Range Rover Automatic Transmission. Manual — part 8
System Information Document
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[ZF_4SPD\Project_Specs]
[Revision: 2.3]
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© Rover Group 1998
Page 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 1998
Page 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 Low
BOSCH
GS8.87
Transmission
ECU
ZF
4HP22
Automatic
Transmission
Position Switch
BOSCH ME 5.2.1
or THUNDER
Engine
Management
Pressure Regulator
Solenoid Valves
Output Speed
9
Z (L4, GS8.87.0)
W (L1)
Y (L3)
X (L2)
15
14
42
5
33
32
30
37
8
36
16
44
26
54
Permanent power supply
Ignition power supply
High / Low range
MES 2 (Mode output)
Mode (Sport / Manual)
51
45
13
Power Supply - Pressure Regulator & Solenoid valves
53
28
6
Power Ground
Ground Electronics
Diagnostics K-wire
31
CAN High
MES 1 (Mode output)
25
System Information Document
____________________________________________________________________________________________________
_
[ZF_4SPD\Project_Specs]
[Revision: 2.3]
____________________________________________________________________________________________________
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© Rover Group 1998
Page 5 of 52
2.2 Interface specification
2.2.1 Gear Shift Solenoids
2.2.1.1 Pin 5 - Pressure regulator
The purpose of the Pressure regulator is to generate modulation pressure for the gearbox clutches. The
pressure regulator is mounted between the common output supply (pin 53) and pin 6. It is driven by a
pulse width modulated power signal that is generated and regulated in the CG202 ASIC.
+
The pulse width modulated signal frequency f
0
is generated permanently; the free running duty cycle
corresponds to the minimal current and the maximal modulation pressure
- Component
- Type
2/2-way relief jet with falling characteristic line; the control edge
is closed when the valve is without power supply.
- Coil resistance R
5.5
Ω
+/- 6% @20
°
C
- I_max
700mA mean value
- I_min
150mA mean value
- Chopper frequency
1000Hz +/- 50Hz @ +25
°
C
- Control Unit
- Interface characteristic
current regulated, chopped output stage, pulse width modulated.
- Current range
145mA <= I_min <=175mA @ +25
°
C
- Currrent range
680mA <=I_max <=720mA @ +25
°
C
- Reference point
Pin 6 (power ground
- Recommended wire size:
1.0mm
2
The ASIC status output is fed back to the processor for diagnostic purposes. See the diagnostic
specification for details.
2.2.1.2 Pin 30 (MV1), 32 (MV3, lockup), 33 (MV2) - Solenoid valves 1,2 and 3
The purpose of solenoid valves 1 and 2 is to switch the hydraulic valves and thus control the hydraulic
logic for gear selection. Solenoid valve 3 is to lock the torque converter.
The solenoid valves are mounted between the common output plus supply (pin 53) and their
corresponding control pin. The solenoid valves are activated if the output control pins are drawn to
ground.
- Component
- Type
3/2-way valves, inlet closed without power supply
- Coil resistance
R20 = 32.5
Ω
+/- 2
Ω
- Operating voltage range
9.5V <=U<=14V
- Drop off current
I<30mA @ P-o = 4.5 bar +/- 0.1 bar
- Temperature range
-30
°
C to +150
°
C under test conditions
System Information Document
____________________________________________________________________________________________________
_
[ZF_4SPD\Project_Specs]
[Revision: 2.3]
____________________________________________________________________________________________________
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© Rover Group 1998
Page 6 of 52
- Control unit
- Interface characteristic
Power output
- Output voltage low
U_sat <=1V at I=1A
- Reference point
Pin 6 (power ground)
- Recommended wire size:
1.0mm
2
The output voltages of Pin30, Pin32 and Pin33 are fed back over a resistor network to the processor for
diagnostic purposes. During initialisation and operation the output signal is toggled periodically for a
short time in order to enhance the diagnosis of the outputs.
2.2.1.3 Pin 53 - Power supply to Pressure regulator
When an ignition supply is available at the controller, pin 53 is a permanent power supply to the pressure
regulator and the solenoid valves. This power supply can be switched off with hardware and software in
the event of a failure in the transmission electrical system.
- Recommended wire size:
1.5mm
2
2.2.2 Controller power supply
2.2.2.1 Pin 6 - Power ground
Permanent connection from the ECU to 0V. This is used for driving the Solenoid valves and the Pressure
regulator.
- Recommended wire size:
1.5mm
2
2.2.2.2 Pin 28 - Electronics ground
Permanent connection from the ECU to 0V. This is used for driving the electronics within the controller.
- Recommended wire size:
1.5mm
2
2.2.2.3 Pin 26 - Permanent ignition supply
Permanent connection to 12V required. This is essential in order to allow storage of data for adaptive
pressure control.
- Recommended wire size:
0.5mm
2
2.2.2.4 Pin 54 - Ignition supply
Connection to +12V when the igntion is switch on. This is the main feed to the controller, allowing the
transmission system to operate. It is essential that this supply is switch on at exactly the same time the
engine management system receives an ignition supply. This is to ensure serial communications can be
established between the two controllers.
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