminal
4 5
12
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
92
TB50LS Kontroll av oljenivå 2/4
Utfør følgende punkter (punkt 6 og 7) for å bekrefte at
oljetemperaturen er i området merket blått (se under) hvor
oljetemperaturen kan justeres.
(6)
(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:
<SLUKKER>
(Blått område)
ATF er i området hvor temperaturen kan justeres.
GÅ TIL NESTE PUNKT
<LYSER>
(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.
<BLINKER>
(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.
(7)
Varsellampe for ATF temperatur
ATF Temperature
Engine
℃
35
36
37
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
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
4JJ1-HiHi
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
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
93
TB50LS Kontroll av oljenivå 3/4
(8) Etter å ha bekreftet at temperaturen er i riktig område (blått),
hvor temperaturen kan justeres, kan temperaturøkningsprosedyre og nivåkontroll starte.
For å få ATF temperaturen i området for nivåkontroll, utfør
følgende 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.
<Varsellampe slukker>
(Blått område)
ATF er under temperatur for nivåkontroll.
KAN IKKE GÅ TIL NESTE PUNKT
Start igjen fra punkt b.
<Varsellampe lyser>
(Grønt område)
ATF temperatur er i området for nivåkontroll.
Om lampen fortsetter å lyse i 1 minutt, fortsett til neste punkt.
Hold i 5 sekunder
og sett girvelger i ”N”
Om lampen lyser mindre enn 1 minutt, start igjen fra punkt b.
<Varsellampe blinker>
(Rødt område)
ATF olje for varm.
KAN IKKE GÅ TIL NESTE PUNKT
Vent til ATF oljen er kald og start deretter fra punkt 5
Varsellampe for ATF temperatur
ATF Temperature
Engine
℃
35
36
37
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
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
4JJ1-HiHi
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
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
94
TB50LS Kontroll av oljenivå 4/4
(9)
(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.
Nivå (overflow) plugg
(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.
(10)
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
95
GIRKASSE
AY6
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
96
AY6
2WD model
The new manual transmission AY6 is adopted
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.
Model
Supplier
Dry weight (kg)
Transmission type
Control type
Gear ratio
1st
2nd
3rd
4th
5th
6th
Reverse
Oil
4WD model
AY6
AISIN AI CI.,LTD
56,2
Fully synchronized forward
and reverese gear
Direct control with gear shift lever
5,232
2,644
1,606
1,219
1,000
0,728
4,525
75W-90 GL5　(1.8L)
Shift patterm
Clutch size
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
Ф275
97
AY6
9
5
10
8
6
2
1
11
7
3
4
19
18
20
17
12
20.10.2012
13
16
14
15
Kurs Isuzu D-Max 2012 rev. A
21
1. Revers gear lamp switch
2. Clutch housing
3. Clutch housing bolt
4. Clutch housing hole plug
5. Breather
6. Reverse idler gear
7. Reverse idler gear bearing
8. Reverse idler gear shaft
9. Intermediate case
10. Oil separater
11. Drain plug
12. Oil trough
13. Oil seal
14. Tapered bearing race
15. Rear case housing
16. Fill plug
17. Shift shaft detent plug & spring & pin
18. Rear output shaft seal
19. Oil trough
20. Extension housing
21. Neutral switch
98
AY6
Input reduction type manual transmission
3 2
4
1
R
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 is
located 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”.
5
Approx. 1.6
times
Input reduction
AY6 : Output reduction type manual transmission
R
1
2
4
3
6
5
Output reduction
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
99
Clutch
When
disengaged
When
engaged
3
1
4
2
Push
1. Clutch disc
2. Clutch pressure plate
3. Clutch cover
4. Diaphragm spring
The clutch assembly consists of a clutch pressure
plate, a clutch cover, a diaphragm spring drive pin and
clutch disc.
The clutch pedal is connected to the release bearing
assembly via the shift fork.
The clutch disc is installed between the flywheel and
clutch pressure plate. A push-type clutch is adopted
in AY6 transmission.
When the clutch pedal is pressed, the shift fork
moves toward the release bearing assembly.
The force applied to the release bearing assembly
exceeds the diaphragm spring force and the clutch
disc is released from the flywheel and clutch pressure
plate to disengage the clutch.
