torque JAGUAR XJ6 1994 2.G Electrical Diagnostic Manual

Automatic Transmission (AJ16) w
8.1.1 ZF 4HP 24 E TRANSMISSION, SYSTEM DESCRIPTION
The electronic transmission system fitted to normally aspirated 4.0 liter vehicles comprises the following components:
0 ZF 4HP 24 E Automatic Transmission
0 Rotary selector switch
0 Electronic Transmission Control Module
0 Decoder Module
0 Performance Mode Switch
0 Kickdown Switch
0 Gear Selection Illumination Module
System control is effected by the transmission control module (TCM), located behind the passenger side fascia, which
continuously monitors requests made by the drivervia the gearselector, throttle pedal etc. This data is used
inconiunc- tion with the speed input from the transmission and inputs from the engine management system, to calculate optimum
shift points and control parametersfor shift pressure and ignition retardation to enhance shift quality and reduce trans-
mission unit wear.
TheTCM is also able to detect faults within the system and store the relevant fault codes for interrogation with diagnos-
tic equipment.
Gear shifts are controlled by three solenoid valves, and
a pressure control regulator, located on the valve block within
the transmission unit assembly. If a serious fault occurs, the TCM removes all electrical power from these valves and
the transmission system reverts to a mechanical default condition. This condition allows only mechanical selection
of reverse and one forward gear, either third or fourth, depending on prevailing conditions at the time of the default.
The decoder module receives inputs from the rotary switch and decodes these to drive one of six possible outputs,
illuminating the correct gear indicator on the gear selector illumination module.
The performance mode switch and kick
-down switch are used to adjust transmission operation as required by the
driver. Performance mode selection, made via a switch mounted on the gear selector mechanism surround, can be
either NORMAL, for everyday use, or SPORT, for enhanced performance. Kick
-down is activated by a switch mounted
below the accelerator pedal and is used to initiate a downward gear change, increasing torque and acceleration.
8.1.2 COMPONENT DESCRlPTIONS
Transmission Unit
The ZF 4HP 24 E automatic transmission unit houses the three solenoid valves which control gear shifts. A pressure
control valve is also located on the solenoid valve block. These four valves initiate and control shift patterns within
the transmission unit by regulating fluid flow.
Rotary Selector Switch
The seven position rotary gear selector switch is mounted on the LH side of the transmission unit and indicates gear
selection to the TCM and decoder module.
Transmission Control Module
The electronic transmission control module regulates gear changes by controlling the operation of the transmission
unit solenoid valves, and monitoring the state of other vehicle systems which have an effect on torque demand, vehicle
speed etc. The module also interfaces with the engine management system, climate control system, body processor
unit and ABS
I traction control system.
Connections from the TCM are listed on the following page.
X300 EDM 1 Issue 1 August 1994

Automatic Transmission (AJ16)
8.1.3 DIAGNOSTIC FAULT CODES
The following codes are stored within the TCM whenever a fault is detected on the system. The codes can be accessed
using Jaguar Diagnostic Equipment or a hand held, proprietary scan tool.
Code Description
MIL Indication Page No.
P 0603 Internal control module memory error MIL on 26
P 0605 Internal control module ROM test error
MIL on 26 I P 0702 Transmission control system electrical MIL on 5
P 0705 Transmission range sensor circuit malfunction MIL on 6
P 0706 Transmission range sensor circuit range / performance MIL on 6
8
8
P 0712 Transmission fluid temperature sensor low input -
P 0713 Transmission fluid temperature sensor high input -
P 0721 Output speed sensor circuit range / performance MIL on 10
P 0722 Output speed sensor circuit no signal MIL on 10
P 0726 MIL on 12
P 0727 1 Engine speed input circuit no signal MIL on 12
P 0743 Torque converter clutch system electrical MIL on 14
P 0748 Pressure control solenoid electrical MIL on 14
' Engine speed input circuit range / performance
P 0753 Shift solenoid A electrical MIL on 14
P 0758 Shift solenoid B electrical MIL on 14
P 1608 TCM watch-dog fault MIL on 26
P 1780 Torque reduction signal malfunction - 16
P 1781 Torque signal malfunction - 16
P 1782 Traction control input electrical - 18
P 1785 Transmission fault lamp malfunction - 20
P 1790 TP signal system range / performance MIL on 21
P 1791 TP electrical signal system MIL
on 21
P 1792 Sport mode indicator - 23
P 1794 System voltage malfunction MIL on 24
P 1796 Kickdown switch system - 24
t: Codes which do not cause the MIL to illuminate cannot be read by the hand-held scan tool as they are not SA€ P- generated.
I. Transmission Control Module (TCM)
2. Transmission Unit
3. TCM Multi-pin Connector
4. Transmission Rotary Switch
5. Transmission Connector Plug
6. Engine Control Module
7. Instrument Pack
8. ABS /Traction Control Control Module
9. Kickdown Switch
Issue 1 August 1994 4 X300 EDM

