instrument cluster test.pdf

DIAGNOSIS AND TESTING

Instrument Cluster

Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information.

Principles of Operation

The instrument cluster is a configurable, hybrid electronic cluster (HEC) that contains a microprocessor, gauges, indicator lamps, backlighting lamps and internal circuitry. The instrument cluster is non-repairable at the dealership level with the exception of the warning indicator bulb, the backlighting bulb and the instrument cluster lens replacement. The instrument cluster utilizes hardwired circuitry, the standard corporate protocol (SCP), and UART based protocol (UBP) communication networks. Communication using the SCP network transmits and receives data between the instrument cluster and the PCM. Communication using the UBP network utilizes data transmitted and received by the instrument cluster and the body security module, driver

SECTION 413-01: Instrument Cluster 2002 F-Super Duty, Excursion Workshop Manual

Special Tool(s)

73III Automotive Meter 105-R0057 or equivalent

Instrument Gauge System Tester 014-R1063 or equivalent

Worldwide Diagnostic System (WDS) 418–F224, New Generation STAR (NGS) Tester 418-F052, or equivalent diagnostic tool

of 1222002 F-Super Duty, Excursion Workshop Manual

6/17/2009file://C:\TSO\tsocache\KITCHEN_5600\S2O~us~en~file=S2OD1002.htm~gen~ref.htm

seat module and the electronic air temperature control (EATC).

It is very important to understand:

� where the input originates from.

� all the information necessary in order for a feature to operate.

� which module(s) receive(s) the input or command message.

� whether the module which received the input controls the output of the feature, or whether it outputs a message over the SCP or UBP network to another module.

� which module controls the output of the feature.

The instrument cluster carries out a display prove-out to verify that the warning/indicator lamps and monitored systems are operating correctly. When the ignition switch is turned to the ON position with the engine off, the following indicators will illuminate:

� 4x4 LOW indicator

� 4x4 high indicator

� BRAKE warning indicator

� malfunction indicator lamp (MIL) indicator

� check fuel cap indicator

� CHECK GAGE warning indicator

� CK SUSP indicator

� door ajar indicator

� low fuel warning indicator

� safety belt warning indicator

� wait to start indicator

� water in fuel indicator

Gauge Indication Systems

The instrument cluster and gauges are non-repairable at the dealership level. No adjustment, calibration, or maintenance is required for any gauges.

Instrument Cluster Replacement

CAUTION: When installing a new instrument cluster, the instrument cluster must be re-configured. For additional information, refer to Section 418-01 .

When installing a new instrument cluster, contact a Ford authorized instrument cluster repair facility.

Speedometer

The instrument cluster is hardwired to the four wheel anti-lock brake system (4WABS) module. The instrument cluster micro-processor monitors the VSS data from the 4WABS module and commands the speedometer with a corresponding movement of the pointer. The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4WABS module. The 4WABS module sends the vehicle speed signal via circuit 679 (GY/BK) to all systems that require a vehicle speed signal input.

Odometer



A million-mile tamper-resistant odometer is standard. New speedometers have a reset table odometer.

NOTE: When installing a new instrument cluster some state laws require that the new odometer must register the same as the removed odometer.

If the actual vehicle mileage cannot be determined, the repair centers are able to supply odometers set to "0" miles. An odometer mileage sticker must display the estimated vehicle mileage and be affixed to the driver door jamb. The odometer mileage sticker is available through the parts distribution center.

Trip Odometer

The trip odometer indicates how many miles the vehicle has been driven since the last reset.

Fuel Gauge

The instrument cluster is hardwired to the fuel sending unit, which is a variable resistor controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. The instrument cluster micro-processor monitors the input from the fuel sender and commands the fuel gauge indication according to the fuel level data.

Temperature Gauge

The instrument cluster is hardwired to the engine coolant temperature (ECT) sensor on vehicles equipped with the diesel engine. When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current to the instrument cluster. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow to the instrument cluster. On vehicles equipped with gasoline engines, the instrument cluster receives the temperature signal from the PCM via the standard corporate protocol (SCP) network.

Transmission Temperature Gauge (Automatic Transmission Only)

The instrument cluster receives the transmission temperature information from the PCM via the SCP network. The instrument cluster micro-processor monitors the transmission temperature data and commands the gauge indication with a corresponding movement of the pointer.

Oil Pressure Gauge

The instrument cluster is hardwired to the oil pressure sender unit. The instrument cluster micro-processor monitors the oil pressure data and commands the oil pressure gauge indication with a corresponding movement of the pointer. The oil pressure indicator sender unit consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure.

Voltage Gauge (Manual Transmission Only)

The voltage gauge displays the system voltage as measured at the instrument cluster run input.

Tachometer

Gasoline vehicles are equipped with a 6,000 rpm tachometer and diesel vehicles are equipped with a 4,500 rpm tachometer. The instrument cluster receives the tachometer data from the PCM via the SCP network and commands the tachometer according to the data.



Warning Indicators

Charging System Indicator

On vehicles equipped with gasoline engines, the ignition switch contacts are closed, battery current flows through the charging system indicator and the parallel resistor (390 ohms) to the voltage regulator. Internal circuitry in the voltage regulator provides a ground path to the instrument cluster and the indicator illuminates. When the generator builds up enough voltage to energize the voltage regulator, voltage is applied to the ground side of the indicator effectively removing the ground path and turning the indicator off.

On vehicles equipped with diesel engines, the ignition switch contacts are closed, battery current flows through the charging indicator and the parallel resistor (390 ohms) to the PCM. The PCM provides a ground to the instrument cluster and the charging system indicator illuminates. When the generator builds up enough voltage to energize the voltage regulator, voltage is applied to the PCM. The PCM upon receipt of the generator charging voltage, removes the ground to the instrument cluster and turns off the charging system indicator.

Brake Warning Indicator

The red brake warning light (BRAKE) is used to indicate a low fluid level, brake concern, a parking brake that is not fully released, or an anti-lock brake system (ABS) fault. The brake fluid level switch is located in the brake fluid reservoir.

ABS Warning Indicator

The yellow brake warning indicator is used to indicate a concern or deactivation of the ABS. It illuminates when triggered by the ABS control module and stays illuminated as long as the concern remains in the system.

Malfunction Indicator Lamp (MIL) Indicator

The malfunction indicator lamp (MIL) indicator is illuminated when a diagnostic trouble code (DTC) is sensed in the closed loop by the powertrain control module (PCM). The instrument cluster receives engine data from the PCM via the SCP network.

Air Bag Warning Indicator

The instrument cluster is hardwired to the restraint control module. If an air bag system DTC is detected, the restraint control module provides a ground path to the instrument cluster and the air bag indicator is illuminated.

Safety Belt Warning Indicator

The safety belt warning indicator is powered through the instrument cluster and is grounded through the safety belt retractor switch. When the safety belt is extended, indicating a buckled condition, the switch will open to the instrument cluster and the safety belt indicator is extinguished. When the safety belt is retracted, indicating an unbuckled condition, the switch closes and provides a ground to the instrument cluster and the safety belt indicator is illuminated.

Low Fuel Warning Indicator

The low fuel warning indicator is controlled by the instrument cluster microprocessor and illuminates when the fuel level drops below approximately one-sixteenth of a tank or 4-8L (1-2 gal).

Door Ajar Indicator



On vehicles that are equipped with remote keyless entry, the door ajar switches provide a ground signal to the body security module which subsequently provides a ground signal to the instrument cluster via the UBP network and illuminates the door ajar indicator. On vehicles not equipped with remote keyless entry, the door ajar switches are hardwired to the instrument cluster and provide the ground to illuminate the door ajar indicator.

High Beam Indicator

The instrument cluster provides a ground for the high beam indicator. The multifunction switch provides a switched power source to the instrument cluster to illuminate the high beam indicator when in the high beam position. When the high beams are activated, the multifunction switch sends a power signal to the instrument cluster and illuminates the high beam indicator.

Speed Control Indicator

The instrument cluster provides power to the speed control indicator. On gasoline vehicles, the speed control indicator is controlled by the speed control module. When the speed control is engaged, the speed control module provides the instrument cluster with a ground signal and illuminates the speed control indicator. On diesel vehicles, the speed control indicator is controlled by the PCM. When the speed control is engaged, the PCM provides a ground to the instrument cluster and illuminates the speed control indicator.

Water in Fuel Indicator (Diesel only)

The water in fuel signal is transmitted to the instrument cluster via the SCP network from the powertrain control module (PCM). The water in fuel indicator will illuminate when 100 cc (0.2 pints) of water has accumulated in the fuel filter/water separator.