Clutch type
Size (mm/ in)
Pressure plate
Outside diameter (mm/ in)
275 (10.83)
275/ 10.83
Inside diameter (mm/ in)
180/ 7.09
Free thickness (mm/ in)
9.2/ 0.35
Compressed thickness (mm/ in)
8.5/ 0.33
Driven plate
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
100
TRANSFERKASSE
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
101
Transferkasse
Transfer:
Transferkassen overfører trekkraft til
forakselen.
Transferkassen har også et reduksjonsgir.
4WD bryteren er nå plassert i
midtkonsollen og styrer transferkassen.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
102
Transferkasse, fra 2H til 4H
2H
4H
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
103
Transferkasse, fra 4H til 4L
4H
4L
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
104
Transferkasse, operasjonsbryter
Drive type
2WD
2H
4WD
4H (4WD high)
4L (4WD low)
4WD switch
Indicator light
OFF
Model with MID
Driving conditions
20.10.2012
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.
Kurs Isuzu D-Max 2012 rev. A
Steep slopes,
rough roads,
sand, mud or
deep snow, and
other roads where
the vehicle needs
significant
traction.
105
Transferkasse, operasjonsbryter
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 til
100 km/h.
For å velge 4L, stopp bilen, sett girkassen i fri, trykk ned og vri 4WD
bryteren med klokken.
For å koble ut 4L igjen, stopp bilen og trykk og vri 4WD bryteren mot
klokka.
Tauehastighet i 2H er: 30 km/h
Tauedistanse er: 80 km
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
106
TCCM, feilkoder
DTC
B2725
C0306
C0316
C0327
C0390
C0391
C0563
C0867
C0868
U2104
U2105
20.10.2012
Symptom
Mode switch circuit
Motor A or B Circuit
Axle motor circuit
Limit switch circuit malfunction
Transfer 4WD switch circuit low
Transfer 4WD switch circuit high
ROM checksum error
System voltage input low
System voltage input high
CAN bus reset counter overrun
Lost communication with ECM
Kurs Isuzu D-Max 2012 rev. A
107
BREMSER/ESC
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
108
ESC
CAN LINE for scan tool
Scan tool
Tire
Tire
Switch ESC OFF
Fluid
line
Master cylinder
pressure sensor in
EHCU
Sensor
Yaw rate
Meter
Sensor
Steering
angle
Warning lamp for ABS & EBD
& ESC
Indicator lamp for TCS & ESC
EHCU
Electrical
line
10 Solenoid
Master
vac
Rear brake right and left
independence
Master
cylinder
New wheel
speed sensor
Wheel speed sensor
Tire
20.10.2012
Wheel speed sensor
Brake wheel cylinder
Kurs Isuzu D-Max 2012 rev. A
Tire
109
ESC
<Actuator control>
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
<Speed sensor input>
Front left wheel speed sensor
Front right wheel speed sensor
Rear left wheel speed sensor
Rear right wheel speed sensor
<Sensor input>
G sensor (4WD For ABS & EBD)
YAW & G sensor (For ESC)
Steering Sensor
Master cylinder (M/C) pressure sensor
EHCU
<Switch input>
Ignition switch
Brake pedal switch
ESC (TCS) cut off switch
<Lamp control>
ABS warning lamp
Brake (EBD) system warning lamp
ESC system warning lamp
ESC cut off Illumination lamp
TCS cut off Illumination lamp
<Output>
Vehicle speed pulse
<Communication>
CAN
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
110
ESC
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”
EHCU location
For ABS / EBD / TCS
/ESC
(1)
(2)
(3) (4) (5) (6)
20.10.2012
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 cylinder
5. To rear right wheel cylinder
(Without ESC :Dummy hole)
6. To rear left wheel cylinder
(Without ESC : To rear wheel cylinder)
Kurs Isuzu D-Max 2012 rev. A
111
ESC
vehicles with ESC
Terminal
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Terminal name
Ground (solenoid valve)
Brake switch signal
CAN low 2 signal (local)
Wheel speed sensor rear left signal
Wheel speed sensor rear left 12 volts reference
Wheel speed sensor front right signal
Wheel speed sensor front right 12 volts reference
Not used
Not used
Not used
Vehicle speed signal output
Battery voltage (solenoid valve)
Ground (motor)
CAN low signal
CAN high 2 signal (local)
Wheel speed sensor rear right signal
Wheel speed sensor rear right 12 volts reference
20.10.2012
Terminal
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Terminal name
Wheel speed sensor front left signal
Wheel speed sensor front left 12 volts reference
Not used
Not used
Not used
Not used
Battery voltage (motor)
CAN high signal
Not used
Not used
Not used
Not used
ESC OFF switch signal
Not used
Not used
Diagnostic request switch
Ignition voltage
Kurs Isuzu D-Max 2012 rev. A
112
ESC
ECM
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 the
controller area network (CAN) link. Following signals are communicated
via a CAN bus.
