1994 JAGUAR XJ torque

4
AFLR M- -1
4 13 9
14
15 7
J44-718
1.
Selector 2. Mode switch 3. Rotary switch
4. Transmission control unit 5. Output shaft speed sensor 6. Kick-down switch 7. Battery
8. Transmission relay
9.
10.
11.
12.
13.
14.
15.
16.
Transmission control module (TCM)
Reverse lamps
Start inhibiter
Engine speed
Ignition retard
Engine load
Engine control module
(ECM) Engine speed sensor
Fig.
1 Control Layout Schematic
2.1.5 Transmission Control Module (TCM)
The Transmission Control Module (TCM) is an electronic control unit located in the front passenger footwell behind
the underscuttle pad. It is electrically connected to the transmission and other components through a cable harness
and multiple pin plug.
The TCM continuously monitors the gear selected (via the rotary transmission switch), the speed of the output shaft
(by speed sensor on the output shaft) and throttle position ('kick
-down' switch). This information plus input from the
Engine Control Module (ECM) of throttle angle and engine speed and load in conjunction with a pre-programmed con- trol map, enables the most suitable gear to be selected.
The TCM, by operating solenoid valves
MVI, MV2 and MV3, controls the gear shift speed and in conjunction with the
solenoid operated pressure control valve, controls the gear shift quality. Gear shift quality on upshifts is improved by
the TCM momentarily retarding the ignition to reduce the torque input as the gear change takes place. Information
is fed to the TCM from sensors and
if any electronic component fails, the basic shift changes will be performed by the
hydro-mechanical system, ie Park, Reverse, Neutral, D3 or D4.
46
Issue 1 August 1994

ZF Automatic Transmissions Service Manual
Vehicle speed sensor plus input
Engine speed input
Program switch input
Solenoid valve
MVI output
Pressure control valve PCV output
?. 1.13 Harness Connections
3&31 not used
32
33 Position code
Z input
38 Torque
reduction
T (I) output
34
-37 not used
Vehicle speed sensor minus input
37
55
not used
\I
41 I Kick down switch input
J" i"
Diagnostic L-line
Transmission malfunction indicator lamp
output
not used
Solenoid valves plus input
Vehicle speed sensor screen
Engine torque signal
T(T) input
I IU,MW II
43 not used
44 Oil temperature sensor ground
45 not used
46
Oil temperature sensor input
47 Throttle position input
48 not used
I
not used
Solenoid valve
MV2 output
not used
Power ground input 19
49 Sport mode indicator output
50 Position code X input
51 Diagnostics K
-line
52
-55 not used

J86 I I69 1
Fig.
1 Transmission Control Module Connections - Pin Locations
I1
12
13
: I
17-18
22
-23
t 27-28
25
26
Function I Pin I Function I
Power supply input I 29 I Program switch /Traction control input I
Digital ground input I 39-40 lnot used I
not used
-~
48 Issue 1 August 1994

ZF Automatic Transmissions Service Manual
2.2 HYDRAULIC CIRCUIT DIAGRAMS
Component Engagement
Key
To Hydraulic Diagrams (commencing on page 52)
1. 2.
3. 4.
5. 6.
7.
8. 9. 10. 11. 12. 13.
14. 15. 16.
17.
18.
Oil pump Sump
Torque converter
Olil cooler
Clutch 'A' damper
Clutch 'B' valve and damper
Clutch 'Cl' damper
Clutch 'Cl' valve
Clutch 'C' valve and damper
Clutch
'D' valve and damper
Clutch 'E' damper
Clutch
'F' valve and damper
Reverse locking valve
Shift valve
1 - 2
Shift valve 2 - 3
Shift valve 3 - 4
Safety valve
Pressure valve
1
A Clutch 'A' D Clutch 'D B Clutch 'B' E Clutch 'E'
C Clutch 'C' F Clutch 'F'
C1 Clutch 'C"
19.
20.
21.
22.
23. 24.
25.
26.
27.
28.
29.
30.
31.
32.
33. 34.
35.
G
H J K
Pressure valve 2
Torque converter pressure valve
Lubrication valve
Lubrication valve
Lock
-up control valve
Modulation pressure valve
Main pressure valve
Gear change valve
Solenoid valves
MVllMV2l MV3
Pressure regulator
ECM
- inputs and outputs
Engine torque
Throttle valve Engine speed
(RPM) Transmission speed (RPM) Transmission rotary switch
Oil filter
Torque converter freewheel
(C) Clutch freewheel (D) Clutch freewheel (E) Clutch freewheel
Exhaust - Reduced pressure
=X= Th rott le - Modulation pressure
4= Orifice 2- Sump
- Main pressure - Lubrication pressure
- Converter pressure
Throttle pressure
Issue 1 August 1994 51

