Land Rover Range Rover Automatic Transmission System Rover Manual
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© Rover Group 1997 Automatic Transmission Syste m Informat ion Document Range Rover Automatic Transmission System Information Document APPLICABILITY1995-1997 Range Rover DATE OF REVISION 1997
Page 1 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - System Information Model: 1995-97 Range Rover See page 8 for SRO and time for Electrical Symptom diagnosis The diagnosis of automatic transmission faults requires that the technician take a systematic ap- proach to the determination of the fault involved. There are two systems involved; the mechanical operation of the transmission and the electronic control of the transmission via the Transmission Control Module (TCM). It is important to realize that a mechanical problem can set a Diagnostic Trouble Code (DTC) and also that an electronic failure can produce a mechanical symptom. The following flowchart will help to direct you to the area requiring investigation first. The information following the chart is split into 2 key areas: System Information Electrical Symptoms NO DOES VEHICLE MOVE ? IS MIL ON P1775? REFER TO ELECTRICAL DIAGNOSIS PAGES 8 THRU 24YES YESNOMECHANICAL PROBLEM SEEK HELP LINE ASSISTANCE IF NECESSARY Mechanical Controls The ZF 4HP22/24 automatic transmission is basically the same as the previous ZF automatic transmission with the addition of electronic control over the pressure regulator, torque converter lockup and shift valves. Mechanical selection of Park, Reverse, Neutral and Drive is the same on both Mechanical and Electronic Transmissions. This allows the vehicle to be operated in Limp Home Mode if the elec- tronic controls fail. The mechanical diagnosis of the transmission is the same as before and would require the same repair procedure. Electronic Controls Refer to the following schematic to graphically demonstrate the interconnection of the various control units used in the operation of the electronically controlled transmission.
Page 2 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - System Information Model: 1995-97 Range Rover Schematic 1 MV1MV2TC LOCKPRESSURE LRLR 32 15 17 34 18 35 16 33 KRKUKNKBBG NBNBNBNB MILInstrument Pack C4 C31 A27 A29C27 A23 A22 C7 BeCM GEMS Serial Link H Gate C617 X Y Z Vehicle SpeedEngine Speed MILFuel LevelP1607 P0460/1( ) ( ) ABS TCU C603TCM 19 17 32 31 7 30 1350 29 Output Shaft Speed Sensor Motor Encoder 14 19 5 24 42 6 20 2 38 32 47 213 (ECU 2/28) (1/9/10) Front Rear Road Wheel SensorsRU (30/31) (20)(6)(7)(13)(22) (24/27) 123 Output Shaft Speed SensorFuel Level Sensor Torque Throttle Angle YOTransfer FaultTorque SP Reduction Speed (23) P1775/6/7 (5/12) (26) P1701/3/8 REG. 46 29 MES 31 16 28 29 Vehicle Speed( ) P0500 C114 PIN 11 28 C1 Rough Road Misfire Detection Inhibit P1317/8 C112 PIN 13C112 PIN 9C114 PIN 5C112 PIN 14 8 10 7 65 4 3 33 Engine Speed( ) (21) Fuel Level P1199/P0460/1 97 MY MES 1MES 2 C626 PIN 18C626 PIN 9C626 PIN 8C626 PIN 5C626 PIN 16C626 PIN 11C114 PIN 10 PARK NEUTRAL POSITION SWITCH (PNPS) 15 51 A C626 PIN 1C626 PIN 12 DIAG `LDIAG `K A 35 HI/LOW C23 13 C255 PIN 8 14 C255 PIN 17 DIAG `LDIAG `K PIN 7 PIN 15DLC C231 Note: A number preceded by a P, for example P1775, relates to fault codes stored in GEMS if the signal/component fails. A number in parenthesis, for example (23), relates to fault codes stored in the TCM if the signal/component fails.