EGR valve
TCM
Yaw rate
G sensor
DRM
TCCM
<EHCU and ECM >
• Injection volume reduction signal (with ESC model)
(EHCU→ECM)
• Accelerator pedal position signal (with ESC model)
(ECM→EHCU)
Steering
angle sensor
EHCU
<EHCU and TCCM>
• Transfer case range ( High / Low)
ICU
12V
<EHCU and IP cluster>
• 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
SRS
BCM
Auto A/C
CAN communication
EHCU local CAN communication
IP cluster
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
113
ESC
The wheel speed sensors use a hall IC type
sensor.
3
1
3
1. Front wheel speed sensor
2. Rear wheel speed sensor
3. Connector
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.
4
5
5
2
4
4. Wheel speed sensor
5. Sensor rotor
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
114
ESC
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.
Without ABS
With ABS
EHCU
Four wheel speed sensors
Vehicle Speed Sensor
4 pulse
by hard wire
4 pulse
by hard wire
ECM
100ms by CAN
Cluster
TCM
TCCM
SRS
4 pulse
by hard wire
Audio / DVD
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
115
ESC
1
The steering angle sensor is placed in the
steering column part. This sensor detects the
sheering's angle and direction, and sends the
signal to EHCU by CAN (Local CAN).
2
3
1. SRS coil assembly
2. Steering angle sensor
3. Large gear
4. Detection gear
5. Magnet
6. Sensor
4
• 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.
4
5
when following actions are made, 0 point
learning for the steering angle sensor must be
performed:
6
-Scan Tool Data DisplaysFollowing data can be observed on the scan
tool.
•Steering Sensor Centered Status
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
116
ESC
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.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
117
ESC
Left
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
1. G sensor
2. Yaw rate sensor
3. Yaw rate sensor
assembly
Forward
G detection
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)
Right
and ESC controls suitable brake force and engine
torque.
Backward
Rotating angular speed
YAW rate
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
118
ESC
When Canceling the TCS:
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.
TCS OFF indicator lamp
ESC OFF indicator lamp
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
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
119
ESC
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
120
ESC
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
121
ESC
Control
Lamps
Disable：Prohibition control
○：Lighting、 △：Blink
ABS/ESC　Mode
ABS
E-TCS
B-TCS
ESC
TCS
OFF
EBD
ABSW/L
TCS OFF ESCOFF
ESCW/L
BRKW/L
○
ESC&TCS
Failed
Disable Disable Disable
ABS&ESC&TCS
Failed
Disable Disable Disable Disable
○
○
ABS&EBD&ESC&TCS
Failed
Disable Disable Disable Disable Disable
○
○
○
Initial check
check
CAN Communication
Failed
Disable Disable Disable
○
○
○
○
○
○
○
○
○
○
• 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.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
122
Endringer bremser
Diameter på bremseskivene foran på 4X2 Hi-ride og 4X4 er endret for å gjøre
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:
Master cylinder:
8+9 inch Twin → 10.5 inch Single
Ф25.4 cylinder → Ф22.22 cylinder
Reservoartanken er den samme for bremser og clutch.
Current model
12MY
Bremsepedalen er endret for å øke sikkerheten.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
123
RAMME/FJÆRER
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
124
Ramme
Sterkere
Ny D-Max
• Økt tverrsnitt/styrke på rammevanger
90 x 173.6 mm
• Ekstra “bjelker” mhp kollisjonssikkerhet
• Deformasjonssone i front
Tidligere D-Max
89 x 138.9 mm
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
125
Ramme
The following items has been changed to improve the impact
performance:
1.) 150 mm expansion of the forward end
Addition of the two cross member s
Addition of the front brace
2.) The wheel base has been extended
3.) To obtain more clearance for the riding comfort this value has been upped to 29 mm.