Wait to Start Indicator (Diesel only)

The wait to start signal is transmitted to the instrument cluster via the SCP network from the PCM. The wait to start indicator will illuminate when the ignition switch is in the ON position with the engine OFF indicating that the glow plugs are heating.

Theft Indicator

The instrument cluster provides the THEFT indicator with power. The theft indicator is hardwired to the PATS module and will flash when the PATS system is activated.

Check Air Filter Indicator

The check air filter indicator is hardwired to the air filter indicator switch (located in the air filter housing) and monitors the air flow through the air cleaner. The air filter indicator is powered by the instrument cluster and when air flow is low, the air filter indicator switch provides a ground to the instrument cluster illuminating the check air filter indicator.

Check Gauge Warning Indicator

The check gauge warning indicator will illuminate when any of the three following conditions exist:

� if the engine oil pressure drops below approximately 42 kPa (6 psi).

� if the engine temperature exceeds approximately 121° C (250° F).

� if the transmission temperature (automatic transmission only) reaches approximately 135° C (275°F).

Check Fuel Cap Indicator



The check fuel cap indicator is used to indicate significant leaks in the fuel tank evaporative system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM and once a leak is detected, the PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a loose fuel cap and the check fuel cap indicator is illuminated, the check fuel cap indicator will remain illuminated until the fuel cap is secured and the vehicle has been running for several minutes or the ignition has been cycled once. For additional information, refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ).

CK SUSP Indicator

The CK SUSP indicator is powered through the instrument cluster. When the air suspension is activated, the suspension control module provides the ground to the instrument cluster and illuminates the CK SUSP indicator.

4x4 High/4x4 LOW Indicators

The 4x4 high and 4x4 LOW indicators are both hardwired to the instrument cluster from the 4x4 control module when equipped with electronic shift, or from the 4x4 control switch when equipped with manual shift. The instrument cluster provides the 4x4 indicators with power and the 4x4 control module, or 4x4 switch, provide the ground depending on whether 4x4 high or 4x4 low is selected.

CHECK GAGES Warning Indicator

The CHECK GAGES warning indicator monitors the coolant temperature and the engine oil pressure. The indicator will illuminate if the SCP coolant temperature data is missing or invalid, if the engine temperature reaches 121°C (249.8°F) or higher, or if the engine oil pressure is low.

Inspection and Verification

1. Verify the customer concern by operating the system.

2. Visually inspect for obvious signs of mechanical or electrical damage.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)

before proceeding to the next step.

4. If the concern remains after the inspection, connect the diagnostic tool to the data link connector

Visual Inspection Chart

Mechanical Electrical

� Engine oil filter � Engine oil level � Oil pump � Door adjustment � Engine coolant level � Water thermostat � Fuel tank � Fuel evaporative system � Low alternative fuel or gasoline � Alternative fuel or gasoline tank(s)

� Central junction box (CJB) fuses: � 35 (10A) � 33 (15A) � 41 (10A) � 45 (10A)

� Miniature bulb(s) � Circuitry � Instrument cluster



(DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:

� check that the program card or disk is correctly installed.

� check the connections to the vehicle.

� check the ignition switch position.

5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.

6. Carry out the DATA LINK DIAGNOSTICS TEST. If the diagnostic tool responds with:

� CKT914, CKT915, CKT693 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00 .

� NO RESP/NOT EQUIP for body security module, refer to Section 419-10 ; for anti-lock brake system (ABS), refer to Section 206-09 ; or for restraint control module, refer to Section 501-20B .

� SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the instrument cluster.

7. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Index or the Restraint Control Module Diagnostic Trouble Code (DTC) Index to continue diagnostics.

8. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.

Instrument Cluster Diagnostic Trouble Code (DTC) Index

DTC Description Source Action

B1201 Fuel Sender Circuit Failure

Instrument Cluster

Go To Pinpoint Test B .

B1204 Fuel Sender Circuit Short To Ground

Instrument Cluster

Go To Pinpoint Test B .

B1317 Battery Voltage High Instrument Cluster

Go To Pinpoint Test C .

B1318 Battery Voltage Low Instrument Cluster

Go To Pinpoint Test C .

B1320 Driver Door Ajar Circuit Open

Instrument Cluster

Go To Pinpoint Test J .

B1328 Passenger Door Ajar Circuit Open

Instrument Cluster

Go To Pinpoint Test J .

B1342 ECU is Defective Instrument Cluster

INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for

normal operation.

B1360 Ignition Run/Acc Circuit Open

Instrument Cluster

Go To Pinpoint Test A .

B2143 NVM Memory Failure Instrument Cluster

Go To Pinpoint Test A .

B2658 Wait To Start Warning Indicator Circuit Open

Instrument Cluster

Go To Pinpoint Test V .



For a complete list of instrument cluster DTCs, refer to Section 419-10 .

For a complete list of RCM DTCs, refer to Section 501-20B .

For a complete list of ABS control module DTCs, refer to Section 206-09 .

For a complete list of the PCM DTCs, refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ).

Instrument Cluster Self-Diagnostic Mode

To enter the instrument cluster self diagnostic mode with the engine off, depress and hold the odometer reset button. Turn the ignition switch to the RUN position and hold until the gauges sweep (within five to eight seconds). Depress the reset button once to advance to each stage of the self-test.

Turn the ignition to the OFF position to exit the instrument cluster self-diagnostic mode. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.

C1284 Oil Pressure Switch Failure

Instrument Cluster

Go To Pinpoint Test D .

U1027 Invalid or Missing Data for Engine RPM

Instrument Cluster

Go To Pinpoint Test I .

U1051 Invalid or Missing Data for Brakes

Instrument Cluster

Go To Pinpoint Test M .

U1073 Invalid or Missing Data for Engine Coolant

Instrument Cluster

Go To Pinpoint Test E .

Restraint Control Module Diagnostic Trouble Code (DTC) Index


B1869 Lamp Air Bag Warning Indicator Circuit Open Restraint Control Module

Go To Pinpoint Test P .

B1870 Lamp Air Bag Warning Indicator Circuit Short to Battery

Restraint Control Module

Go To Pinpoint Test P .

ABS Control Module Diagnostic Trouble Code (DTC) Index


C1226 Brake Warning Lamp Output Short to Ground ABS Go To Pinpoint Test M .

Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index


P4057 Fuel Fill Cap Off PCM Go To Pinpoint Test Z .

P0381 Glow Plug Indicator Circuit Malfunction PCM Go To Pinpoint Test V .



Symptom Chart

Instrument Cluster Self-Diagnostic Mode

Odometer display Description

GAGE Carries out gauge sweep of all gauges, then displays the present gauge values. Also carries out the check sum test on ROM and EEPROM.

All segments illuminated.

Illuminates all odometer segments.

bulb Illuminates all micro-controlled lamps and LEDs.

r #### Returns to normal operation of all micro-controlled lamps and LEDs and displays hexadecimal value for ROM level (used when requesting assistance from the hotline).

nr#### Displays hexidecimal ROM level and type as stored in non-volatile memory (NVM).

EE ## Displays hexadecimal value for EE level (used when requesting assistance from the hotline).

dt #### Displays hexadecimal code for the final manufacturing date.

###C Gas engines display last temperature gauge input value from SCP, temperature gauge will indicate present temperature. Diesel engine displays present temperature

analog/digital input in decimal as a ratio, temperature gauge will indicate present temperature.

dtc #### Displays a 16 bit DTC in hexidecimal format. DTCs displayed are those detected in continuous operation not during self-test.

EnG Displays English speed value being input, speedometer will indicate present speed.

m Displays metric speed value being input, speedometer will indicate present speed.

tAc Displays the tachometer value being input to the instrument cluster. Tachometer will indicate present rpm.

FUEL Displays the present analog/digital fuel level being input to the instrument cluster as a ratio.

OIL Displays the last analog/digital reading of the oil pressure switch contact resistance, oil gauge will indicate present level.

br Displays the brake fluid level in an analog/digital ratio value.

bAt ##.# Displays present battery analog/digital voltage.

rhEo Displays present hexadecimal pulse width modulation (PWM) dimming input.

rhi, rhS, rho Alternating 1 second display of pulse width modulation (PWM) input duty cycle, SCP hexidecimal dimming step, output driver counts in hexadecimal.

Cr RUN/START sense circuit check.