Page 3 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - System Information Model: 1995-97 Range Rover Economy, Sport and Manual Modes The TCM has various different driving modes available, with Economy being selected automati- cally on start up. When the vehicle is in High range, Sport mode can be selected. Sport mode makes gear change much more sensitive to throttle movement, thereby shifting down earlier and holding onto lower gears longer than Economy mode. If the vehicle is in Low range, then the manual mode can be selected. Manual mode will make the transmission change to the gear se- lected as quickly as possible and hold onto that gear at all speeds, i.e. if ª3º is selected, then the gear box will not shift down to ª2º or ª1º as the vehicle slows down. It will only shift down to pre- vent the vehicle from stalling. In addition to the manual mode of operation in low range, the Economy mode is also different than that of the High range Economy mode. This Economy mode has to be different because of the low ratio the transfer box employs, thus causing a torque multiplication, which increases the need to change the shift points and ignition retard points. The shift points will also be modified by the vehicle speed in relation to the engine rpm to ensure shifts at the best points for fuel economy. Interface with Engine Control Module (ECM), see schematic 1 The TCM takes the engine torque, engine speed and throttle angle signals from the ECM and cal- culates which gear is required. The TCM then provides outputs to the solenoid valves and sends a torque reduction signal back to the ECM. The ECM then retards the ignition point on each of the cylinders, resulting in a reduction in engine power to produce smoother shifts. If the TCM detects a fault that affects emissions levels, the TCM has the ability to output a ªCheck Engineº request to the ECM. The TCM does this by sending a signal to the ECM on the ignition retard request line. When the ECM receives this signal, it knows that it is a request to illuminate the ªCheck Engineº light and not a ignition retard request. The reason the ECM handles the ªCheck Engineº request is because the TCM does not have the ability to illuminate a ªCheck Engineº light directly. When the ECM receives this signal, it will flag a DTC P1775 immediately and illuminate the ªCheck Engineº light. Interface with TCM and Park Neutral Position Switch (PNPS), see schematic 1 The PNPS is mounted on the side of the transmission and contains five internal switches, al- though only three, known as the ªXYZº switches, are used by the TCM. The other two switches are for reverse selection and start inhibit, neither of which is required by the TCM. By analyzing the status of the ªXYZº switches, the TCM calculates which gear has been selected. If a fault oc- curs with a switch, the TCM may try to put the transmission into a different gear than requested.
Page 4 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - System Information Model: 1995-97 Range Rover Interface with Body electronic Control Module (BeCM) , see schematic 1 The BeCM provides power to the TCM via an ignition feed fuse F6 and a permanent feed via fuse F3. In addition to power, the BeCM also routes the engine speed signal that the GEMS ECM outputs and the diagnostic K/L lines that go to the Data Link Connector (DLC). The TCM, ECM, HEVAC, ABS and BeCM are all attached to the same K/L lines in the DLC. The TCM also uses the Manual Economy Sport (MES) lines to signal to the BeCM what mode of operation it is in. If a fault condition occurs, these lines will remain high (battery voltage minus 2 volts) to indicate to the BeCM that the TCM has encountered some form of failure. The BeCM uses this information to send a ªGEARBOX FAULTº message to the instrument pack message center. The BeCM also receives the gear position switch information to allow it to display the currently se- lected gear on the message center. However, it too does not need the reverse selection or starter inhibit switch positions as it can determine this information from the status of the ªXYZº switches. The MES lines are also connected to the H-Gate so that the currently selected gear can be indi- cated by a ªred dotº on the shifter mechanism. Interface with the Transfer Box Control Unit (TCU) , see schematic 1 The High/Low signal is used by the TCU to select the correct mode on application of the ªMESº switch lines, i.e. Economy or Sport modes in High range and Economy or Manual modes in Low range. Shift points are very different in the Economy mode in the High/Low ranges. In addition, it should also be noted that cruise control does not function when in low range. Cruise control is controlled by the BeCM and not the TCM. Solenoid Valves The TCM has control over four solenoid valves: MV1 (shift valve 1), MV2 (shift valve 2), pressure regulator and torque converter lock up. The power for all the solenoids comes from the TCM via pin 19; this power is controlled by an in- ternal relay. If any fault occurs which needs limp home capability, the TCM will interrupt the power supply. Interupting the power supply defaults the transmission to third if the vehicle was stationary and fourth if the vehicle was moving. Figure 1 shows the transmission electrical connections and the resistance across all pins. The transmission electrical connector is located on the left hand side of the transmission about 8 inches from the rear of the gear position switches. Shift Valves When the driver selects Drive, the TCM controls the gear selection by the use of the two solenoid valves, MV1 and MV2. If a fault occurs in one or both of these valves, then a different gear than the one selected will result. If the TCM defaults the transmission, then the common supply to all the solenoid valves is removed and the transmission mechanically shifts either to third gear, if the vehicle is stationary, or fourth, if moving. MV2 is also used to prevent the driver from selecting re- verse when the vehicle is moving at more than 8 km/h ( 5 mph) and from disengaging at reverse speeds greater than 6 km/h (4 mph). This is known as ªReverse Safetyº and will not be available if MV2 is non-operational or the transmission is defaulted. Figure 1 shows the transmission electri- cal connections and the resistance across all pins.
