INstrument Cluster Test PDF

2002 F-Super Duty, Excursion Workshop Manual
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SECTION 413-01: Instrument Cluster DIAGNOSIS AND TESTING
Instrument Cluster
Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information.
Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent
Instrument Gauge System Tester 014-R1063 or equivalent
Worldwide Diagnostic System (WDS) 418F224, New Generation STAR (NGS) Tester 418-F052, or equivalent diagnostic tool
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
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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 reconfigured. 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
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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.
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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
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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
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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 (249.8 or higher, or if the engine oil pressure is low. C F)
Inspection and Verification 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart Mechanical 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) Electrical Central junction box (CJB) fuses: 35 (10A) 33 (15A) 41 (10A) 45 (10A) Miniature bulb(s) Circuitry Instrument cluster
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
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(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 50120B . 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 B1201 Description Fuel Sender Circuit Failure Source Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster Action Go To Pinpoint Test B . Go To Pinpoint Test B . Go To Pinpoint Test C . Go To Pinpoint Test C . Go To Pinpoint Test J . Go To Pinpoint Test J . INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. Go To Pinpoint Test A . Go To Pinpoint Test A . Go To Pinpoint Test V .
B1204 Fuel Sender Circuit Short To Ground B1317 B1318 B1320 B1328 B1342 Battery Voltage High Battery Voltage Low Driver Door Ajar Circuit Open Passenger Door Ajar Circuit Open ECU is Defective
B1360 B2143 B2658
Ignition Run/Acc Circuit Open NVM Memory Failure Wait To Start Warning Indicator Circuit Open
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C1284 U1027 U1051 U1073
Oil Pressure Switch Failure Invalid or Missing Data for Engine RPM Invalid or Missing Data for Brakes Invalid or Missing Data for Engine Coolant
Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster
Go To Pinpoint Test D . Go To Pinpoint Test I . Go To Pinpoint Test M . Go To Pinpoint Test E .
For a complete list of instrument cluster DTCs, refer to Section 419-10 .
Restraint Control Module Diagnostic Trouble Code (DTC) Index DTC B1869 B1870 Description Lamp Air Bag Warning Indicator Circuit Open Lamp Air Bag Warning Indicator Circuit Short to Battery Source Restraint Control Module Restraint Control Module Action Go To Pinpoint Test P. Go To Pinpoint Test P.
For a complete list of RCM DTCs, refer to Section 501-20B .
ABS Control Module Diagnostic Trouble Code (DTC) Index DTC Description Source ABS Action Go To Pinpoint Test M . C1226 Brake Warning Lamp Output Short to Ground
For a complete list of ABS control module DTCs, refer to Section 206-09 .
Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index DTC P4057 Description Fuel Fill Cap Off Source PCM PCM Action Go To Pinpoint Test Z . Go To Pinpoint Test V .
P0381 Glow Plug Indicator Circuit Malfunction
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.
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Instrument Cluster Self-Diagnostic Mode Odometer display GAGE All segments illuminated. bulb r #### nr#### EE ## dt #### ###C Description Carries out gauge sweep of all gauges, then displays the present gauge values. Also carries out the check sum test on ROM and EEPROM. Illuminates all odometer segments. Illuminates all micro-controlled lamps and LEDs. 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). Displays hexidecimal ROM level and type as stored in non-volatile memory (NVM). Displays hexadecimal value for EE level (used when requesting assistance from the hotline). Displays hexadecimal code for the final manufacturing date. 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. Displays a 16 bit DTC in hexidecimal format. DTCs displayed are those detected in continuous operation not during self-test. Displays English speed value being input, speedometer will indicate present speed. Displays metric speed value being input, speedometer will indicate present speed. Displays the tachometer value being input to the instrument cluster. Tachometer will indicate present rpm. Displays the present analog/digital fuel level being input to the instrument cluster as a ratio. Displays the last analog/digital reading of the oil pressure switch contact resistance, oil gauge will indicate present level. Displays the brake fluid level in an analog/digital ratio value. Displays present battery analog/digital voltage. Displays present hexadecimal pulse width modulation (PWM) dimming input. Alternating 1 second display of pulse width modulation (PWM) input duty cycle, SCP hexidecimal dimming step, output driver counts in hexadecimal. RUN/START sense circuit check. Displays 8-bit hexadecimal value for the Port A, B, C, and D readings (used when requesting information from the hotline). Displays 8-bit hexadecimal value for the Port E0-Port E7 in analog/digital readings.
