Land Rover Range Rover Automatic Transmission System Rover Manual
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Page 20 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - Electrical Symptoms Model: 1995-97 Range Rover REPAIR Check the gear position on the PRNDL, message center and from the gearbox diagnostic in the real time monitor section on TestBook. Verify they all return the same information as the lever is moved through all possible combinations. Check mechanical selector for correct positioning. CODE: 40 FGANG1, First gear ratio incorrect (97 MY onwards) EFFECT: Limp home in third or fourth DESCRIPTION During normal operation, the TCM will monitor the input speed and output speed to determine if the transmission is operating in the gear selected. The TCM will compare the ratio between the calculated input speed and the output speed with the value for first gear stored in ROM. If this val- ue is incorrect, the TCM will store code 40 for a first gear ratio fault. CAUSE Selected transmission gear has an incorrect ratio compared to its known value. See mechanical diagnosis. Incorrect input/output shaft speeds being sensed. REPAIR Transmission may need replacing. Check input/output speed signals for correct operation. CODE: 41 FGANG2, Second gear ratio incorrect (97 MY onwards) EFFECT: Limp home in third or fourth DESCRIPTION During normal operation, the TCM will monitor the input speed and output speed to determine if the transmission is operating in the gear selected. The TCM will compare the ratio between the calculated input speed and the output speed with the value for second gear stored in ROM. If this value is incorrect, the TCM will store code 41 for a second gear ratio fault. CAUSE Selected transmission gear has an incorrect ratio compared to its known value. See mechanical diagnosis. Incorrect input/output shaft speeds being sensed. REPAIR Transmission may need replacing. Check input/output speed signals for correct operation.
Page 21 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - Electrical Symptoms Model: 1995-97 Range Rover CODE: 42 FGANG3, Third gear ratio incorrect (97 MY Onwards) EFFECT: Limp home in third or fourth DESCRIPTION During normal operation, the TCM will monitor the input speed and output speed to determine if the transmission is operating in the gear selected. The TCM will compare the ratio between the calculated input speed and the output speed with the value for third gear stored in ROM. If this value is incorrect, the TCM will store code 42 for a third gear ratio fault. CAUSE Selected transmission gear has an incorrect ratio compared to its known value. See mechanical diagnosis. Incorrect input/output shaft speeds being sensed. REPAIR Transmission may need replacing. Check input/output speed signals for correct operation. CODE: 43 FGANG4, Fourth gear ratio incorrect (97 MY onwards) EFFECT: Limp home in third or fourth DESCRIPTION During normal operation, the TCM will monitor the input speed and output speed to determine if the transmission is operating in the gear selected. The TCM will compare the ratio between the calculated input speed and the output speed with the value for fourth gear stored in ROM. If this value is incorrect, the TCM will store code 43 for a fourth gear ratio fault. CAUSE Selected transmission gear has an incorrect ratio compared to its known value. See mechanical diagnosis. Incorrect input/output shaft speeds being sensed. REPAIR Transmission may need replacing. Check input/output speed signals for correct operation. CODE: 44 FWK, TCC gear ratio incorrect (97 MY onwards) EFFECT: Limp home in third or fourth At predetermined speeds, the TCM will lock the converter clutch via the TCC solenoid; this occurs in third and fourth gears thereby giving a direct drive through the transmission. Once the convert- er is locked up, the TCM will compare the input speed and output speed of the transmission and verify if the gear ratio is the same as the one stored internally. If not, the TCM will store code 44.