Page 5 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - System Information Model: 1995-97 Range Rover Pressure Regulator Solenoid The gear shift quality is controlled by modulating the pressure regulator, which is controlled by the TCM. The solenoid is powered closed, so that if a failure occurs, then the regulator will allow de- fault gear change. Figure 1 shows the transmission electrical connections and the resistance across all pins. Torque Converter Lock-Up Solenoid The torque converter slips to allow smooth operation of the transmission. Lock-up occurs when the vehicle reaches a speed of 48-72 km/h (30-45 mph), depending on model year, in either third or fourth gears. Figure 1 shows the transmission electrical connections and the resistance across all pins. Output Shaft Speed Sensor The automatic transmission system incorporates an output shaft speed sensor which is an input to the TCM. This is a two wire shielded input and enables the TCM to compare input shaft speed (engine speed) with the output shaft speed. This comparison is used to determine which gear is currently selected and allows the TCM to ac- curately determine the upshift/downshift points and the duration of the shift, ensuring smooth gear shifts under all conditions. Figure 1 shows the transmission electrical connections and the resis- tance across all pins. B -PRESSURE REGULATOR E -ROAD SPEED SENSOR +VE F -ROAD SPEED SENSOR ±VE H -MV1 SOLENOID K -MV2 SOLENOID L -MVWK SOLENOID M -SOLENOID SUPPLY BEFHKL M B± O/C O/C 32 32 37 5 EO/C ± 320 O/C O/C O/C O/C FO/C 320 ± O/C O/C O/C O/C H32 O/C O/C ± 53 58 26 K32 O/C O/C 53 ± 58 26 L37 O/C O/C 58 58 ± 32 M5 O/C O/C 26 26 32 ± ± O/C = OPEN CIRCUIT ± FIGURES SHOWN ARE TYPICAL VALUES OF RESISTANCE TRANSMISSION ELECTRICAL PINOUTS (MATING FACE) H B K MJ F E
Page 6 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - System Information Model: 1995-97 Range Rover PIN FUNCTION 1 Rough Road Detected 2 Cam Sensor 3Ð 4 Low Range Detected 5Ð 6Ð 7 Fuel Level 8 HO2S Bank B Upstream 9Ð 10 Knock Sensor Ground 11 Knock Sensor A 12 Knock Sensor B 13 Air Temperature 14 Coolant Temp 15 Throttle Position 16 Mass Air Flow 17 HO2S Bank A Downstream 18 Park/Neutral 19 Ð 20 Diagnostic L Line 21 Heated Front Windshield 22 Ð 23 Diagnostic K Line 24 Ð 25 Ð 26 Immobilization 27 Vehicle Speed 28 A/C Request 29 Condenser Cooling Fan Request 30 Fuel Pressure (97.5 MY) 31 Ignition Retard Request (PWM) 32 O2 Sensor Ground 33 HO2S Bank B Downstream 34 HO2S Bank A Upstream 35 Fuel Temp 36 Sensor GroundPIN FUNCTION 1 A/C Grant 2 Fuel Used 3 Condenser Cooling Fan 4Ð 5Ð 6 Canister Vent Solenoid (97.5 MY) 7Ð 8Ð 9Ð 10 Ð 11 Injector, Cyl 3 12 Ð 13 Injector, Cyl 1 14 Ð 15 IACV-D 16 IACV-B 17 Injector, Cyl 6 18 Injector, Cyl 8 19 Purge Valve 20 Ð 21 Oxygen Sensor Heater Upstream 22 MIL 23 Engine Speed output 24 Fuel Pump 25 Ð 26 Ð 27 Throttle Position (PWM) 28 Oxygen Sensor Heater Downstream 29 Engine Torque (PWM) 30 Injector, Cyl 4 31 Ð 32 Injector, Cyl 7 33 Injector, Cyl 5 34 IACV-C 35 IACV-A 36 Injector, Cyl 2 18 136 1 1 36 121313122 5 72413 62512 24 CONNECTOR B (POWER) C509 (18-BLACK)CONNECTOR A (OUTPUTS) C505 (36-BLACK) CONNECTOR C (INPUTS) C507 (36-RED) PIN FUNCTION 1 Coil Driver Cyls 5&8 2Ð 3Ð 4 TPS 5V Supply 5 Ground 6Ð 7 Main Relay Supply 8 Ignition Sense 9 Ground 10 Ground 11 Crank Sensor Neg 12 Crank Sensor Pos 13 Coil Driver Cyls 2&3 14 Coil Driver Cyls 1&6 15 Coil Driver Cyls 4&7 16 Ground 17 Main Relay Control 18 Ð GEMS CONNECTOR LAYOUT