dtc #### EnG m tAc FUEL OIL br bAt ##.# rhEo rhi, rhS, rho Cr PA, Pb, PC, and Pd PE0-PE7
Symptom Chart Symptom Chart
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Condition No communication with the instrument cluster
Possible Sources Central junction box (CJB) fuse(s): 33 (15A). 35 (10A). 41 (10A). 45 (10A). Circuitry. J1850 standard corporate protocol (SCP) communication network. Instrument cluster. Fuel sender. Circuitry. Fuel tank. Instrument cluster. Instrument cluster. Circuitry. Instrument cluster. Circuitry. Oil pressure switch. Circuitry. Coolant temperature sender (diesel only). J1850 standard corporate protocol (SCP) communication network. Instrument cluster. Powertrain control module (PCM). Circuitry. Transmission temperature sensor. Powertrain control module (PCM). Instrument cluster. Instrument cluster. Low fuel indicator bulb. Instrument cluster. Circuitry. Anti-lock brake system (ABS) module. Circuitry.
Action Go To Pinpoint Test A .
Incorrect fuel gauge indication
Go To Pinpoint Test B .
Incorrect voltage gauge indicationmanual transmission only Incorrect oil pressure gauge indication
Go To Pinpoint Test C .
Go To Pinpoint Test D .
Incorrect temperature gauge indication
Go To Pinpoint Test E .
Incorrect transmission temperature gauge indicationautomatic transmission only
Go To Pinpoint Test F .
The low fuel warning indicator is never/always on The speedometer is inoperative
Go To Pinpoint Test G .
Go To Pinpoint Test H .
The tachometer is
Go To Pinpoint Test I .
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inoperative
Instrument cluster. Generator (diesel only). 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. Go To Pinpoint Test J .
Trip odometer inoperative, speedometer OK
The door ajar indicator is inoperative (chime is operative)/does not operate correctly The safety belt warning indicator is inoperative (chime is operative)/does not operate correctly Inaccurate speedometer reading
Indicator bulb. Circuitry. Instrument cluster. Body security module. Indicator bulb. Circuitry. Instrument cluster. Safety belt switch (part of the safety belt retractor). Instrument cluster. Anti-lock brake system (ABS) module. Tires. Indicator bulb. Circuitry. Instrument cluster. Anti-lock brake system (ABS) module. Indicator bulb. Circuitry. Instrument cluster. Brake warning indicator relay. Anti-lock brake system (ABS) module. Brake fluid level switch. Parking brake switch. Circuitry. Brake fluid level switch. Parking brake switch. Anti-lock brake system (ABS) module. Hydromax module (if equipped). Instrument cluster.
Go To Pinpoint Test K .
Go To Pinpoint Test H .
The ABS warning indicator is never/always on
Go To Pinpoint Test L .
The brake warning indicator is never on
Go To Pinpoint Test M .
The brake warning indicator is always on
REFER to Section 206-00 .
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Malfunction indicator lamp (MIL) indicator is never on
Indicator LED. Circuitry. Instrument cluster. J1850 standard corporate protocol (SCP) communication network. Powertrain control module (PCM). Diagnostic trouble code (DTC) related concern(s).
Go To Pinpoint Test N .
Malfunction indicator lamp (MIL) indicator is always on
REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ). Go To Pinpoint Test O .
The charging system indicator is never on
Central junction box (CJB) fuse 29 (5A). Charging system. Indicator LED. Circuitry. Instrument cluster. Circuitry. Generator (charging system). Indicator bulb. Circuitry. Instrument cluster. Air bag diagnostic monitor. Indicator bulb. Circuitry. Instrument cluster. Indicator bulb. Circuitry. Instrument cluster. Indicator bulb. Circuitry. Instrument cluster. Circuitry. 4X4 range select switch. Indicator bulb. Circuitry. 4X4 range select switch. Circuitry. Powertrain control module (PCM). Indicator bulb. Circuitry.