Page 22 of 24 Automatic Transmission Diagnostics - Electrical Symptoms TRANSFER BOX CONTROL UNIT (TCU) INDIC ATES LOW RANGE TRANSFER BOX CONTROL UNIT (TCU) INDIC ATES HIGH RANGE
Page 23 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - Electrical Symptoms Model: 1995-97 Range Rover REPAIR If the shift into low range does not take place, check TCU connector C603 pin 35 and TCM con- nector C601 pin 46 for 0V in high range and greater than 10V when in low range. Check the TCU for signs of overheating or a burning smell. If evident, replace the TCU. Make sure the motor is in good condition before powering up with the new TCU as a failed motor will damage the new TCU. GEMS P1775 code EFFECT: ªCHECK ENGINEº light on DESCRIPTION This code confirms the existence of a stored TCM fault code. The fault is flagged when the Pulse Width Modulation (PWM) signal on the ignition retard line has a duty cycle of between 10% and 14% for 100 ms or longer. CAUSE If the fault is permanent and not intermittent, then the ignition retard value can be viewed by Test- Book through the Real Time Monitoring section under the Switches and Status icon. A normal val- ue of 17% should be shown if the fault is not present at the time of viewing. A value of 10% - 14%, for example 12%, would indicate that the TCM fault is currently present. REPAIR Diagnose the TCM, retrieve the fault codes and follow the diagnosis for the stored faults. GEMS P1776 code EFFECT: ªCHECK ENGINEº light on DESCRIPTION The ignition retard line from the ECM to the TCM will have a PWM signal to identify any ignition retard requests during normal operation of the TCM. The values for this signal are: 17% to indicate ignition retard is not active. 20% to 90% to indicate 0 to 27.8 retard. CAUSE During normal operation if the ignition retard request exceeds 4 seconds, then P1776 will be flagged. This can also be caused by a variety of electrical connector/terminal problems between the ECM and TCM.
Page 24 of 24 1-13 Operation Pride Automatic Transmission Diagnostics - Electrical Symptoms Model: 1995-97 Range Rover REPAIR Check the following connectors for any signs of loose connectors, lack of terminal tension, water ingress, terminals backed out or dirt/corrosion on the terminals: In-line connector C551 (near coil pack) pins 4, 5 and 6 ECM connectors C505 pins 27 and 29 and C507 pin 31 If nothing was found during this inspection and the fault is still present, check in-line connector C659 pins 1, 7 and 9 under the center console for any similar connector problems. GEMS P1777 code EFFECT: ªCHECK ENGINEº light on DESCRIPTION The ignition retard line from the ECM to the TCM will have a PWM signal to identify any ignition retard requests during normal operation of the TCM. This line will also indicate a fault condition when the TCM sends a PWM of less than 10% or greater than 93%. CAUSE This can also be caused by a variety of electrical connector/terminal problems between the ECM and TCM. REPAIR Check the following connectors for any signs of loose connectors, lack of terminal tension, water ingress, terminals backed out or dirt/corrosion on the terminals: In-line connector C551 (near coil pack) pins 4, 5 and 6 ECM connectors C505 pins 27 and 29 and C507 pin 31 If nothing was found during this inspection and the fault is still present, check in-line connector C659 pins 1, 7 and 9 under the center console for any similar connector problems.
System Information Document ________________________________________________________________________\ ____________________________ [Revision: 2.3] ________________________________________________________________________\ ____________________________ _ © Rover Group 1998 Page 1 of 52 ZF - 4HP22EH -4.0l V8 vehicles 4HP24 -4.6l V8 vehicles BOSCH - GS8.87.0 -99MY Discovery Series II GS8.87.1 -99MY Range Rover 4 Speed Electronic Automatic Transmission System APPLICABILITY: 99MY Discovery Series II - 4.0 Petrol and 2.5 Turbo Diesel 99MY Range Rover - 4.0l and 4.6l Petrol Vehicles 99MY Range Rover Diesel transmissions are not covered by this document DATE: 19th May 1998
System Information Document ____________________________________________________________________________________________________ _ [ZF_4SPD\Project_Specs][Revision: 2.3] ____________________________________________________________________________________________________ _ © Rover Group 1998Page 2 of 52 INDEX 1INTRODUCTION.................................................................................................................................3 1.1GENERAL.......................................................................................................................................................................3 2VEHICLE INTERFACE REQUIREMENTS....................................................................................4 2.1BLOCK DIAGRAM..........................................................................................................................................................4 2.2INTERFACE SPECIFICATION............................................................................................................................................5 2.2.1Gear Shift Solenoids................................................................................................................................................................5 2.2.2Controller power supply..........................................................................................................................................................6 2.2.3Serial information - inputs.......................................................................................................................................................7 2.2.4Serial information – outputs....................................................................................................................................................7 2.2.5Digital inputs...........................................................................................................................................................................7 2.2.6Digital outputs.......................................................................................................................................................................13 2.2.7Analogue