Page 7 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - System Information Model: 1995-97 Range Rover 1 20 38 PIN FUNCTION 1 Ignition Supply 2 Vehicle Speed Sensor Positive 3 Engine Speed 4Ð 5 Solenoid Valve MV2 6 Pressure Regulator Solenoid 7 Digital Ground 8Ð 9Ð 10 Ð 11 Ð 12 Ð 13 Ð 14 Gear Position Switch-Y Line 15 Diagnostic L Line 16 MES 1 17 Ð 18 Ð 19 Solenoid Valves Supply 20 Earth (Screens) 21 Engine Torque (PWM) 22 Ð 23 Ð 24 Solenoid Valve MV2 25 Ð 26 Power Ground 27 Ð 28 Ð PIN FUNCTION 29 MES Mode Select 30 Ð 31 MES 2 32 Torque Reduction Request (PWM) 33 Gear Position Switch - Z Line 34 Ð 35 Ð 36 Ð 37 Ð 38 Vehicle Speed Sensor Negative 39 Permanent 12V Supply 40 Ð 41 Ð 42 Torque Convertor Solenoid 43 Ð 44 Ð 45 Ð 46 Transfer Box High/Low 47 Throttle Position Input (PWM) 48 Ð 49 Ð 50 Gear Position Switch - X Line 51 Diagnostic K Line 52 Ð 53 Ð 54 Ð 55 Ð C601 TCM CONNECTOR LAYOUT 55 37 19
Page 8 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - Electrical Symptoms SRO/Time: Model: 1995-97 Range Rover 19.22.97 - TestBook hookup access codes, compete DTCR and diagnostic drive cycle ªBº per bulletin W96-007 1.05 hrs. TestBook 1. Hookup TestBook and follow directions to retreive fault codes in line with service bulletin W96-007. 2. Complete a DTC refport and fax to LRNkA. 3. Follow diagnostic directions from TestBook in order to locate problem. 4. Use the following information to help investigate the fault condition. DTC DTC NAME FAULT DESCRIPTION OBD MONITORING CONDITIONS TRIP OCCURRENCES TO MIL GEARBOX FAULT MESSAGE LIMP HOME DEFAULT 1 FTGR Solenoid supply malfunction Run engine above 1600 rpm for more than 1 sec. Switch engine off 2 Y Limp home in third if stationary, fourth if moving. 2 FEPROM TCM data corrupted Run engine for more than 180 secs. 1 Y Limp home in third if stationary, fourth if moving. 5 FDKI Throttle angle malfunction Start engine and run at idle. 2 Y Substitute throttle angle of 30% 6 FMV1 Shift solenoid A malfunction Drive through all gear ranges. 2 Y Limp home in third if stationary, fourth if moving. 6 FMV1 Shift solenoid A electrical short Drive through all gear ranges. 2 Y Limp home in third if stationary, fourth if moving. 7 FMV2 Shift solenoid B malfunction Drive through all gear ranges. 2 Y Limp home in third if stationary, fourth if moving. 7 FMV2 Shift solenoid B electrical short Drive through all gear ranges. 2 Y Limp home in third if stationary, fourth if moving. 9 FPRGANGZ1 Mode output 1 Operate Mode switch in high and low range with the ignition on N/A N No default condition 10 FPRGANGZ2 Mode output 2 Operate Mode switch in high and low range with the ignition on N/A N No default condition 12 FDKT Throttle angle electrical short Start engine and run at idle. 2 Y Substitute throttle angle of 30% 13 FMVWK TCC circuit output state does not match command state Drive vehicle at a steady speed of 55 mph (88.5 kph) or above. 2 Y Limp home in third if stationary, fourth if moving. 