The charging system indicator is always on The air bag indicator warning is never/always on
REFER to Section 414-00 .
Go To Pinpoint Test P .
High beam indicator is never on The LH turn indicator is never on The RH turn indicator is never on The 4X4 high/4X4 LOW range indicator is never/always on electronic The 4X4 high/4X4 LOW range indicator is never/always on manual The wait to start indicator is never/always on diesel only The water in fuel indicator is
Go To Pinpoint Test Q .
Go To Pinpoint Test R .
Go To Pinpoint Test S .
Go To Pinpoint Test T .
Go To Pinpoint Test U .
Go To Pinpoint Test V .
Go To Pinpoint Test W .
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never/always on diesel only The speed control indicator is never/always on
Water in fuel switch. Instrument cluster. Indicator bulb. Circuitry. Speed control servo. Instrument cluster. Indicator bulb. Circuitry. Passive anti-theft (PATS) module. Instrument cluster. Evaporative system. Powertrain control module (PCM). Instrument cluster. CHECK GAGE indicator bulb. Circuitry. Instrument cluster. Check air filter indicator bulb. Circuitry. Check air filter switch. Instrument cluster. Circuitry. Air suspension module. Instrument cluster. Central junction box (CJB) fuse(s): 33 (15A). 35 (10A). 41 (10A). 45 (10A). Circuitry. Instrument cluster. Go To Pinpoint Test X .
The theft indicator is never/always on
Go To Pinpoint Test Y .
The check fuel cap indicator is inoperative/always on
Go To Pinpoint Test Z .
The CHECK GAGE warning indicator is inoperative/always on The check air filter indicator is never/always on diesel only
Go To Pinpoint Test AA .
Go To Pinpoint Test AB .
The CK SUSP indicator is never/always on
Go To Pinpoint Test AC .
The instrument cluster is inoperative
Go To Pinpoint Test AD .
Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE INSTRUMENT CLUSTER 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
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Instrument Cluster C220c
Using the following table, measure the voltage between the instrument cluster C220c, harness side and ground. Pin 12 20 Circuit 785 (BK/LG) 640 (RD/YE)
11 705 (LG/OG) 19 1002 (BK/PK)
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)
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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 . No REPAIR the circuit(s) in question. TEST the system for normal operation.
PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION 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. B1 CARRY OUT THE INSTRUMENT CLUSTER FUEL GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL
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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.
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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.
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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.
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B4 INSPECT THE FUEL PUMP ASSEMBLY Check the fuel pump assembly intank 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?
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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.
Is the resistance less than 5
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ohms? Yes GO to B8 . No REPAIR the circuit. TEST the system for normal operation. 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.
PINPOINT TEST C: INCORRECT VOLTAGE GAUGE INDICATIONMANUAL TRANSMISSION ONLY 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. 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 ondemand self-tests. Are any instrument cluster DTCs recorded?
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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%? Yes REFER to Section 414-00 . No GO to C3 . C3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors. Check for:
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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. 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.
PINPOINT TEST D: INCORRECT OIL PRESSURE GAUGE INDICATION 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. D1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS Use the recorded instrument cluster DTCs from the continuous and ondemand 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
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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 .
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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.
Is the resistance less than 5 ohms between the instrument cluster and the oil pressure
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switch; and greater than 10,000 ohms between the instrument cluster and ground? Yes GO to D5 . No REPAIR the circuit. TEST the system for normal operation. 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. No REPAIR the circuit. TEST the system for normal operation. D6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors. Check for: corrosion
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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. 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.
PINPOINT TEST E: INCORRECT TEMPERATURE GAUGE INDICATION 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. E1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS Use the recorded instrument cluster DTCs from the continuous and ondemand 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 .
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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 , OBDIIBi-Fuel ). For diesel engine, GO to E3 . No GO to E7 . E3 CHECK CIRCUIT 45 (YE/RD) FOR OPEN OR SHORT TO GROUND
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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.
Is the resistance less than 5 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 . No REPAIR the circuit. TEST the system for normal operation.
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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 . No REPAIR the circuit. TEST the system for normal operation. 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.
Is the resistance less than 5 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
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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.
Is any voltage indicated? Yes REPAIR the circuit. TEST the system for normal operation. 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 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. TEST the system for normal operation.