inputs.....................................................................................................................................................................14 2.2.8Diagnostic interface...............................................................................................................................................................15 2.3ECU CONNECTOR PIN-OUT.........................................................................................................................................16 2.4VEHICLE CONNECTOR PIN OUTS...................................................................................................................................17 2.4.1Diagnostic Connector............................................................................................................................................................17 2.4.2Harness to Position switch (mounted on Transmission).........................................................................................................17 2.4.3Harness to Solenoid Valves (mounted on Transmission)........................................................................................................17 3DESCRIPTION OF FUNCTIONALITY..........................................................................................18 3.1SPECIAL FEATURES......................................................................................................................................................18 3.1.1Sport Mode............................................................................................................................................................................18 3.1.2Manual Mode.........................................................................................................................................................................18 3.1.3Towing / Driving up steep gradients......................................................................................................................................18 3.1.4Compensation for reduced engine torque..............................................................................................................................18 3.1.5Calibration Selection (99MY V8 Range Rover Only).............................................................................................................18 4FAULT FINDING...............................................................................................................................19 4.1FIXING FAULTS............................................................................................................................................................19 4.1.1The transmission ECU is disconnected..................................................................................................................................19 4.1.2The transmission has diagnosed a fault.................................................................................................................................19 4.1.3Power to the ECU has been lost or K line not connected.......................................................................................................19 4.2MIL LIGHT ILLUMINATION (N.A.S. VEHICLES ONLY)...................................................................................................20 5FAULT CODES..................................................................................................................................21 5.1AMBIENT CONDITIONS STORED....................................................................................................................................21 5.2FAULT CODES DESCRIPTIONS.......................................................................................................................................21 5.3IMPACT ON THE SYSTEM OF EACH FAULT.....................................................................................................................30 6GENERAL INFORMATION............................................................................................................31 6.1DIMENSIONS AND FIXING DETAILS...............................................................................................................................31 6.2VOLTAGE REQUIREMENTS...........................................................................................................................................31 7FAULT TREE ANALYSIS................................................................................................................32
System Information Document ____________________________________________________________________________________________________ _ [ZF_4SPD\Project_Specs][Revision: 2.3] ____________________________________________________________________________________________________ _ © Rover Group 1998Page 3 of 52 1 Introduction 1.1 General This document is intended to be a guide to the BOSCH Transmission controllers for the ZF 4 Speed Automatic Transmission unit incorporating the Torque Converter (4HP22). The information contained within gives the outline functionality, architecture and electrical specification. There should also be enough information to diagnose any system fault, which is complemented with a fault diagnosis tree.
System Information Document ____________________________________________________________________________________________________ _ [ZF_4SPD\Project_Specs][Revision: 2.3] ____________________________________________________________________________________________________ _ © Rover Group 1998Page 4 of 52 2 Vehicle Interface requirements 2.1 Block Diagram The Diagram below shows a summary of the vehicle architecture with reference to the Automatic Transmission Controller. For more detail, please refer to the following pages. CAN LowBOSCH GS8.87 Transmission ECUZF 4HP22 Automatic TransmissionPosition SwitchBOSCH ME 5.2.1or THUNDEREngineManagementPressure Regulator Solenoid Valves Output Speed 9 Z (L4, GS8.87.0) W (L1) Y (L3)X (L2) 15 14 425 33 32 30 378 36 16 4426 54 Permanent power supply Ignition power supply High / Low range MES 2 (Mode output)Mode (Sport / Manual)51 45 13Power Supply - Pressure Regulator & Solenoid valves 53 286Power Ground Ground ElectronicsDiagnostics K-wire31 CAN High MES 1 (Mode output)25