w Automatic Transmission (AJ16)
SOL ENOlD VALVES
The following tests are performed continuously by a background task. If a fault is detected, it is filtered for a set period.
When filtering ends a fault code is stored in the TCM and action is taken to ensure the integrity of the system.
During limp home mode the internal relay is turned
off to remove the supply to the solenoids and the gearbox with default to fourth gear (if aforward gear is alreadyselected) and third gear (if P.R.N.). Selecting N and then D will engage
3rd gear only.
Each test checks that the feedback from the output stage module is consistent
with the driven state of the solenoid
output, detects short circuit to ground, short circuit to battery voltage and open circuit.
TORQUE CONVERTER CLUTCH SYSTEM - P 0743
PRESSURE CONTROL SOLENOID ELECTRICAL
- P 0748
SHIFTSOLENOID A ELECTRICAL - P 0753
SHIH SOLENOID B ELECTRICAL - P 0758
TCM TRANSMISSION
ccoo7/042 G B003/L
CC007l005 GBOOYH
ccoo7/024 GB003lK
CC007/006 GB003/B
CC007/0 19 G B003/M
TORQUE CONVERTER CLUTCH
SHIFT SOLENOID
A
SHIFT SOLENOID B
PRESSURE CONTROL SOLENOID
SOLENOID SUPPLY
Possible Causes:
. Faulty valve.
Faulty harness wiring /connectors.
Effects:
MIL illuminated.
. Transmission warning lamp illuminated.
Maximum fluid pressure applied.
Limp home mode applied.
Remedy:
Renew valve.
. Repair or renew harness I connector.
Issue 1 August 1994 14 X300 EDM

Automatic Transmission (AJ16)
TORQUE REDUCTION SIGNAL - P 1780
The diagnostic for this signal is based entirely on feedback from the ECM. If the torque reduction request is active for
greater than 2 seconds, the ECM starts the torque reduction fault timeout (IO seconds). If the signal returns to the
standby condition within this time, the timeout is reset. If the timeout matures then the ECM stores a fault code and
transmits 93% on the torque signal line and also lights the MIL where necessary.
The ECM will also initiate the torque reduction fault timeout
if the signal line is permanently high or low for greater
than 125ms. The conditions for resetting the timeout and the actions if the timeout matures are the same as previously
described above. When the TCM receives the correct indication on the torque signal line, this fault code will be stored
and
a substitute function will be adopted and the warning lamp will be illuminated. The engine management will send
normal torque signal when the torque reduction signal returns to standby or when the ignition is reset.
This torque reduction signal is used during gearshifts to conveythe actual amount of retard to be applied to the ignition
advance angle
afterthe other trims. The signal idles at 17% (or 12% if theTCM wishes to drive the MIL on), and changes
to 20% at the start of a gearshift. This represents 0" retard. When an amount of retard is required, the PWM will increase
to the desired value (between 20% and 90%) and return to 20% and then to idle state at the end of the shift.
TCM
PI HARNESS ECM
CC007/032 P1063/008 P1105/026
TORQUE SIGNAL MALFUNCTION - P 1781
The torque signal is a PWM signal from the ECM to the TCM which conveys information about the actual torque devel- oped by the engine in the range 0 to 510Nm. The base frequency is 91Hz and the signal which is active low should be
within the range 10% to 90% modulation. The torque signal is monitored continuously during initialization and oper
- ation. If the frequency of the signal is incorrect or the signal is out of range, then this fault code will be flagged. The
TCM will adopt a substitute function and the warning lamp will be illuminated. This fault code will only be flagged if the engine speed is above 448 rpm.
TCM
PI HARNESS ECM
CC007/02 1 P1063/007 PI 105/033
Possible causes:
. Faulty harness wiring I connector.
. Faulty signal from ECM.
Effects:
. Transmission warning lamp illuminated.
Substitute torque signal adopted by TCM.
. =Normal mode only available.
. No kickdown facility.
. Maximum fluid pressure applied.
Remedy:
. Repair or renew harness / connector.
Examine ECM fault diagnosis (refer to EDM, section 5.1).
Issue 1 August 1994 16 X300 EDM