PA, Pb, PC, and Pd

Displays 8-bit hexadecimal value for the Port A, B, C, and D readings (used when requesting information from the hotline).

PE0-PE7 Displays 8-bit hexadecimal value for the Port E0-Port E7 in analog/digital readings.

Symptom Chart



Condition Possible Sources Action

� No communication with the instrument cluster

� Central junction box (CJB) fuse(s):

� 33 (15A). � 35 (10A). � 41 (10A). � 45 (10A).

� Circuitry. � J1850 standard

corporate protocol (SCP) communication network.

� Instrument cluster.

� Go To Pinpoint Test A .

� Incorrect fuel gauge indication

� Fuel sender. � Circuitry. � Fuel tank. � Instrument cluster.

� Go To Pinpoint Test B .

� Incorrect voltage gauge indication—manual transmission only

� Instrument cluster. � Circuitry.

� Go To Pinpoint Test C .

� Incorrect oil pressure gauge indication

� Instrument cluster. � Circuitry. � Oil pressure

switch.

� Go To Pinpoint Test D .

� Incorrect temperature gauge indication

� Circuitry. � Coolant

temperature sender (diesel only).

� J1850 standard corporate protocol (SCP) communication network.

� Instrument cluster. � Powertrain control

module (PCM).

� Go To Pinpoint Test E .

� Incorrect transmission temperature gauge indication—automatic transmission only

� Circuitry. � Transmission

temperature sensor.

� Powertrain control module (PCM).


� Go To Pinpoint Test F .

� The low fuel warning indicator is never/always on

� Instrument cluster. � Low fuel indicator

bulb.

� Go To Pinpoint Test G .

� The speedometer is inoperative

� Instrument cluster. � Circuitry. � Anti-lock brake

system (ABS) module.

� Go To Pinpoint Test H .

� The tachometer is � Circuitry. � Go To Pinpoint Test I .



inoperative � Instrument cluster. � Generator (diesel

only).

� Trip odometer inoperative, speedometer OK

� Instrument cluster. � VERIFY the trip odometer reset button is not binding. If OK, INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation.

� The door ajar indicator is inoperative (chime is operative)/does not operate correctly

� Indicator bulb. � Circuitry. � Instrument cluster. � Body security

module.

� Go To Pinpoint Test J .

� The safety belt warning indicator is inoperative (chime is operative)/does not operate correctly

� Indicator bulb. � Circuitry. � Instrument cluster. � Safety belt switch

(part of the safety belt retractor).

� Go To Pinpoint Test K .

� Inaccurate speedometer reading

� Instrument cluster. � Anti-lock brake


� Tires.

� Go To Pinpoint Test H .

� The ABS warning indicator is never/always on

� Indicator bulb. � Circuitry. � Instrument cluster. � Anti-lock brake


� Go To Pinpoint Test L .

� The brake warning indicator is never on

� Indicator bulb. � Circuitry. � Instrument cluster. � Brake warning

indicator relay. � Anti-lock brake


� Brake fluid level switch.

� Parking brake switch.

� Go To Pinpoint Test M .

� The brake warning indicator is always on

� Circuitry. � Brake fluid level

switch. � Parking brake

switch. � Anti-lock brake


� Hydromax module (if equipped).


� REFER to Section 206-00 .



� Malfunction indicator lamp (MIL) indicator is never on

� Indicator LED. � Circuitry. � Instrument cluster. � J1850 standard

corporate protocol (SCP) communication network.


� Go To Pinpoint Test N .

� Malfunction indicator lamp (MIL) indicator is always on

� Diagnostic trouble code (DTC) related concern(s).

� REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ).

� The charging system indicator is never on

� Central junction box (CJB) fuse 29 (5A).

� Charging system. � Indicator LED. � Circuitry. � Instrument cluster.

� Go To Pinpoint Test O .

� The charging system indicator is always on

� Circuitry. � Generator

(charging system).

� REFER to Section 414-00 .

� The air bag indicator warning is never/always on

� Indicator bulb. � Circuitry. � Instrument cluster. � Air bag diagnostic

monitor.

� Go To Pinpoint Test P .

� High beam indicator is never on

� Indicator bulb. � Circuitry. � Instrument cluster.

� Go To Pinpoint Test Q .

� The LH turn indicator is never on


� Go To Pinpoint Test R .

� The RH turn indicator is never on


� Go To Pinpoint Test S .

� The 4X4 high/4X4 LOW range indicator is never/always on—electronic

� Circuitry. � 4X4 range select

switch. � Indicator bulb.

� Go To Pinpoint Test T .

� The 4X4 high/4X4 LOW range indicator is never/always on—manual

� Circuitry. � 4X4 range select

switch.

� Go To Pinpoint Test U .

� The wait to start indicator is never/always on—diesel only

� Circuitry. � Powertrain control

module (PCM).

� Go To Pinpoint Test V .

� The water in fuel indicator is

� Indicator bulb. � Circuitry.

� Go To Pinpoint Test W .



Pinpoint Tests

PINPOINT TEST A: NO COMMUNICATION WITH THE INSTRUMENT CLUSTER

never/always on—diesel only

� Water in fuel switch.


� The speed control indicator is never/always on

� Indicator bulb. � Circuitry. � Speed control

servo. � Instrument cluster.

� Go To Pinpoint Test X .

� The theft indicator is never/always on

� Indicator bulb. � Circuitry. � Passive anti-theft

(PATS) module. � Instrument cluster.

� Go To Pinpoint Test Y .

� The check fuel cap indicator is inoperative/always on

� Evaporative system.



� Go To Pinpoint Test Z .

� The CHECK GAGE warning indicator is inoperative/always on

� CHECK GAGE indicator bulb.

� Circuitry. � Instrument cluster.

� Go To Pinpoint Test AA .

� The check air filter indicator is never/always on—diesel only

� Check air filter indicator bulb.

� Circuitry. � Check air filter

switch. � Instrument cluster.

� Go To Pinpoint Test AB .

� The CK SUSP indicator is never/always on

� Circuitry. � Air suspension

module. � Instrument cluster.

� Go To Pinpoint Test AC .

� The instrument cluster is inoperative

� Central junction box (CJB) fuse(s):

� 33 (15A). � 35 (10A). � 41 (10A). � 45 (10A).

� Circuitry. � Instrument cluster.

� Go To Pinpoint Test AD .

CONDITIONS DETAILS/RESULTS/ACTIONS

CAUTION: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

A1 CHECK THE INSTRUMENT CLUSTER POWER SUPPLY



Instrument Cluster C220c

Using the following table, measure the voltage between the instrument cluster C220c, harness side and ground.

Pin Circuit

11 705 (LG/OG)

12 785 (BK/LG)

19 1002 (BK/PK)

20 640 (RD/YE)

� Are the voltages greater than 10

volts?

Yes GO to A2 .

No REPAIR the circuit(s) in question. TEST the system for normal operation.

A2 CHECK INSTRUMENT CLUSTER GROUND CIRCUITS 57 (BK) AND 676 (PK/OG)



PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION

Measure the resistance between the instrument cluster C220c pin 13, circuit 676 (PK/OG), harness side and ground; and between the instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground.

� Are the resistances less than 5

ohms?

Yes REFER to Section 418-00 .




B1 CARRY OUT THE INSTRUMENT CLUSTER FUEL GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL



Instrument Cluster

Select the instrument cluster FUEL LEVEL CONTROL active command. Trigger, monitor, and scroll FUELLEVEL at: 0% , 50%, and 100%.

� Does the fuel gauge display:

below E with 0%, half with 50%, and full stop with 100%?

Yes GO to B2 .

No GO to B8 .

B2 CHECK THE FUEL GAUGE OPERATION

Fuel Pump Assembly C433 or C4033 (California)

Connect one lead of the Instrument Gauge System Tester to the fuel pump assembly C433 pin 1 or C4033 pin 5 (California), circuit 29 (YE/WH), harness side and the other lead to the fuel pump assembly C433 pin 3 or C4033 pin 8 (California), circuit 396 (BK/OG), harness side.



Set the Instrument Gauge System Tester to 160 ohms.

Wait one minute for the gauge to respond.

Set the tester to 15 ohms.

NOTE: The fuel gauge should read below E (empty mark) when carrying out this test step.

Wait one minute and read the fuel gauge.



Set the tester to 145 ohms.

NOTE: The fuel gauge should read F (full) or above when carrying out this test step.

Wait one minute and read the fuel gauge.

� Does the fuel gauge operate

correctly?

Yes GO to B3 .

No GO to B5 .