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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.
PINPOINT TEST F: INCORRECT TRANSMISSION TEMPERATURE GAUGE INDICATIONAUTOMATIC TRANSMISSION ONLY CONDITIONS DETAILS/RESULTS/ACTIONS
F1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS Use the recorded instrument cluster DTCs from the continuous and ondemand self-tests. Are any instrument cluster DTCs recorded? Yes If instrument cluster DTC U1059 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 F2 . F2 CARRY OUT THE TRANSMISSION TEMPERATURE GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL
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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 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. 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. REPEAT the self-test.
PINPOINT TEST G: THE LOW FUEL WARNING INDICATOR IS NEVER/ALWAYS ON CONDITIONS DETAILS/RESULTS/ACTIONS
G1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE
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COMMAND USING THE DIAGNOSTIC TOOL
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
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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 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. 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. REPEAT the self-test.
PINPOINT TEST H: THE SPEEDOMETER IS INOPERATIVE 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. H1 CARRY OUT THE SPEEDOMETER ACTIVE COMMAND USING THE DIAGNOSTIC TOOL
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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
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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.
Is the resistance less than 5 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 . No REPAIR the circuit. TEST the system for normal operation. 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.
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Is any voltage indicated? Yes REPAIR the circuit. TEST the system for normal operation. No REFER to Section 206-09 . H4 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. 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. REPEAT the self-test.
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PINPOINT TEST I: THE TACHOMETER IS INOPERATIVE CONDITIONS DETAILS/RESULTS/ACTIONS
I1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS Use the recorded instrument cluster DTCs from the continuous and ondemand self-tests. Are any instrument cluster DTCs recorded? Yes If instrument cluster DTC U1027 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 I2 . I2 CARRY OUT THE TACHOMETER ACTIVE COMMAND USING THE DIAGNOSTIC TOOL
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.
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Does the tachometer gauge increase within specifications? Yes REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ). No GO to I3 . I3 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. 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. REPEAT the self-test.
PINPOINT TEST J: THE DOOR AJAR INDICATOR IS INOPERATIVE (CHIME IS OPERATIVE)/DOES NOT OPERATE CORRECTLY 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. 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 . No REFER to Section 417-02 .
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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
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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.
Is the resistance less than 5 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 . No REPAIR the circuit. TEST the system for normal operation.
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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.
Is the resistance less than 5 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
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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: corrosion pushed-out pins Connect all body security module 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 body security module. REFER to Section 419-10 . 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. REPEAT the self-test. J6 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. TEST the system for normal operation.
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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.
PINPOINT TEST K: THE SAFETY BELT WARNING INDICATOR IS INOPERATIVE (CHIME IS OPERATIVE)/DOES NOT OPERATE CORRECTLY 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. 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
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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. Is the resistance less than 5 ohms? Yes INSTALL a new safety belt retractor switch. REFER to Section 501-20A . TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. K3 CHECK CIRCUIT 85 (BN/LB) FOR OPEN
Measure the resistance between the
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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.
Is the resistance less than 5 ohms? Yes GO to K4 . No REPAIR the circuit. TEST the system for normal operation. 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.
Is any voltage indicated? Yes REPAIR the circuit. TEST the system for normal operation. No GO to K5 . K5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors.
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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. 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.
PINPOINT TEST L: THE ABS WARNING INDICATOR IS NEVER/ALWAYS ON 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. L1 VERIFY LAMP OPERATION
Observe the ABS warning indicator lamp prove-out.
Does the ABS warning indicator
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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 . No REFER to Section 206-09 . L3 CHECK CIRCUIT 603 (DG) FOR SHORT TO GROUND
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ABS Module C135
Measure the resistance between the 4WABS module C135 pin 15, circuit 603 (DG), harness side and ground.
Is the resistance greater than 10,000 ohms? Yes GO to L7 . No REPAIR the circuit. TEST the system for normal operation. L4 CHECK THE ABS WARNING INDICATOR CONTROL CIRCUIT
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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? Yes REFER to Section 206-09 . 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.
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Is the resistance less than 5 ohms? Yes GO to L6 . No REPAIR the circuit. TEST the system for normal operation. 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 . No REPAIR the circuit. TEST the system for normal operation. L7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors.