20 FPLUSMV Solenoid supply malfunction Run engine above 1600 rpm for more than 1 sec. Switch engine off 1 Y Limp home in third if stationary, fourth if moving. 21 FN_MOT Engine speed signal high out of range Start engine 1 Y Limp home in third if stationary, fourth if moving. 21 FN_MOT Engine speed, no signal Drive vehicle above 10 mph (16 kph). 1 Y Limp home in third if stationary, fourth if moving. 22 FDR Pressure control regulator malfunction Drive through all gear ranges. 2 Y Limp home in third if stationary, fourth if moving. 22 FDR Pressure control regulator electrical short Drive through all gear ranges. 2 Y Limp home in third if stationary, fourth if moving.
Page 9 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - Electrical Symptoms Model: 1995-97 Range Rover DTC DTC NAME FAULT DESCRIPTION OBD II MONITORING CONDITIONS TRIP OCCURRENCES TO MIL GEARBOX FAULT MESSAGE LIMP HOME DEFAULT 23 FME Engine torque reduction Drive through all gear ranges. 2 Y Poor shift quality ± maximum pressure on shifts 24 FRSS Output speed sensor signal out of range Drive vehicle and accelerate to force a downshift. 2 Y Limp home in third if stationary, fourth if moving. 26 FT_T Engine torque signal out of range Start engine and run at idle. 2 Y Poor shift quality ± maximum pressure on shifts 27 FFSTBR Output speed sensor, no signal Drive forward at an rpm greater than 2200. 2 Y Limp home in third if stationary, fourth if moving. 28 FEPROM TCM data corrupted Run engine for more than 180 secs. 1 Y Limp home in third if stationary, fourth if moving. 30 FPOS Gear position switch inaccurate while running Start engine. Operate gear selector momentarily through all ranges. 2 Y Limp home in third if stationary, fourth if moving. 31 FPOSST Gear position switch inaccurate while starting Start engine. Operate gear selector momentarily through all ranges. 2 Y Limp home in third if stationary, fourth if moving. 40 FGANG1 (97 MY) First gear ratio incorrect Drive vehicle forward, held in first fear to above 2500 rpm. 2 N Limp home in third if stationary, fourth if moving. 41 FGANG2 (97 MY) Second gear ratio incorrect Drive vehicle forward and ensure all upshifts occur 2 N Limp home in third if stationary, fourth if moving. 42 FGANG3 (97 MY) Third gear ratio incorrect Drive vehicle forward and ensure all upshifts occur 2 N Limp home in third if stationary, fourth if moving. 43 FGANG4 (97 MY) Fourth gear ratio incorrect Drive vehicle forward and ensure all upshifts occur 2 N Limp home in third if stationary, fourth if moving. 44 FWK (97 MY) TCC gear ratio incorrect Drive vehicle forward and ensure converter lockup occurs in 3rd and 4th. 2 N Limp home in third if stationary, fourth if moving. Note: Limp home mode differs depending upon the selected range of the transfer box. If High range is selected, then the default condition is third if stationary and fourth if moving when the fault occurred. Low range default conditions will vary depending on the fault. If a fault occurs while in Low range, change to High range and verify that the fault can be induced. FAULT CORRECTIVE ACTION TRIP OCCURANCES TO MIL CHECK ENGINE Transfer Box Fault ± Low Range Status ± High Range Status GEMS Faults ± P1775 ± P1776 ± P1777 Check for correct range change occurring Check wiring between TCM, GEMS or BECM N/A 1 2 1 N Y Y Y