(1)
(1)
(2)
(3)
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
126
Hjuloppheng foran
4X4
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”
RT56
TF190
Uavhengig dobbel wishbone
med spiralfjærer
Upper link
gas shock
absorber
Torsjonsfjæring
Stabilizer
Lower link
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
127
Endringer hjuloppheng bak
Fjærene bak er endret for å øke kjørekomfort.
TF190: Under slung
RT56: Over slung
(1) Ved å endre boltøyet er fjærene forlenget (nå: 1360 mm)
Current
shackle
type
Front Rear
Soft type
Berlin eye
Leaf suspention
Hard type
Up turn eye
Leaf suspention
20.10.2012
12MY shackle type
Front
Rear
Berlin eye Up turn eye
Berlin eye Up turn eye
+ 160 mm
Kurs Isuzu D-Max 2012 rev. A
128
4WD off-road egenskaper
– Inngangsvinkel
• 30o
– Utgangsvinkel
• 22.7o
– Sidevinkel
• 49o statisk
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
129
STYRING
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
130
Servopumpe
Servopumpe med variabel kapasitet er innført for 4JK1 (og 4JJ1).
Engine
4JA1/H1
Current model
STD
4JJ1/K1
Hi
Blue : Current model
Drive type
Pulley drive
Gear drive
Engine
Current model
4JA1/
4JJ1/K1
Drive type
Pulley drive
Remark
C/O
STD
Gear drive
Hi/Hi Hi
Variable capacity
Red : 12MY
A
En konvensjonell pumpe gjør mye arbeid unødvendig. Området
merket A indikerer det unødvendige arbeidet.
En variabel pumpe reduserer belastningen på motoren og forebygger
økning i servooljetemperatur.
Følgen av dette er redusert drivstofforbruk.
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
131
Servopumpe
Ved lave hastigheter:
(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)
Control valve
Valve chamber A
(Pink room of control valve)
Valve chamber B
(Red room of control valve)
20.10.2012
Control valve spring
Kurs Isuzu D-Max 2012 rev. A
132
Servopumpe
Ved høy hastighet:
(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 passasjen C.
(4) ATF-olje fra ventilkammeret B strømmer til kamvolum b via C.
(5) Kamringen presses til høyre av trykket fra kamvolum b.
Control valve
Control valve spring
Cam ring
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
133
Tannstang
The following items has been changed for 4X2 and 4X4 drive system.
(1) Expansion of the tie rod end
(2) Improvement and expansion of the steering gear
The ball diameter of the eye ball joint has been changed from φ28 to φ30 to improve the durability.
Eye ball joint
(2)
(2)
+4mm
4x2
+6mm
+26mm
20.10.2012
(1)
(1)
4x4
Kurs Isuzu D-Max 2012 rev. A
+20mm
134
Rattaksel
The steering adjustment type has been changed to reduce cost and weight.
The tilt fixed method has been changed to the clamp type.
Current model
1
12MY
2
70 mm
Gear type
20.10.2012
40 mm
Clamp type
Kurs Isuzu D-Max 2012 rev. A
135
MELLOMAKSEL
BAKAKSEL
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
136
Mellomaksel
The following items have been changed to adopt the over slung suspension.
(1) Expansion of the spline york
(2) Improvement of the center bearing
(3) Expansion of the shaft end
(4) Expansion of the york
 The following items has been changed to reduce the noise from the transmission and diff.
(5) Improvement of the tube diameter and thickness for shaft.
2
１
Φ: -6 mm.
T: + 0.4mm
4
5
5
+ 7mm
+ 20mm
+ 12.5 mm
3
+7mm
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
137
Bakaksel
The length of the rear axle case and axle shaft has been extended for expansion of the tread.