Automatic Transmission (V12) Powertrain
8.2.1 POWERTRAIN
41-80-E TRANSMISSION, SYSTEM DESCRIPTION
The electronic transmission system fitted to 6.0 liter and 4.0 liter super-charged vehicles comprises the following com- ponents:
0 Hydra-matic 4L-80-E Automatic Transmission
0 Electronic Transmission Control Module
0 Performance Mode Switch
0 Kickdown Switch
0 Gear Selection Module (illuminated)
System control is effected by the transmission control module
(TCM), located behind the passenger side fascia, which continuously monitors requests made bythe driver via the gearselector, throttle pedal etc. This data is used inconjunc- tion with the speed input from the transmission and inputs from the engine management system, to calculate optimum
shift points and control parametersfor shift pressure and ignition retardation to enhance shift quality and reduce trans- mission unit wear.
TheTCM is also able to detect faults within the system and store the relevant fault codes for interrogation with diagnos- tic equipment.
Gear shifts are controlled
by three solenoid valves, and a pressure control regulator, located on the valve block within
the transmission unit assembly. If a serious fault occurs, the TCM removes all electrical power from these valves and
the transmission system reverts to a mechanical default condition. This condition allows only mechanical selection
of reverse and one forward gear, either
third or fourth, depending on prevailing conditions at the time of the default.
The performance mode switch and kick
-down switch are used to adjust transmission operation as required by the
driver. Performance mode selection, made via a switch mounted on the selector switch surround, can be either NOR- MAL, for everyday use, or SPORT, for enhanced performance. Kick-down is activated by a switch mounted below the
accelerator pedal and is used to initiate a downward gear change, increasing torque and acceleration.
8.2.2 COMPONENT DESCRIPTIONS
Transmission Unit
The powertrain 4L-80-E transmission unit houses the two solenoid valves which control gear shifts. A pressure control
valve is also located on the solenoid valve block. These three valves initiate and control shift patterns within the trans- mission unit by regulating fluid flow.
Performance Mode Switch
The two position performance mode switch allows selection of 'sport' or 'normal' mode as required by the driver. The
switch input to TCM causes a gear shift pattern change so that gear shifts take place at higher engine revs, enhancing
performance, when in 'sport' mode. For everyday use, 'normal' mode utilises a shift pattern for optimum driver com- fort.
Kickdown Switch
The 'kick-down' facility is activated when full downward travel of the accelerator pedal occurs.
Activation of the switch provides a signal to TCM indicating that greater acceleration, and hence downward gear shifts
are required. Switch height is adjustable
so that kick-down can be achieved at a pre-determined throttle opening.
Gear Selection Illumination Module
This module is located above the gear selector mechanism and its sole purpose is to display the selected gear (in red)
on receipt of a signal from the decoder module.
X300 EDM 1 Issue 1 August 1994

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TCM
Pressure switch manifold X 03 Pressure switch manifold Z 04
Performance mode select 05 Calibration select 06
Engine toque reduction 07 Throttle position 11 Engine troque 12 Sensor ground 14 Pressure switch Y 22
Traction control inpuit 23 Kickdown switch 24 Brake switch 25
Transmission temperature 26 Engine speed 30 Vehicle speed output 34 Transmission output speed 36
Transmission input speed 37 Shift solenoid A 39 Transmission malfunction lamp 40 Sport mode lamp 41
Torque converter clutch 42 Shift solenoid B 43 Force motor low 49 Transmission input speed GND 50 .ransmission output spped GND 51 Force motor high 52
55
Vban
53 Vignition
16JDSLIscantool
45 JDS K I scan tool
54 Power ground
I TRANSMISSION Ignition
-OK -OB
-Rw -P - su - GN -Pw - BU -ON - RP - BS - PU - OY - BIN - SB -U -G -OR -s
- GU -ow - OP -0s -N -R
-OB
14/01 Transmission input speed GND
14/02 Transmission input speed
13/01 Transmission output speed GND
13/02 Transmission output speed
1 - 12/10 TCCsolenoid high
- 12/09 TCC solenoid signal
-
-
- -
12/03 Shift solenoid A high
12/01 Shift solenoid A signal
12/03 Shift solenoid B high 12/02 Shift solenoid B signal
-
- 12/13 Force Motor Signal
1211 1 Force motor HI
-
-
-
12/04 Pressure switch manifold X
12/04 Pressure switch manifold Y
12/04 Pressure switch manifold Z
- 12/07 Transmission temperature
- 12/08 Sensor GND
44 Transmission malfunction
14 Sport mode indication
ABS 1 TC CM
03 Traction control signal
iI I
VI2 EMS
II
I -
I - 03 Engine torque
I - 06 torque reduction request
I - 10 Engine speed
I - 07 Vehicle speed
04 throttle position
I
I
I
I - I 04 throttle position
I - 03 Engine torque
I - 06 torque reduction request
I - 10 Engine speed
I - 07 Vehicle speed
I
I
I
I I
I 6 Cyl. GEMS I
I
I
I
1- I
I- 22 Engine speed I
I
,I I
I
I
I - 33 Engine toque
26 Torque reduction request
I - 32 Throttle position
' Performance Mode I
I
000 I
Switch I
I
02 Performance mode select
I
Vban + oq 04 I
r---- 1
I
Brake Switch
I
r---- 1
I
Kickdown Switch
I