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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. 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. REPEAT the self-test.
PINPOINT TEST M: THE BRAKE WARNING INDICATOR IS NEVER ON 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. 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
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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.
Is the resistance less than 5 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
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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.
Is the resistance less than 5 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 . No REPAIR the circuit. TEST the system for normal operation. M4 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE
ABS Module C135
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Check the red BRAKE warning indicator for illumination. Does the red BRAKE warning indicator illuminate? Yes GO to M5 . No REFER to Section 206-09 . 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).
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Is the resistance greater than 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?
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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.
Are the resistances less than 5 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.
Is the resistance less than 5 ohms?
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Yes GO to M9 . No REPAIR the circuit. TEST the system for normal operation. M9 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors. Check for: corrosion pushed-out pins Correct all instrument cluster connectors and make sure they seat correctly. Operate the system and verify that concern is still present. Is the concern still present? 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. TEST the system for normal operation.
PINPOINT TEST N: MALFUNCTION INDICATOR LAMP (MIL) INDICATOR IS NEVER ON CONDITIONS DETAILS/RESULTS/ACTIONS
N1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL
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Diagnostic Tool
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? Yes REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ). No GO to N2 . N2 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?
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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. REPEAT the self-test.
PINPOINT TEST O: THE CHARGING SYSTEM INDICATOR IS NEVER ON 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. 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.
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Does the charging system warning indicator illuminate? Yes For gasoline engine, INSTALL a new generator. REFER to Section 41402 . TEST the system for normal operation. For diesel engine, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDIIBi-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.
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Is the resistance less than 5 ohms? Yes GO to O4 . No REPAIR the circuit. TEST the system for normal operation. 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.
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Is the resistance less than 5 ohms? Yes GO to O4 . No REPAIR the circuit. TEST the system for normal operation. 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.
Is any voltage indicated? Yes REPAIR the circuit. TEST the system for normal operation. No GO to O5 . O5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors.
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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. 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. REPEAT the self-test.
PINPOINT TEST P: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON 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. P1 VERIFY LAMP OPERATION
Observe the air bag indicator lamp prove out.
Does the air bag indicator lamp
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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.
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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.
Is the resistance less than 5 ohms?
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Yes GO to P6 . No REPAIR the circuit. TEST the system for normal operation. 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 indicator illuminate? Yes GO to P5 . No REFER to Section 501-20B . P5 CHECK CIRCUIT 608 (BK/YE) FOR SHORT TO GROUND
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Measure the resistance between the instrument cluster C220c pin 14, circuit 608 (BK/YE), harness side and ground.
Is the resistance greater than 10,000 ohms? Yes GO to P6 . No REPAIR the circuit. TEST the system for normal operation. P6 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
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concern is still present. Is the concern still present? 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. REPEAT the self-test.
PINPOINT TEST Q: HIGH BEAM INDICATOR IS NEVER ON 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. Q1 VERIFY HIGH BEAM OPERATION Verify the high beam headlamps operation. Do the high beam headlamps operate correctly? Yes GO to Q2 . No REFER to Section 417-01 . 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.
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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.
Is the resistance less than 5 ohms between the instrument
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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. No REPAIR the circuit. 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.
Is the resistance less than 5 ohms? Yes GO to Q5 . No REPAIR the circuit. TEST the system for normal operation. Q5 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.
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Is the concern still present? 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. REPEAT the self-test.
PINPOINT TEST R: THE LH TURN INDICATOR IS NEVER ON 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. R1 VERIFY TURN SIGNAL OPERATION Verify the turn signal operation. Do the turn signals operate correctly? Yes GO to R2 . No REFER to Section 417-01 . R2 CHECK CIRCUIT 3 (LG/WH) FOR VOLTAGE
Instrument Cluster C220a
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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.
Is the resistance less than 5
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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. No REPAIR the circuit. TEST the system for normal operation. R4 CHECK CIRCUIT 57 (BK) FOR OPEN
Measure the resistance between instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground.
Is the resistance less than 5 ohms? Yes GO to R5 .
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No REPAIR the circuit. TEST the system for normal operation. R5 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. 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. REPEAT the self-test.