ZF Automatic Transmissions Service Manual
Problem Possible Cause
2.3.4 Road Test
. Fully check all shift speeds and note. Compare the results with the specification in addition to general observations of transmission behaviour, noises, leaks etc., and consult the following Fault Finding Chart.
Action
CAUTION:
When renewing the transmission, ALWAYS flush out the oil cooler and feed and return pipes.
2.3.5 Electrical Checks
. Check 'Kick-down'.
If any electrical component fault is suspected, refer to Electrical Diagnostic Manual (EDM) to verify the failure mode
before a repair or replacement is attempted.
2.3.6 Fault Finding Chart
Stall speed too low
Stall speed too high and keeps
,ising
hceleration below specification
Top speed below specification
'osition 'P - Park
Nil1 not move out of Park
Ioes not engage Park
Ioes not hold Stator
freewheel faulty allowing stator to
revolve
Engine out of tune
Transmission slip
Engine out of tune
Torque converter freewheel faulty
allowing stator to revolve.
'Kick
-down' switch defective.
Transmission
in 'Limp Home' mode
Engine out of tune
Torque converter freewheel seized
Engine out of tune
Gearshift interlock failure
Check cable adjustment
Parking pawl mechanism sticking
Check cable adjustment
Parking pawl mechanism damaged Renew
torque converter
Check engine tune
Check oil level, check mechanical
failure, renew transmission as
necessary
Check engine tune
Renew torque converter.
Refer to EDM, rectify
I renew
'Kick
-down'switch.
Check.
Check
engine tune
Renew torque converter
Check engine tune
Refer to EDM, rectify
- renew fuse,
check circuits, renew relay and
solenoid.
Check central
'P, check Park switch,
check Brake switch.
Adjust to correct setting
Renew park pawl components:
connecting bar, pawl pin, torsion
spring, pawl, guide piece and guide
sheet.
Adjust to correct setting
Replace park pawl components
61 Issue 1 August 1994

ZF Automatic Transmissions Service Manual
No engine braking
Manual gearchange 3rd to 2nd
inoperative Clutch 'Cl' or
Clutch 'E' faulty
Speed sensor faulty.
MV2 faulty.
a
Renew transmission
Check TCM Diagnostics
1 renew
speed sensor.
Renew valve block.
a
0
Problem
Vo 'kick-down' change
Light throttle speeds only
Light throttle gear change too
hard
1st to
2nd, 2nd to 3rd and 3rd to
4th changes too long
Full load and 'kick
-down'
changes too long
Full load and 'kick
-down'
changes too hard ~
Possible Cause
'Kick-down'
switch out of adjustment 1
full throttle stop adjustment.
'Kick
-down' switch faulty.
'Kick
-down' switch connector or wiring
Fa u Ity.
TCM faulty
Valve block bolt torque incorrect.
Modulation pressure too high.
Damper faulty.
Clutch plates faulty.
Valve block bolt torque incorrect.
Damper faulty.
PRSV faulty.
PRSV wire earthed.
Modulation valve seized.
Pressure regulator valves
1 and 2 seized.
mve block bolt torque incorrect.
Modulation pressure too low.
Clutch plates faulty.
Valve block bolt torque incorrect.
Modulation pressure too low.
Clutch plates faulty.
Action
Adjust as per Engine Set Up
procedure on JDS.
Renew 'kick
-down' switch.
Rectify.
Check TCM
Reset to correct torque.
Renew valve block.
Renew valve block.
Renew gear unit.
Reset to correct torque.
Renew valve block.
Renew valve block.
Renew harness.
Renew valve block.
Renew valve block.
Reset to correct torque.
Renew valve block.
Renew transmission.
Reset to correct torque.
Renew valve block.
Renew transmission.
issue 1 August 1994 65

ZF Automatic Transmissions Service Manual
0
3il in bell housing
2.3.6 Fault Finding Chart (continued)
Oil pump seal leaking.
Oil pump 0
-ring leaking.
Pump housing leaking.
Converter seam leaking.
Problem Possible Cause Action
:onverter clutch
-eakage between gearbox and
sump
Leakage between intermediate
date and gearbox
Leakage at harness plug
:onnector
Leakage at drive flange
:Iutch engagement speed
ncorrect
Loose fastening screws.
Sump gasket faulty.
Bell housing to gearbox screws loose
Connector 'O'ring faulty
Rear oil seal faulty
ingagement
too hard
Jo clutch engagement
Ionverter clutch engaging at
dle (engine will not idle in
'D')
Control circuit fault.
Speed sensor faulty.
Valve body problem.
Converter unit faulty
Control circuit fault
MV3 faulty.
Converter clutch valve seized.
Converter faulty. Pressure reducing valve
1 seized.
Incorrect oil level.
Oil filter not sealing.
Control circuit fault.
MV3 faulty.
MV3 wire earthed.
Converter clutch valve
sticking.
Check TCM Diagnostics / rectify
fault.
Check TCM Diagnostics
1 renew
speed sensor.
Renew valve body
Renew converter unit
Check TCM Diagnostics
1 rectify
fault.
Renew valve block.
Renew valve block.
Renew converter.
Renew valve block.
Check oil level.
Check 0
-ring etc.
Check TCM Diagnostics
/ rectify
fault.
Renew valve block.
Renew harness.
Renew valve block.
Renew oil pump seal.
Renew 0
-ring.
Renew oil pump.
Renew converter.
Torque tighten.
Renew gasket.
Torque tighten
Renew
'0' ring
Renew oil seal
Issue 1 August 1994 66
. _.~ -