B3 CHECK THE FUEL TANK

Check the fuel tank for any damage or deformation.

� Is the fuel tank OK?

Yes GO to B4 .

No INSTALL a new fuel tank. REFER to Section 310-01 . TEST the system for normal operation.



B4 INSPECT THE FUEL PUMP ASSEMBLY

Check the fuel pump assembly in-tank mounting, float, float rod, wiring and connections for damage or obstruction.

� Are the fuel pump assembly

and wiring OK?

Yes INSTALL a new fuel sender. TEST the system for normal operation.

No REPAIR or INSTALL a new fuel pump assembly as necessary. TEST the system for normal operation.

B5 CHECK CIRCUIT 29 (YE/WH) FOR SHORT TO POWER

Instrument Cluster C220b

Measure the voltage between the instrument cluster C220b pin 3, circuit 29 (YE/WH), harness side and ground.

� Is any voltage present?



Yes REPAIR the circuit. TEST the system for normal operation.

No GO to B6 .

B6 CHECK CIRCUIT 29 (YE/WH) FOR OPEN OR SHORT TO GROUND

Measure the resistances between the instrument cluster C220b pin 3, circuit 29 (YE/WH), harness side and the fuel pump assembly C433 pin 1 or C4033 pin 5 (California), circuit 29 (YE/WH), harness side; and between the instrument cluster C220b pin 3, circuit 29 (YE/WH), harness side and ground.

� Is the resistance less than 5

ohms between the instrument cluster and the fuel pump assembly; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to B7 .

No REPAIR the circuit. TEST the system for normal operation.

B7 CHECK FUEL SENDING UNIT GROUND CIRCUIT 396 (BK/OG) FOR OPEN

Measure the resistance between the instrument cluster C220b pin 4, circuit 396 (BK/OG), harness side and the fuel pump assembly C433 pin 3 or C4033 pin 8 (California), circuit 396 (BK/OG), harness side.




PINPOINT TEST C: INCORRECT VOLTAGE GAUGE INDICATION—MANUAL TRANSMISSION ONLY

ohms?

Yes GO to B8 .


B8 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION

Disconnect all instrument cluster connectors.

Check for:

� corrosion � pushed-out pins

Connect all instrument cluster connectors and make sure they seat correctly.

Operate the system and verify the concern is still present.

� Is the concern still present?

Yes INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. REPEAT the Instrument Cluster self-test.

No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.



C1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS

Use the recorded instrument cluster DTCs from the continuous and on-demand self-tests.

� Are any instrument cluster DTCs recorded?



Yes If instrument cluster DTC B1317 or B1318 is retrieved, REFER to Section 414-00 . All other instrument cluster DTCs, REFER to the Instrument Cluster Diagnostic Trouble Code (DTC) Index.

No GO to C2 .

C2 CARRY OUT THE VOLTMETER ACTIVE COMMAND USING THE DIAGNOSTIC TOOL

Instrument Cluster Active

Command

Select the instrument cluster voltmeter active command.

Trigger the voltmeter active command. Scroll in three increments 0%, 50% and 100%.

� Did the voltmeter start at L (low) when at 0%, move to half at

50% and H (high) at 100%?


No GO to C3 .

C3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:



PINPOINT TEST D: INCORRECT OIL PRESSURE GAUGE INDICATION





Yes INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation.

No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. TEST the system for normal operation.



D1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS


� Are any instrument cluster

DTCs recorded?

Yes If instrument cluster DTC C1284 is retrieved, INSTALL a new oil pressure switch. TEST the system for normal operation. All other instrument cluster DTCs, REFER to the Instrument Cluster Diagnostic Trouble Code (DTC) Index.

No GO to D2 .

D2 CARRY OUT THE OIL PRESSURE GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL



Instrument Cluster Active Command

Select the instrument cluster oil pressure gauge active command.

Trigger the oil pressure gauge active command. Scroll in three increments 0%, 50% and 100%.

� Did the engine oil pressure

gauge start at L (low) when at 0%, move to half at 50% and H (high) at 100%?

Yes GO to D3 .

No GO to D6 .

D3 CHECK THE ENGINE OIL PRESSURE

Carry out the engine oil pressure test. Refer to Section 303-00 .



� Is the oil pressure within specification?

Yes GO to D4 .

No REFER to Section 303-00 .

D4 CHECK CIRCUIT 31 (WH/RD) FOR OPEN OR SHORT TO GROUND


Oil Pressure Switch C103

Measure the resistance between the instrument cluster C220c pin 8, circuit 31 (WH/RD), harness side and the oil pressure switch C103, circuit 31 (WH/RD), harness side; and between the instrument cluster C220c pin 8, harness side and ground.


ohms between the instrument cluster and the oil pressure



switch; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to D5 .


D5 CHECK CIRCUIT 31 (WH/RD) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220c pin 8, circuit 31 (WH/RD), harness side and ground.

� Is the resistance greater than

10,000 ohms?

Yes INSTALL a new oil pressure switch. TEST the system for normal operation.


D6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:

� corrosion



PINPOINT TEST E: INCORRECT TEMPERATURE GAUGE INDICATION

� pushed-out pins








E1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS


� Are any instrument cluster

DTCs recorded?

Yes If instrument cluster DTC U1073 is retrieved, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ). All other instrument cluster DTCs REFER to the Instrument Cluster Diagnostic Trouble Code (DTC) Index.

No GO to E2 .



E2 CARRY OUT THE COOLANT TEMPERATURE GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL


Select the instrument cluster engine coolant active command.

Trigger the engine coolant active command. Scroll in three increments 0%, 50% and 100%.

� Did the temperature gauge start

at cold when at 0%, move to half at 50% and full hot at 100%?

Yes For gasoline engine, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ). For diesel engine, GO to E3 .

No GO to E7 .

E3 CHECK CIRCUIT 45 (YE/RD) FOR OPEN OR SHORT TO GROUND




Engine Coolant Temperature Sensor C1064

Measure the resistance between the instrument cluster C220c pin 6, circuit 45 (YE/RD), harness side and the engine coolant temperature sensor C1064 pin 2, circuit 45 (YE/RD), harness side; and between the instrument cluster C220c pin 6, circuit 45 (YE/RD), harness side and ground.


ohms between the instrument cluster and the engine coolant temperature sensor; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to E4 .




E4 CHECK CIRCUIT 45 (YE/RD) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220c pin 6, circuit 45 (YE/RD), harness side and ground.

� Is any voltage indicated?

Yes GO to E5 .


E5 CHECK CIRCUIT 39 (RD/WH) FOR OPEN OR SHORT TO GROUND

Measure the resistance between the instrument cluster C220c pin 7, circuit 39 (RD/WH), harness side and the engine coolant temperature sensor C1064 pin 1, circuit 39 (RD/WH), harness side; and between the instrument cluster C220c pin 7, circuit 39 (RD/WH), harness side and ground.


ohms between the instrument cluster and the engine coolant temperature sensor; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to E6 .

No



REPAIR the circuit. TEST the system for normal operation.

E6 CHECK CIRCUIT 39 (RD/WH) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220c pin 7, circuit 39 (RD/WH), harness side and ground.



No INSTALL a new engine coolant temperature sensor. REFER to Section 303-14B . TEST the system for normal operation.

E7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:








PINPOINT TEST F: INCORRECT TRANSMISSION TEMPERATURE GAUGE INDICATION—AUTOMATIC TRANSMISSION ONLY



F1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS




No GO to F2 .

F2 CARRY OUT THE TRANSMISSION TEMPERATURE GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL



PINPOINT TEST G: THE LOW FUEL WARNING INDICATOR IS NEVER/ALWAYS ON


Command

Select the instrument cluster transmission temperature gauge active command.

Trigger, monitor, and scroll the transmission temperature gauge at: 0% , 50%, and 100%.

� Does the transmission temperature gauge display: low (L) with

0%, half with 50%, and high (H) with 100%?

Yes REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ).

No GO to F3 .

F3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:








G1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE



COMMAND USING THE DIAGNOSTIC TOOL


Command

Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on and off. Observe the low fuel warning indicator.

� Does the low fuel warning indicator illuminate when commanded

on and turn off when commanded off?

Yes GO to G2 .

No GO to G3 .

G2 CHECK THE FUEL GAUGE



PINPOINT TEST H: THE SPEEDOMETER IS INOPERATIVE

Check the fuel gauge.

� Does the fuel gauge operate correctly?

Yes GO to G3 .

No Go To Pinpoint Test B .