Automatic Transmission (V12) Powertrain
8.2.3 OPERATING PRlNClPL ES
The electronic control system is split into four main functional areas:
0 Shift Point Control
0 Lock-up Control
0 Pressure Modulation
0 Engine Torque Control
0
Shift Point Control
The optimum gear ratio is selected as a function of transmission output speed, engine load, position of selector switch
and program switch.
Lock-up Control
The torque converter clutch is engaged as a function of load, output speed, gear selected and drive program. Lock-up
is possible in second, third and fourth gear. Apply and release quality is controlled by the pulse width modulated pres-
sure regulator solenoid.
Pressure Modulation
Hydraulic pressure in the transmission shift friction elements is accurately matched to transmission output torque
using an electrically operated solenoid valve to control pressure level. Transmission input torque is calculated from
an output torque value, supplied by EMS, and converter slip.
Engine Torque Control
Engine torque control reduces the energy dissipated within the system during gear shifts. The effect of this control
increase the transmission service life by reducing slippage time, increases comfort by reducing clutch torque trans- mission and allows a greater transfer of power by the transmission unit.
8.2.4 INPUTS / OUTPUTS
8.2.4.1 INPUTS
Transmission Range
The transmission range is detectec ,ythe pressureswitch manifold located within the transmission unit. The manifold
transmits a coded message to the TCM indicating gear selector position.
Performance Mode Select
Performance mode select uses a two wire input to the TCM allowing selection of different transmission operating
modes.
Line A; Used for selection of traction control shift pattern and controlled
by the ABS /TC CM.
Line
B; Used for selection of 'Normal' or 'Sports' mode, manually selected at a two position rocker switch mounted
on the gear selector unit. Switch resistance is equal to or greaterthan look$, open circuit and equal to or less than 0.5$ closed circuit, measured across contacts at a current of 10mA.
Kickdown Switch
This signal is controlled by the operation ofthe kickdown switch on depression of the accelerator pedal to its full extent.
The switch remains in 'normally open' position until contact with the pedal closes the contacts. Switch resistance is
equal to or greater than look$, open circuit, and equal to or less than 0.5$ closed circuit, measured across contacts at
a current of
10Ma.
Calibration Select
The calibration select input allows identification of different vehicle specifications, ie 4.0 liter supercharged, or 6.0 liter (V12). The link, to ground, from the TCM is either short or open circuit, dependant upon internal software calibration
for each vehicle variant.
X300 EDM 5 Issue 1 August 1994

Automatic Transmission (V12) Powertrain
Engine Speed
The engine speed is provided by an open collector signal supplied from the engine management control module
(ECM).
Throttle Position
This signal, from the ECM, performs the following two functions:
1.
2.
Engine Torque (and warm-up)
This signal, from the ECM, performs the following three functions:
1. During cranking to convey the completion of an engine warm
-up cycle to TCM.
2. To convey engine torque information, under normal running conditions, to TCM.
3. To convey engine torque fault signals to TCM.
Engine ‘warm
-up’ cycle commences from ignition ON until 500ms after the engine exceeds 400rpm. After this time
delay either an engine torque, or torque fault signal will be transmitted.
Transmission Input Speed
The transmission input speed sensor is mounted within the transmission housing and produces a variable frequency
signal, directly proportional to forward clutch housing rotational speed which is transmitted to the TCM. Sensor resis- tance equals 1.25kQ f 0.25.
Transmission Output Speed
The transmission output speed sensor is mounted within the transmission housing and produces a variable frequency
signal, directly proportional to the rear carrier rotational speed which is transmitted to the TCM. Sensor resistance
equals
1.25w2 + 0.25.
hake Application
When a brake application signal is received, due to brake switch operation, the torque convertor clutch lock-up sole- noid is de-energized, releasing lock-up mode if already applied
Transmission Oil Temperature
The transmission oil temperature sensor, located within the internal harness, monitors oil temperature and transmits a corresponding signal to the TCM.
To convey throttle position information to the TCM.
To indicate fault conditions between ECM and throttle potentiometer.
8.2.4.2 OUTPUTS
Gear Shift Solenoids
The two gear shift solenoids, located within the transmission housing, determine gear ratio when the selector is in any
of the forward gear positions.
Force Motor
The force motor, mounted within the transmission housing acts as a transmission torque fluid pressure regulator.
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch solenoid, mounted within the transmission housing, provides a direct drive from the en- gine, via the converter clutch, to the driven wheels, giving the efficiency of a manual gearbox. The solenoid also pro- vides a ’ramp‘ apply and release to engage / disengage the clutch gently.
0
0
0
e
X300 EDM Issue 1 August 1994 6