ZF Automatic Transmissions Service Manual
2.3.6 Fault Finding Chart (continued)
a
0
0
a
Problem
Leakage at breather
Leakage from oil cooler circuit
Leakage at intermediate plate
Leakage between gearbox and
extension housing
General
Noise and associated
interruption of power
Loud noise with no drive
forward or reverse
Groaning or buzzing noise (can
sound like mechanical damage)
in all selector positions,
especially when cold.
Sucking noise from pump.
Loud noise on converter clutch
engagement
Engine vibrations when
converter clutch engaged
Possible Cause
Oil level too high.
Incorrect oil specification.
Breather cover missing.
Breather cover
'0' ring faulty.
Breather cover loose.
Pipe lock nuts loose.
Pipe line faulty.
Oil cooler leaking.
Intermediate plate plug leaking
Fastening screws loose. Gasket
faultv.
Oil filter dirty
Drive plate to converter connection
damaged.
Pump drive damaged.
Oil level too low.
Valve block leaking.
Torsion damper defective
Change point too low
Action
Rectify.
Change
oil and flush system.
Replace breather cover.
Renew
'0' ring.
Renew lockwasher.
Torque tighten.
Renew relevant pipes.
Renew oil cooler.
Torque tighten plug.
Renew sealing washer.
Torque tighten
Renew gasket.
Clean
/ replace filter. If clutch debris
found, renew transmission, flush
cooling system
Renew drive plate and converter as
necessary.
Renew transmission.
Rectify.
Renew valve block.
Renew converter
Check TCM
Issue 1 August 1994 67

E
Fau;t diagnosis
ZF 4HP 22
Electrical checks,
33
Engine tune, 33
Fault finding chart, 34
Initial checks, 33
Road test, 33
Stall test, 33
Electrical tests, 61
Engine tune, 60
Fault finding chart, 61
Initial checks, 60
Road test, 61
Stall test, 60
ZF 4HP 24 E
Foreword, ii
G
General description
ZF4HP22
Epicyclic gear train, 2
Gear train clutches operation, 3
Gearshift interlock, 8
Gearshift selection, 8
Output shaft extension housing, 4
Starter inhibit switch, 8
Throttle valve mechanism, 8
Torque converter, 1
Transmission control unit, 4
Control layout schematic illustration, 46
Decoder module, 47
Epicyclic gear train, 40
Gear train clutches operation, 41
Gearshift interlock, 47
Harness connections, 48
Kick-down mechanism, 47
Main harness connector
ZF
4HP 24 E
12-way, 50
Sway, 50
Performance mode switch, 47
Reverse safety inhibit, 47
Rotary switch connector pins, 49
Rotary switch harness, 49
Starter inhibit switch, 47
TCM connector pins, 48
Torque converter, 39
Transmission control module, 46
Transmission control unit, 42
Transmission rotary switch, 47
H
Hydraulic circuit diagrams
‘1 ’ - 1 st, full throttle, 32
‘1’ - 21-14 idling, 31
‘1 ’ - 3rd, idling, 30
‘2’ - 2nd, full throttle, 29
‘2’ - 3rd, idling, 28
‘3’ - 3rd, full throttle, 26
‘3’ - 3rd, kickdown, 27
‘3’ - 3rd, part throttle, 25
ID’- drive, Ist, full throttle, 14
ZF 4HP 22
‘D’ - drive, lst, idle, 13
‘D’ - drive, lst, kickdown, 15
‘D’ -drive, 2nd, full throttle, 17
‘D’ - drive, 2nd, idle, 16
‘D’ - drive, 2nd, kickdown, 18
‘D’ -drive, 3rd, full throttle, 20
‘D’ - drive, 3rd, kickdown, 21
‘D’ -drive, 3rd, part throttle, 19
‘D’ -drive, 4th, full throttle lock-up, 24
‘D’ -drive, 4th, part throttle, 22
‘D’ - drive, 4th, part throttle lock-up, 23
‘N’ - neutral, 12
‘P’ - park, 10
‘R‘ - reverse, 11
Key, 9
‘1’ - Ist, 59
‘D’ - drive, 1 st, 55
‘D’ - drive, 2nd, 56
‘D’ - drive, 3rd, 57
‘D’ - drive, 4th, lock-up, 58
‘N’ - neutral, 54
‘P’ - park, 52
‘R‘ - reverse, 53
Key, 51
ZF 4HP 24 E
S
Service data, iii
Service materials, iii
Service operations
ZF 4HP 22, Not yet available, 68
ZF 4HP 24 E, Not yet available, 68
Service tools & equipment, iii
T
Torque tightening specifications, iii