G3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:









H1 CARRY OUT THE SPEEDOMETER ACTIVE COMMAND USING THE DIAGNOSTIC TOOL




Select the instrument cluster speedometer active command.

Trigger the speedometer and scroll in increments of 10% while monitoring the speedometer. The speedometer should increase in increments of approximately 16 km/h (10 mph) for each 10% change.

� Does the speedometer increase

within specifications?

Yes GO to H2 .

No GO to H4 .

H2 CHECK THE CIRCUIT 679 (GY/BK) FOR OPEN OR SHORT TO GROUND




4WABS Module C135

Measure the resistance between the instrument cluster C220b pin 3, circuit 679 (GY/BK), harness side and the 4WABS module C135 pin 11, circuit 679 (GY/BK), harness side; and between the instrument cluster C220b pin 3, circuit 679 (GY/BK), harness side and ground.


ohms between the instrument cluster and the 4WABS module; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to H3 .


H3 CHECK THE CIRCUIT 679 (GY/BK) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220b pin 3, circuit 679 (GY/BK), harness side and ground.






H4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:









PINPOINT TEST I: THE TACHOMETER IS INOPERATIVE


I1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS




No GO to I2 .

I2 CARRY OUT THE TACHOMETER ACTIVE COMMAND USING THE DIAGNOSTIC TOOL


Command

Select the instrument cluster tachometer active command.

Trigger the tachometer and scroll in increments of 10%. Monitor the tachometer gauge. The tachometer should increase in increments of approximately 600 rpm for each 10% change.



PINPOINT TEST J: THE DOOR AJAR INDICATOR IS INOPERATIVE (CHIME IS OPERATIVE)/DOES NOT OPERATE CORRECTLY

� Does the tachometer gauge increase within specifications?


No GO to I3 .

I3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:









J1 CHECK THE INTERIOR LAMPS OPERATION

Open and close each door while monitoring the interior lamps.

� Do the interior lamps operate

correctly?

Yes GO to J2 .




J2 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL


Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command. Observe the door ajar indicator.

� Is the door ajar indicator

illuminated?

Yes With remote keyless entry system, GO to J5 . Without remote keyless entry system, GO to J3 .

No GO to J6 .

J3 CHECK CIRCUIT 759 (LG/YE) FOR OPEN OR SHORT TO GROUND



Driver Door Ajar Switch C526


Measure the resistance between the instrument cluster C220b pin 1, circuit 759 (LG/YE), harness side and the driver door ajar switch C526 pin 1, circuit 759 (LG/YE), harness side; and between the instrument cluster C220b pin 1, circuit 759 (LG/YE), harness side and ground.


ohms between the instrument cluster and the driver door ajar switch; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to J4 .




J4 CHECK CIRCUIT 760 (PK/LB) FOR OPEN OR SHORT TO GROUND

Door Ajar Switch C715 (LR), C820 (RR), and C602 (RF)


Measure the resistance between the instrument cluster C220b pin 2, circuit 760 (PK/LB), harness side and the RF door ajar switch C602 pin 1, circuit 760 (PK/LB), harness side; and between the instrument cluster C220b pin 2, circuit 760 (PK/LB), harness side and ground.


ohms between the instrument cluster and the driver door ajar switch; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to J6 .

No



REPAIR the circuit. TEST the system for normal operation

J5 CHECK FOR CORRECT BODY SECURITY MODULE OPERATION

Disconnect all body security module connectors.

Check for:


Connect all body security module connectors and make sure they seat correctly.



Yes INSTALL a new body security module. REFER to Section 419-10 . TEST the system for normal operation.


J6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:








PINPOINT TEST K: THE SAFETY BELT WARNING INDICATOR IS INOPERATIVE (CHIME IS OPERATIVE)/DOES NOT OPERATE CORRECTLY




K1 CHECK THE SAFETY BELT RETRACTOR SWITCH OPERATION

Safety Belt Retractor Switch C323

Connect a fused (10A) jumper wire between the safety belt retractor switch C323 pin 1, circuit 85 (BN/LB), harness side and ground.

Observe the safety belt warning indicator.

� Is the safety belt warning



indicator illuminated?

Yes GO to K2 .

No GO to K3 .

K2 CHECK CIRCUIT 57 (BK) FOR OPEN

Measure the resistance between the safety belt retractor switch C323 pin 4, circuit 57 (BK), harness side and ground.


ohms?

Yes INSTALL a new safety belt retractor switch. REFER to Section 501-20A . TEST the system for normal operation.


K3 CHECK CIRCUIT 85 (BN/LB) FOR OPEN


Measure the resistance between the



instrument cluster C220b pin 6, circuit 85 (BN/LB), harness side and the safety belt retractor switch C323 pin 1, circuit 85 (BN/LB), harness side.


ohms?

Yes GO to K4 .


K4 CHECK CIRCUIT 85 (BN/LB) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220b pin 6, circuit 85 (BN/LB), harness side and ground.



No GO to K5 .

K5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION




PINPOINT TEST L: THE ABS WARNING INDICATOR IS NEVER/ALWAYS ON

Check for:









L1 VERIFY LAMP OPERATION

Observe the ABS warning indicator lamp prove-out.

� Does the ABS warning indicator



lamp prove out?

Yes If the ABS warning indicator is always on, GO to L2 .

No If the ABS warning indicator is inoperative, GO to L4 .

L2 CHECK ABS INDICATOR LAMP OPERATION

ABS Module C135

Observe the ABS indicator lamp.

� Is the ABS indicator lamp

illuminating?

Yes GO to L3 .


L3 CHECK CIRCUIT 603 (DG) FOR SHORT TO GROUND



ABS Module C135

Measure the resistance between the 4WABS module C135 pin 15, circuit 603 (DG), harness side and ground.


10,000 ohms?

Yes GO to L7 .


L4 CHECK THE ABS WARNING INDICATOR CONTROL CIRCUIT



ABS Module C135

Connect a fused (10A) jumper wire between the 4WABS module C135 pin 15, circuit 603 (DG), harness side and ground.

� Does the indicator illuminate?


No GO to L5 .

L5 CHECK CIRCUIT 603 (DG) FOR OPEN


Measure the resistance between the 4WABS module C135 pin 15, circuit 603 (DG), harness side and the instrument cluster C220c pin 18, circuit 603 (DG), harness side.




ohms?

Yes GO to L6 .


L6 CHECK CIRCUIT 603 (DG) FOR SHORT TO POWER

Measure the voltage between the 4WABS module C135 pin 15, circuit 603 (DG), harness side and ground.

� Is there any voltage indicated?

Yes GO to L7 .


L7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION




PINPOINT TEST M: THE BRAKE WARNING INDICATOR IS NEVER ON

Check for:









M1 CHECK THE BRAKE FLUID LEVEL AND PARKING BRAKE

Check the parking brake control and brake fluid level.

� Is the parking brake control

fully disengaged and the brake fluid level at the correct level?

Yes GO to M2 .

No DISENGAGE the parking brake control and FILL the brake fluid to the correct level as necessary. TEST the system for normal operation.

M2 CHECK PARKING BRAKE SWITCH



Parking Brake Switch C2015

Measure the resistance between the parking brake switch (component side) and ground while engaging and fully disengaging the parking brake control.


ohms with the parking brake engaged and greater than 10,000 ohms with the parking brake fully disengaged?

Yes GO to M3 .

No INSTALL a new parking brake switch. REFER to Section 206-00 . TEST the system for normal operation.

M3 CHECK CIRCUIT 162 (LG/RD) FOR OPEN OR SHORT TO GROUND




Measure the resistance between the instrument cluster C220b pin 11, circuit 162 (LG/RD), harness side and the parking brake switch C2015, circuit 162 (LG/RD), harness side; and between the instrument cluster C220b pin 11, circuit 162 (LG/RD), harness side and ground.


ohms between the instrument cluster and parking brake switch; and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to M4 .


M4 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE

ABS Module C135




Check the red BRAKE warning indicator for illumination.

� Does the red BRAKE warning

indicator illuminate?

Yes GO to M5 .


M5 CHECK BRAKE FLUID LEVEL SWITCH

NOTE: Verify that the brake fluid level is full.

Brake Fluid Level Switch C124

Measure the resistances between the brake fluid level switch pin 1 (component side) and the fluid level switch pin 3 (component side); and between the fluid level switch pin 2 (component side) and the fluid level switch pin 3 (component side).




10,000 ohms between the fluid level indicator switch pin 1 and the fluid level indicator switch pin 3; and less than 5 ohms between the fluid level indicator switch pin 2 and the fluid level indicator switch pin 3?