Tread
4x2
4x4 & 4x2 HI-RIDE
20.10.2012
Current
1460
1520
12MY
1510
1570
Kurs Isuzu D-Max 2012 rev. A
138
SERVICE
VEDLIKEHOLD
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
139
Vedlikeholdsskjema 1/2
×1,000 km 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Odometer reading or months,
×1,000 miles 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 whichever comes first
Engine oil
R
R
R
R
R
or every 24 months
Engine oil filter
R
R
R
R
R
or every 24 months
Engine oil leakage and contamination
I
I
I
I
I
I
I
I
I
I
or every 12 months
Engine idling speed and acceleration
I
I
I
I
I
I
I
I
I
I
or every 12 months
Fan belt tension and damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Exhaust system
I
I
I
I
I
I
I
I
I
I
or every 12 months
All hoses and pipes in engine compartment for clog of damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Valve clearance
I
I
or every 48 months
or
every 12 months : I
Air cleaner element
I
I
I
R
I
I
I
R
I
I
or every 48 months : R
Fuel filter
Replace the fuel filter when the fuel filter warning light comes on
Fuel tank
I
I
I
I
I
or every 24 months
Draining water separator
Drain the fuel filter when the water separator warning light comes on
Engine coolant concentration
I
I
I
I
I
I
I
I
I
I
or every 12 months
Engine coolant
Every 24 months (when Isuzu recommended coolant is used) : R
Cooling system for water leakage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Clutch fluid
I
I
I
I
I
I
I
I
I
I
or every 12 months
Clutch pedal travel and play
I
I
I
I
I
I
I
I
I
I
or every 12 months
Manual transmission oil
I
I
I
I
I
or every 24 months
Transfer case oil
R
R
R
R
R
or every 24 months
Manual transmission and transfer case oil leakage
I
I
I
I
I
or every 24 months
Gear control mechanism for looseness
I
I
I
I
I
or every 24 months
[AT] Automatic transmission fluid
I
or every 60 months
[AT] Transfer case oil
R
R
R
R
R
or every 24 months
[AT] Automatic transmission and transfer oil leakage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Propeller shaft loose connections
I
I
I
I
I
I
I
I
I
I
or every 12 months
Propeller shaft universal joints and splines for wear
I
I
I
I
I
I
I
I
I
I
or every 12 months
[4WD] Universal joints and sliding sleeve
L
L
L
L
L
L
L
L
L
L
or every 12 months
Initial 10,000km or 12 months : R
Differential gear oil (Front and rear)
R
I
R
I
R
I
or every 24 months : I
or every 48 months : R
Front and rear axle oil leakage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Shift on the fly system gear oil
I
I
I
I
I
I
I
I
I
I
or every 12 months
Front axle shaft boot for damage
I
I
I
I
I
or every 24 months
Axle case for distortion or damage
I
I
I
I
I
or every 24 months
Axle shafts for distortion or damage
I
I
I
I
I
or every 24 months
or every 12 months : I
Power steering fluid
I
I
I
R
I
I
I
R
I
I
or every 48 months : R
Power steering oil leakage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Steering system for looseness or damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
or every 12 months : I
Power steering hose
I
I
I
I
I
I
I
R
I
I
or every 96 months : R
Service Interval
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
140
Vedlikeholdsskjema 2/2
×1,000 km 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Odometer reading or months,
×1,000 miles 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 whichever comes first
or every 12 months
Steering wheel play
I
I
I
I
I
I
I
I
I
I
or every 12 months
Steering function
I
I
I
I
I
I
I
I
I
I
or every 24 months
Right and left turning radius
I
I
I
I
I
or every 24 months
Wheel alignment
I
I
I
I
I
or every 12 months
Steering Joint ball for oil leakage or damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Steering Joint ball rubber boot for damage
I
I
I
I
I
I
I
I
I
I
or every 24 months
Brake fluid
I
I
I
I
I
or every 12 months
Brake system for fluid leakage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Brake function
I
I
I
I
I
I
I
I
I
I
or every 12 months
Front Disc brake pads and discs wear
I
I
I
I
I
I
I
I
I
I
or every 12 months