Automatic Transmission (V12) ~ Pow. rtrain
Engine
Torque Reduction and Malfunction Indication
This signal, to the ECM, has three modes of operation.
1. To indicate normal engine operation to the ECM.
2. During gearshifts, to request reduction of engine torque
3. During fault conditions, to inform the ECM.
During normal operation
theTCM outputs a constant duty cycle signal to the ECM. The signal is changed when torque
reduction is required to indicate to the ECM the degree of ignition retardation necessary. If a fault condition, relating
to OBD
II CARB legislation, occurs the TCM will transmit a signal to the ECM relating this event. The ECM will only
respond to this signal if its duration is 100 milli-seconds or longer.
If the signal from the torque reduction line is either HIGH or LOW for 2 or more seconds the EMS will recognise that
a fault may be present and transmit this information to the TCM.
If the signal from the torque reduction line lasts for 2 or more seconds the EMS will return to normal operation.
Sport Mode Indicator Lamp
The sport mode indicator lamp, mounted on the instrument panel, is illuminate when sport mode is selected and the
ignition switch is ON. Sport mode is selected at a two position switch mounted to the rear of the gear selector assembly.
Gearbox Failure Warning Lamp
The gearbox failure warning lamp, mounted on the instrument panel, is illuminated when afault is detected bytheTCM within the transmission electrical or mechanical systems.
Vehicle Speed (12 cylinder vehicles only)
This output signal is calculated from the transmission output speed and supplied to the ECM as an indication of vehicle
speed.
8.2.5 DIAGNOSTIC LINKS
Diagnostic
L line
One of a two wire interface used to activate stored diagnostic codes for reading by external equipment.
Diagnostic K Line
One of a two-wire interface used to communicate stored diagnostic codes for reading by external diagnostic equip- ment.
X300 EDM 7 Issue 1 August 1994

8.2.6 DIAGNOSTIC FAULT CODES
The following codes are stored within the TCM whenever a fault is detected on the system. The codes relating to OBDll legislation can be accessed using Jaguar Diagnostic Equipment or a hand-held, proprietary scan tool.
Code 1 Description [ OBDII i Page No.
PO605 I TCM internal error Y 8 I
PO703 Brake switch input malfunction N I 9
PO706 Transmission range sensor fault Y I 10 1
1 PO7 12 Transmission fluid temperature sensor low input Y , 11
PO713 Transmission fluid temperature sensor high input Y 11
PO7 15 Turbine / input speed sensor malfunction Y 12 I
I PO716 I Turbine / input speed sensor range / performance IYll21
I PO720 I Output speed sensor circuit malfunction Iy 13 I
1 PO721 [Output speed sensor circuit range / performance Iy 13 I
I PO726 1 Engine speed input circuit performance Iy 14 I PO727 Engine speed input circuit no signal Y I 14
PO730 Incorrect gear ratio Y 15
PO7 4 1 TCC system stuck off Y 16
PO742 TCC system stuck on Y 16
16
PO743 TCC system electrical
17 Pressure control solenoid electrical PO748
ZhTfi solenoid A performance Y 18 PO751
__ p0753-- - -- Shift solenoid A electrical Y 18
Shift solenoid B performance Y I 18 PO756
PO758 Shift solenoid B electrical Y 18
PO780 Shift malfunction (Max-adapt) N 19
PI739 Transmission component slipping Y 19
- __ -
___ __ Y
N - ~_ ~
~
- _____ - __.__ ~ ~~~
~~
I
___. ________ I
__
PI780 Torque
reduction signal malfunction Y 20
PI781 Engine torque signal malfunction Y 20
PI782 Traction active input fault N 22
PI783 Transmission over temperature condition N - I I PI791 I Throttle position electrical signal failure Y 23
Issue 1 August 1994 8 X300 EDM