Yes GO to M6 .

No INSTALL a new brake fluid level switch. TEST the system for normal operation.

M6 CHECK CIRCUIT 531 (DG/YE) AND CIRCUIT 512 (TN/LG) FOR SHORT TO GROUND


ABS Module C135

Measure the resistances between the instrument cluster C220c pin 10, circuit 531 (DG/YE), harness side and ground; and between the instrument cluster C220c pin 9, circuit 512 (TN/LG), harness side and ground.

� Are the resistances greater than

10,000 ohms?



Yes GO to M7 .

No REPAIR circuit 531 (DG/YE) and circuit 512 (TN/LG) as necessary. TEST the system for normal operation.

M7 CHECK CIRCUIT 531 (DG/YE) AND CIRCUIT 512 (TN/LG) FOR AN OPEN

Measure the resistances between the instrument cluster C220c pin 10, circuit 531 (DG/YE), harness side and the brake fluid level switch C124 pin 3, circuit 531 (DG/YE), harness side; and between the instrument cluster C220c pin 9, circuit 512 (TN/LG), harness side and the brake fluid level switch C124 pin 2, circuit 512 (TN/LG), harness side.


ohms?

Yes GO to M8 .

No REPAIR the circuit in question. TEST the system for normal operation.

M8 CHECK CIRCUIT 57 (BK) FOR AN OPEN

Measure the resistance between the brake fluid level switch C124 pin 1, circuit 57 (BK), harness side and ground.


ohms?



PINPOINT TEST N: MALFUNCTION INDICATOR LAMP (MIL) INDICATOR IS NEVER ON

Yes GO to M9 .


M9 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:


Correct all instrument cluster connectors and make sure they seat correctly.

Operate the system and verify that concern is still present.



No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. TEST the system for normal operation.


N1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL



Diagnostic Tool


Command

Select the ICM WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command. Observe the SERVICE ENGINE SOON indicator.

� Is the SERVICE ENGINE SOON indicator illuminating?


No GO to N2 .

N2 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:







PINPOINT TEST O: THE CHARGING SYSTEM INDICATOR IS NEVER ON





O1 CHECK THE CHARGING SYSTEM WARNING INDICATOR OPERATION

Generator C102a

Connect a fused (10A) jumper wire between the generator C102a pin 1, circuit 904 (LG/RD), harness side and ground.



� Does the charging system

warning indicator illuminate?

Yes For gasoline engine, INSTALL a new generator. REFER to Section 414-02 . TEST the system for normal operation. For diesel engine, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ).

No For gasoline engine, GO to O2 . For diesel engine, GO to O3 .

O2 CHECK CIRCUIT 904 (LG/RD) FOR OPEN


Measure the resistance between the instrument cluster C220b pin 12, circuit 904 (LG/RD), harness side and the generator C102a pin 3, circuit 904 (LG/RD), harness side.




ohms?

Yes GO to O4 .


O3 CHECK INDICATOR CONTROL CIRCUIT 904 (LG/RD) FOR OPEN


PCM C175

Measure the resistance between the instrument cluster C220b pin 12, circuit 904 (LG/RD), harness side and the PCM C175 pin 67, circuit 904 (LG/RD), harness side.




ohms?

Yes GO to O4 .


O4 CHECK CIRCUIT 904 (LG/RD) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220b pin 12, circuit 904 (LG/RD), harness side and ground.



No GO to O5 .

O5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION




PINPOINT TEST P: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON

Check for:









P1 VERIFY LAMP OPERATION

Observe the air bag indicator lamp prove out.

� Does the air bag indicator lamp



prove out correctly?

Yes System is OK.

No If the air bag indicator is never on, GO to P2 . If the air bag indicator is always on, GO to P4 .

P2 CHECK CIRCUIT 608 (BK/YE)

Deactivate the restraint control supplemental air bag system. Refer to Section 501-20B .

Restraint Control Module C1041

Connect a fused (10A) jumper wire between the restraint control module C1041 pin 20, circuit 608 (BK/YE), harness side and ground.



� Does the air bag indicator lamp

illuminate?

Yes REFER to Section 501-20B .

No GO to P3 .

P3 CHECK CIRCUIT 608 (BK/YE) FOR OPEN


Measure the resistance between the instrument cluster C220c pin 14, circuit 608 (BK/YE), harness side and the restraint control module C1041 pin 20, circuit 608 (BK/YE) harness side.


ohms?



Yes GO to P6 .


P4 ISOLATE AIR BAG DIAGNOSTIC MODULE

Deactivate the restraint control supplemental air bag system. Refer to Section 501-20B .

Restraint Control Module C1041

Observe the air bag warning indicator.

� Does the air bag warning


Yes GO to P5 .

No REFER to Section 501-20B .

P5 CHECK CIRCUIT 608 (BK/YE) FOR SHORT TO GROUND




Measure the resistance between the instrument cluster C220c pin 14, circuit 608 (BK/YE), harness side and ground.


10,000 ohms?

Yes GO to P6 .


P6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:



Operate the system and verify the



PINPOINT TEST Q: HIGH BEAM INDICATOR IS NEVER ON

concern is still present.






Q1 VERIFY HIGH BEAM OPERATION

Verify the high beam headlamps operation.

� Do the high beam headlamps

operate correctly?

Yes GO to Q2 .


Q2 CHECK CIRCUIT 12 (LG/BK) FOR VOLTAGE


NOTE: Headlamps must be on for this test.

Place the multifunction switch in the high beam position.



Measure the voltage between the instrument cluster C220c pin 5, circuit 12 (LG/BK), harness side and ground.

� Is the voltage greater than 10

volts?

Yes GO to Q4 .

No GO to Q3 .

Q3 CHECK CIRCUITS 12 (LG/BK) AND 632 (GY/OG) FOR OPEN OR SHORT TO GROUND

Place the headlamp switch in the OFF position.

Multifunction Switch C202a

Measure the resistance between the instrument cluster C220c pin 5, circuit 12 (LG/BK), harness side and the multifunction switch C202a pin 7, circuit 632 (GY/OG), harness side; and between the instrument cluster C220c pin 5, circuit 12 (LG/BK), harness side and ground.


ohms between the instrument



cluster and the multifunction switch; and greater than 10,000 ohms between the instrument cluster and ground?

Yes INSTALL a new multifunction switch. REFER to Section 211-05 . TEST the system for normal operation.


Q4 CHECK CIRCUIT 57 (BK) FOR OPEN

Measure the resistance between the instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground.


ohms?

Yes GO to Q5 .


Q5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:






PINPOINT TEST R: THE LH TURN INDICATOR IS NEVER ON






R1 VERIFY TURN SIGNAL OPERATION

Verify the turn signal operation.

� Do the turn signals operate

correctly?

Yes GO to R2 .


R2 CHECK CIRCUIT 3 (LG/WH) FOR VOLTAGE

Instrument Cluster C220a



Place the multifunction switch in the LH turn signal position.

Measure the voltage between instrument cluster C220a pin 5, circuit 3 (LG/WH), harness side and ground.

� Does the voltage fluctuate

between 0 and greater than 10 volts?

Yes GO to R4 .

No GO to R3 .

R3 CHECK CIRCUIT 3 (LG/WH) FOR OPEN OR SHORT TO GROUND

Multifunction Switch C202b

Measure the resistance between the instrument cluster C220a pin 5, circuit 3 (LG/WH), harness side and the multifunction switch C202b pin 10, circuit 3 (LG/WH), harness side; and between the instrument cluster C220a pin 5, circuit 3 (LG/WH), harness side and ground.




ohms between the instrument cluster and the multifunction switch; and greater than 10,000 ohms between the instrument cluster and ground?



R4 CHECK CIRCUIT 57 (BK) FOR OPEN


Measure the resistance between instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground.


ohms?

Yes GO to R5 .



PINPOINT TEST S: THE RH TURN INDICATOR IS NEVER ON


R5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:









S1 VERIFY TURN SIGNAL OPERATION

Verify the turn signal operation.

� Do the turn signals operate

correctly?

Yes GO to S2 .




S2 CHECK CIRCUIT 2 (WH/LB) FOR VOLTAGE


Place the multifunction switch in the RH turn signal position.

Measure the voltage between instrument cluster C220c pin 4, circuit 2 (WH/LB), harness side and ground.

� Does the voltage fluctuate

between 0 and greater than 10 volts?

Yes GO to S4 .

No GO to S3 .