Rear brake lining and drum wear
I
I
I
I
I
I
I
I
I
I
or every 12 months
Brake pedal travel and play
I
I
I
I
I
I
I
I
I
I
or every 12 months
Brake pipes and hoses for loose connections or damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Parking brake function
I
I
I
I
I
I
I
I
I
I
or every 12 months
Parking brake lever travel
I
I
I
I
I
I
I
I
I
I
or every 12 months
Parking brake cables for looseness or damage and guide for damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Ratchet for wear or damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Leaf/Coil springs for damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Suspension mount for looseness or damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Shock absorbers for oil leakage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Shock absorbers mount for looseness
I
I
I
I
I
I
I
I
I
I
or every 12 months
Rubber bushes of suspension wear or damage
I
I
I
I
I
I
I
I
I
I
or every 24 months
Spring action for loss of balance due to weakening
I
I
I
I
I
or every 12 months
Suspension joint ball rubber boot for damage
I
I
I
I
I
I
I
I
I
I
or every 12 months
Wheel nuts
T
T
T
T
T
T
T
T
T
T
or every 12 months
Wheel disc for damage
I
I
I
I
I
I
I
I
I
I
or every 36 months
Front hub bearing grease
R
R
R
or every 12 months
Front and rear hub bearing for looseness
I
I
I
I
I
I
I
I
I
I
or every 12 months
Tire air pressure and damage
I
I
I
I
I
I
I
I
I
I
Tire rotation
Rotate as required
or every 12 months
Other bolts and nuts on chassis and body
I
I
I
I
I
I
I
I
I
I
Air conditioning fillter
or every 12 months
R
R
R
R
R
R
Service Interval
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
141
Vedlikeholdsskjema spesielle kjøreforhold
Driving condition
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on salted roads
E: Towing trailer or climbing mountain frequently
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
142
Valg av oljer
Mengde:
Motor:
Motorolje inkl. filter
Kjølevæske manuell
Kjølevæske automat
Girkasse:
Manuell girkasse (AY6):
Automatgirkasse (TB50-LS):
Transferkasse:
Differensialer:
Foran:
Bak:
Servo:
DEXRON III
Clutch- / Bremsevæske: DOT 3
20.10.2012
7,3 liter (Valvoline ProFleet LS 10W-40 (CJ-4))
10,2 liter
10,7 liter
1,8 liter (75W-90 GL5)
10,7 liter (Valvoline MaxLife)
1,3 liter (Motorolje SJ eller bedre)
1,24 liter (75W-90 GL5)
2,2 liter (75W-90 GL5 LS)
1 liter
Kurs Isuzu D-Max 2012 rev. A
143
ELEKTRISK
KOMPONENTPLASSERING
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
144
Plassering av sikringer og releer
Fuse and relay locations:
Instrumental panel
The fuses and relays are inside the cab and the engine compartment.
No.
1
2
3
4
20.10.2012
Relay name
ACCESSORY SOCKET
REAR DEFOGGER
HEATER CUT
POWER WINDOW
Kurs Isuzu D-Max 2012 rev. A
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Fuse name
KEY INT LOCK
CIGAR LIGHTER
AUDIO
ELEC IG2
H/LAMP LEVELING
TURN LIGHT
TRAILER
SEAT HEATER
BLANK
BACK LIGHT
ENGINE IG
METER
TCM
4WD
ABS
FRT WIPER
SRS
DRL
ELEC IG1
ACC SOCKET
DOOR LOCK
BLANK
STARTER
BCM
AUDIO (+B)
ROOM
4WD (+B) 1
METER (+B)
BLANK
POWER SEAT
RR DEF
POWER WINDOW
145
Rating
10A
15A
10A
10A
10A
10A
10A
15A
15A
10A
10A
15A
10A
10A
20A
10A
10A
10A
15A
20A
10A
10A
15A
10A
10A
10A
20A
20A
30A
Plassering av sikringer og releer
Fuse locations: Engine compartment
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
HEATER
ECM MAIN
GLOW
STARTER
DRL1
STARTER CUT
HEAD LIGHT DIMMER
HEAD LIGHT
TAIL LIGHT
FOG LIGHT
HORN
A/C COMPRESSOR
THERMO
REAR FOG LIGHIT
5
6
8
9
10
11
12
13
2
14
1
3
4
7
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Description
H/LIGHT RH LO
H/LIGHT LH LO
PCV HEATER
ENGINE
RR FOG LIGHIT
TRAILER
ESC
FRT FOG LIGHT
BLANK
STOP LIGHT
HAZARD
HORN
ACG(S)
TCM_B/DRM_B
H/LIGHT LH HI
H/LIGHT RH HI
TAIL LIGHT LH/ILLUMI
TAIL LIGHT RH
A/C
MAIN
IG-2
GLOW
BLOWER
ABS_1/ESC_1
ECM
ABS_2/ESC_2
IG-1
Rating
10A
10A
10A
10A
10A
20A
10A
15A
15A
15A
10A
10A
10A
10A
10A
10A
10A
10A
120A
60A
60A
30A
50A
40A
30A
40A
146
Plassering av styreenheter
20.10.2012
Kurs Isuzu D-Max 2012 rev. A
147