S3 CHECK CIRCUIT 2 (WH/LB) FOR OPEN OR SHORT TO GROUND



Multifunction Switch C202b

Measure the resistance between the instrument cluster C220c pin 4, circuit 2 (WH/LB), harness side and the multifunction switch C202b pin 7, circuit 2 (WH/LB), harness side; and between the instrument cluster C220c pin 4, circuit 2 (WH/LB), harness side and ground.


ohms between the instrument cluster and the multifunction switch; and greater than 10,000 ohms between the instrument cluster and ground?



S4 CHECK CIRCUIT 57 (BK) FOR OPEN

Measure the resistance between instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground.




ohms?

Yes GO to S5 .


S5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:









PINPOINT TEST T: THE 4X4 HIGH/4X4 LOW RANGE INDICATOR IS NEVER/ALWAYS ON—ELECTRONIC



T1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL

Diagnostic Tool


Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on and off. Observe the 4x4 HIGH and 4x4 LOW indicators.

� Do the 4x4 HIGH and 4x4 LOW

indicators illuminate when triggered on and turn off when



triggered off?

Yes If the 4x4 HIGH indicator is inoperative, GO to T2 . If the 4x4 LOW indicator is inoperative, GO to T4 . If the 4x4 HIGH indicator is always on, GO to T6 . If the 4x4 LOW indicator is always on, GO to T7 .

No GO to T9 .

T2 CHECK CIRCUIT 210 (LB) FOR OPEN

4x4 Control Module C281b


Measure the resistance between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and the 4x4 control module C281b pin 9, circuit 210 (LB), harness side.




ohms?

Yes GO to T3 .


T3 CHECK CIRCUIT 210 (LB) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground.



No GO to T8 .

T4 CHECK CIRCUIT 975 (BN/YE) FOR OPEN




4x4 Control Module C281b

Measure the resistance between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side and the 4x4 control module C281b pin 8, circuit 975 (BN/YE), harness side.


ohms?

Yes GO to T5 .


T5 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side



and ground.



No GO to T8 .

T6 CHECK CIRCUIT 210 (LB) FOR SHORT TO GROUND


Measure the resistance between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground.




10,000 ohms?

Yes GO to T8 .


T7 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO GROUND


Measure the resistance between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side and ground.


10,000 ohms?

Yes



GO to T8 .


T8 CHECK FOR CORRECT 4X4 MODULE OPERATION

Disconnect all 4x4 module connectors.

Check for:


Connect all 4x4 module connectors and make sure they seat correctly.



Yes INSTALL a new 4x4 module. REFER to Section 308-07A . TEST the system for normal operation.


T9 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:





Yes INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal



PINPOINT TEST U: THE 4X4 HIGH/4X4 LOW RANGE INDICATOR IS NEVER/ALWAYS ON—MANUAL SHIFT

operation.




U1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL

Diagnostic Tool




Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on and off. Observe the 4x4 HIGH and 4x4 LOW indicators.

� Do the 4x4 HIGH and 4x4 LOW

indicators illuminate when triggered on and turn off when triggered off?

Yes If the 4x4 HIGH indicator is inoperative, GO to U2 . If the 4x4 LOW indicator is inoperative, GO to U4 . If the 4x4 HIGH indicator is always on, GO to U6 . If the 4x4 LOW indicator is always on, GO to U7 .

No GO to U8 .

U2 CHECK CIRCUIT 210 (LB) FOR OPEN

4x4 Range Select Switch C1177




Measure the resistance between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and the 4x4 range select switch C1177 pin 2, circuit 210 (LB), harness side.


ohms?

Yes GO to U3 .


U3 CHECK CIRCUIT 210 (LB) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground.


Yes REPAIR the circuit in question. TEST the system for normal operation.

No GO to U6 .

U4 CHECK CIRCUIT 975 (BN/YE) FOR OPEN





Measure the resistance between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side and the 4x4 range select switch C1177 pin 1, circuit 975 (BN/YE), harness side.


ohms?

Yes GO to U5


U5 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side



ground.


Yes REPAIR the circuit in question. TEST the system for normal operation.

No INSTALL a new 4x4 range select switch. TEST the system for normal operation.

U6 CHECK CIRCUIT 210 (LB) FOR SHORT TO GROUND



Measure the resistance between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground.




10,000 ohms?

Yes INSTALL a new 4x4 select switch. REFER to Section 308-07A . TEST the system for normal operation.


U7 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO GROUND



Measure the resistance between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side and ground.




10,000 ohms?

Yes INSTALL a new 4x4 select switch. REFER to Section 308-07A . TEST the system for normal operation.


U8 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:






No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. TEST



PINPOINT TEST V: THE WAIT TO START INDICATOR IS NEVER/ALWAYS ON—DIESEL ONLY

the system for normal operation.


V1 RETRIEVE THE RECORDED PCM AND INSTRUMENT CLUSTER DTCS BOTH CONTINUOUS AND ON-DEMAND SELF-TESTS

Diagnostic Tool

PCM and Instrument Cluster

DTCs

Retrieve the recorded PCM and instrument panel cluster DTCs from both the continuous and on-demand self-tests.

� Are the any DTCs retrieved?

Yes If PCM DTC P0381 or instrument cluster B2658, GO to V5 . For all other PCM DTCs, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ). For all other instrument cluster DTCs, REFER to Section 419-10 .

No GO to V2 .

V2 CHECK THE WAIT TO START INDICATOR PROVE-OUT

NOTE: The wait to start indicator should prove out for approximately 1 to 10 seconds, then turn off.



Monitor the wait to start indicator during prove-out.

� Does the wait to start indicator prove out correctly?

Yes The system is OK.

No GO to V3 .

V3 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL


Command

Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on then off. Observe the wait to start indicators.

� Does the wait to start indicator illuminate when commanded on,

and turn off when commanded off?

Yes GO to V4 .

No GO to V5 .

V4 CHECK FOR CORRECT PCM OPERATION

Disconnect all PCM connectors.



PINPOINT TEST W: THE WATER IN FUEL INDICATOR IS NEVER/ALWAYS ON—DIESEL ONLY

Check for:


Connect all PCM connectors and make sure they seat correctly.



Yes INSTALL a new PCM. REFER to Section 303-14B . TEST the system for normal operation. If the problem remains, REINSTALL the original PCM and GO to V5 .


V5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:






No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. TEST the sytem for normal operation.


W1 RETRIEVE THE RECORDED PCM DTCS BOTH CONTINUOUS AND ON-DEMAND AND SELF-TESTS



Diagnostic Tool

PCM and Instrument Cluster

DTCs

Retrieve the recorded PCM DTCs from both the continuous and on-demand self-tests.

� Are there any DTCs retrieved?

Yes If PCM DTC P1139 is retrieved, GO to W5 . For all other PCM DTCs, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ).

No GO to W2 .

W2 CHECK THE WATER IN FUEL INDICATOR PROVE-OUT



Monitor the water in fuel indicator during prove-out.

� Does the water in fuel indicator prove out correctly?

Yes The system is OK.

No GO to W3 .

W3 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL


Command

Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on then off. Observe the wait to start indicators.

� Does the water in fuel indicator illuminate when commanded on,

and turn off when commanded off?

Yes GO to W4 .

No GO to W5 .

W4 CHECK FOR CORRECT PCM OPERATION

Disconnect all PCM connectors.

Check for:


Connect all PCM connectors and make sure they seat correctly.




PINPOINT TEST X: THE SPEED CONTROL INDICATOR IS NEVER/ALWAYS ON


Yes INSTALL a new PCM. REFER to Section 303-14B . TEST the system for normal operation. If the problem remains, REINSTALL the original PCM and GO to W5 .

No The sytem is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. TEST the system for normal operation.

W5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:






No The sytem is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. TEST the system for normal operation.



X1 X1CHECK SPEED CONTROL OPERATION

Test drive the vehicle and operate the speed control.

� Does the speed control operate

correctly?

Yes If the speed control indicator is never on, GO to X2 .



If the speed control indicator is always on, GO to X4 .


X2 CHECK THE SPEED CONTROL INDICATOR CIRCUIT

Speed Control Servo (Gasoline Only) C122

PCM (Diesel Only) C175

Connect a fused (10A) jumper wire between the speed control servo C122 pin 1, circuit 203 (OG/LB), harness side and ground (gasoline only); or between the PCM C175 pin 45, circuit 203 (OG/LB), harness side and ground (diesel only).




Yes If gasoline, INSTALL a new speed control servo. REFER to Section 310-03 . If diesel, INSTALL a new PCM. REFER to Section 303-14B . TEST the system for normal operation.

No GO to X3 .

X3 CHECK CIRCUIT 203 (OG/LB)


Measure the resistance between the speed control servo C122 pin 1, circuit 203 (OG/LB), harness side and the instrument cluster C220c pin 17, circuit 203 (OG/LB), harness side (gasoline only); or between the PCM C175 pin 45, circuit 203 (OG/LB), harness side and the instrument cluster C220c pin 17, circuit 203 (OG/LB), harness side (diesel only).



� Is the resistance less than 5 ohms?

Yes GO to X6 .


X4 CHECK SPEED CONTROL SERVO (GASOLINE ONLY) OR PCM (DIESEL ONLY)

PCM (Diesel Only) C175

Speed Control Servo (Gasoline Only) C122


Yes GO to X5 .

No INSTALL a new PCM. REFER to Powertrain Control/Emissions



Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ) (diesel only) or speed control servo. REFER to Section 310-03 (gasoline only). TEST the system for normal operation.

X5 CHECK THE SPEED CONTROL INDICATOR CIRCUIT FOR SHORT TO GROUND


Measure the resistance between the instrument cluster C220c pin 17, circuit 203 (OG/LB), harness side and ground.


10,000 ohms?

Yes GO to X6 .


X6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:



PINPOINT TEST Y: THE THEFT INDICATOR IS NEVER/ALWAYS ON









Y1 CHECK THE THEFT INDICATOR OPERATION

� Is the indicator always on?

Yes GO to Y2 .

No GO to Y3 .

Y2 CHECK THE PATS MODULE



PATS Module C252

� Is the indicator illuminated?

Yes GO to Y4 .

No GO to Y5 .

Y3 CHECK CIRCUIT 1269 (OG/RD) FOR SHORT TO POWER




PATS Module C252

Measure the voltage between the instrument cluster C220c pin 3, circuit 1269 (OG/RD), harness side and ground.

� Is voltage present?


No GO to Y4 .

Y4 CHECK CIRCUIT 1269 (OG/RD) FOR OPEN OR SHORT TO GROUND


Measure the resistance between the instrument cluster C220c pin 3, circuit 1269 (OG/RD), harness side and the PATS module C252 pin 2,



circuit 1269 (OG/RD), harness side; and between the instrument cluster C220c pin 3, circuit 1269 (OG/RD), harness side and ground.


ohms between the instrument cluster and the PATS module and greater than 10,000 ohms between the instrument cluster and ground?

Yes GO to Y6 .


Y5 CHECK FOR CORRECT PATS MODULE OPERATION

Disconnect all PATS module connectors.

Check for:

� pushed-out pins � connector seated correctly

Connect all disconnected PATS module connectors.



Yes INSTALL a new PATS module. REFER to Section 419-01 . CLEAR the DTCs. REPEAT the PATS module self-test.

No The system is operating correctly at this time. Concern may have been caused by a loose or corroded



PINPOINT TEST Z: THE CHECK FUEL CAP INDICATOR IS INOPERATIVE/ALWAYS ON

connector. CLEAR the DTCs. REPEAT the self-test.

Y6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:








Z1 RETRIEVE AND RECORD DTCS FROM CONTINUOUS AND ON-DEMAND SELF-TESTS—PCM

NOTE: Once the check fuel cap indicator does turn on, it does not turn off unless the fuel cap has been correctly secured and the vehicle has been driven for several minutes or the ignition cycled once.

Use recorded PCM DTCs from the continuous and on-demand self-test.

� Are any DTCs recorded?

Yes If PCM DTC P0457, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ).

No GO to Z2 .



Z2 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL

Diagnostic Tool


Command

Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on and off. Observe the check fuel cap indicator.

� Does the check fuel cap indicator illuminate when triggered on

and turn off when triggered off?


No GO to Z3 .

Z3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION




PINPOINT TEST AA: THE CHECK GAGE WARNING INDICATOR IS INOPERATIVE/ALWAYS ON

Check for:

� · corrosion � · pushed-out pins

Connect all instrument cluster connectors and make sure they are seated correctly.



Yes INSTALL a new instrument cluster. REFER to Instrument Cluster in this section.



AA1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL

Diagnostic Tool




Command

Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command. Observe the CHECK GAGE indicator.

� Is the CHECK GAGE indicator illuminating?

Yes GO to AA2 .

No GO to AA3 .

AA2 CHECK THE GAUGES

Verify the fuel gauge, voltmeter and the oil pressure gauge operation.

� Are the gauges operating correctly?

Yes GO to AA3 .

No RETURN to the Symptom Chart.

AA3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:







PINPOINT TEST AB: THE CHECK AIR FILTER INDICATOR IS NEVER/ALWAYS ON—DIESEL ONLY




AB1 VERIFY THE CHECK AIR FILTER INDICATOR OPERATION

Air Filter Switch C1210

Monitor the check air filter indicator.

� Does the check air filter


Yes GO to AB2 .

No GO to AB3 .

AB2 CHECK CIRCUIT 142 (LB/RD) FOR SHORT TO GROUND




Measure the resistance between the instrument cluster C220a pin 6, circuit 142 (LB/RD), harness side and ground.


10,000 ohms?

Yes GO to AB6 .


AB3 CHECK INSTRUMENT CLUSTER

Connect a fused (10A) jumper wire between the air filter switch C1210 pin 1, circuit 142 (LB/RD), harness side and ground.



Observe the check air filter indicator.

� Does the check air filter


Yes GO to AB5 .

No GO to AB4 .

AB4 CHECK CIRCUIT 142 (LB/RD) FOR OPEN

Measure the resistance between the instrument cluster C220a pin 6, circuit 142 (LB/RD), harness side and the air filter switch C1210 pin 1, circuit 142 (LB/RD), harness side.


ohms?

Yes



INSTALL a new air filter switch. TEST the system for normal operation.


AB5 CHECK CIRCUIT 57 (BK) FOR OPEN

Measure the resistance between the air filter switch C1210 pin 2, circuit 57 (BK), harness side and ground.


ohms?

Yes GO to AB6 .


AB6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:


Connect all instrument cluster connectors and make sure they are seated correctly.

Operate the system and verify the



PINPOINT TEST AC: THE CK SUSP INDICATOR IS NEVER/ALWAYS ON

concern is still present.


Yes INSTALL a new instrument cluster. REFER to Instrument Cluster in this section.



AC1 CHECK THE AIR SUSPENSION INDICATOR

Monitor the air suspension indicator during prove-out.

� Is the air suspension indicator

always on?


No GO to AC2 .

AC2 CHECK THE INSTRUMENT CLUSTER INPUT



Air Suspension Control Module C4145

Connect a fused (10A) jumper wire between the air suspension control module C4145 pin 10, circuit 419 (DG/LG), harness side and ground.

� Does the air suspension



No GO to AC3 .

AC3 CHECK CIRCUIT 419 (DG/LG) FOR AN OPEN




Measure the resistance between the instrument cluster C220a pin 10, circuit 419 (DG/LG), harness side and the air suspension control module C4145 pin 10, circuit 419 (DG/LG), harness side.


ohms?

Yes GO to AC4 .

No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.

AC4 CHECK CIRCUIT 419 (DG/LG) FOR SHORT TO POWER

Measure the voltage between the instrument cluster C220a pin 10, circuit 419 (DG/LG), harness side and ground.




Yes GO to AC5 .

No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.

AC5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION

Disconnect all instrument custer connectors.

Check for:



Make sure all other system connectors are fully seated.



Yes INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. CLEAR the DTCs. REPEAT the HEC self-test.

No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs.



PINPOINT TEST AD: THE INSTRUMENT CLUSTER IS INOPERATIVE

REPEAT the self-test.



AD1 CHECK THE INSTRUMENT CLUSTER POWER SUPPLY


Using the following table, measure the voltage between the instrument cluster C220c, harness side and ground.

Pin Circuit

11 705 (LG/OG)

12 785 (BK/LG)

19 1002 (BK/PK)

20 640 (RD/YE)

� Are the voltages greater than 10

volts?



Yes GO to AD2 .


AD2 CHECK INSTRUMENT CLUSTER GROUND CIRCUITS 57 (BK) AND 676 (PK/OG)

Measure the resistance between the instrument cluster C220c pin 13, circuit 676 (PK/OG), harness side and ground; and between the instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground.


ohms?

Yes GO to AD3 .


AD3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION


Check for:





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