PINPOINT TEST S: THE RH TURN INDICATOR IS NEVER ON 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. S1 VERIFY TURN SIGNAL OPERATION Verify the turn signal operation. Do the turn signals operate correctly? Yes GO to S2 . No REFER to Section 417-01 .
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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
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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.
Is the resistance less than 5 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. No REPAIR the circuit. TEST the system for normal operation. S4 CHECK CIRCUIT 57 (BK) FOR OPEN
Measure the resistance between instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground.
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Is the resistance less than 5 ohms? Yes GO to S5 . No REPAIR the circuit. TEST the system for normal operation. S5 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. 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. REPEAT the self-test.
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PINPOINT TEST T: THE 4X4 HIGH/4X4 LOW RANGE INDICATOR IS NEVER/ALWAYS ON ELECTRONIC 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. 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
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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.
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Is the resistance less than 5 ohms? Yes GO to T3 . No REPAIR the circuit. TEST the system for normal operation. 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.
Is any voltage indicated? Yes REPAIR the circuit. TEST the system for normal operation. No GO to T8 . T4 CHECK CIRCUIT 975 (BN/YE) FOR OPEN
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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.
Is the resistance less than 5 ohms? Yes GO to T5 . No REPAIR the circuit. TEST the system for normal operation. 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
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and ground.
Is any voltage indicated? Yes REPAIR the circuit. TEST the system for normal operation. 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.
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Is the resistance greater than 10,000 ohms? Yes GO to T8 . No REPAIR the circuit. TEST the system for normal operation. 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.
Is the resistance greater than 10,000 ohms? Yes
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GO to T8 . No REPAIR the circuit. TEST the system for normal operation. T8 CHECK FOR CORRECT 4X4 MODULE OPERATION Disconnect all 4x4 module connectors. Check for: corrosion pushed-out pins Connect all 4x4 module 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 4x4 module. REFER to Section 308-07A . 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. T9 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. TEST the system for normal
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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.
PINPOINT TEST U: THE 4X4 HIGH/4X4 LOW RANGE INDICATOR IS NEVER/ALWAYS ONMANUAL SHIFT 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. U1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL
Diagnostic Tool
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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
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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.
Is the resistance less than 5 ohms? Yes GO to U3 . No REPAIR the circuit. TEST the system for normal operation. 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.
Is any voltage indicated? Yes REPAIR the circuit in question. TEST the system for normal operation. No GO to U6 . U4 CHECK CIRCUIT 975 (BN/YE) FOR OPEN
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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.
Is the resistance less than 5 ohms? Yes GO to U5 No REPAIR the circuit. TEST the system for normal operation. 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
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ground.
Is any voltage indicated? 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.
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Is the resistance greater than 10,000 ohms? Yes INSTALL a new 4x4 select switch. REFER to Section 308-07A . TEST the system for normal operation. No REPAIR the circuit in question. 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.
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Is the resistance greater than 10,000 ohms? Yes INSTALL a new 4x4 select switch. REFER to Section 308-07A . TEST the system for normal operation. No REPAIR the circuit in question. TEST the system for normal operation. U8 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. 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
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the system for normal operation.
PINPOINT TEST V: THE WAIT TO START INDICATOR IS NEVER/ALWAYS ONDIESEL ONLY CONDITIONS DETAILS/RESULTS/ACTIONS
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.
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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
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.
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Check for: corrosion pushed-out pins Connect all PCM 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 PCM. REFER to Section 303-14B . TEST the system for normal operation. If the problem remains, REINSTALL the original PCM and GO to V5 . 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. V5 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. 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 sytem for normal operation.
PINPOINT TEST W: THE WATER IN FUEL INDICATOR IS NEVER/ALWAYS ONDIESEL ONLY CONDITIONS DETAILS/RESULTS/ACTIONS
W1 RETRIEVE THE RECORDED PCM DTCS BOTH CONTINUOUS AND ON-DEMAND AND SELF-TESTS
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Diagnostic Tool
PCM and Instrument Cluster DTCs
Retrieve the recorded PCM DTCs from both the continuous and ondemand 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
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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
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: corrosion pushed-out pins Connect all PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
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Is the concern still present? 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 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. TEST the system for normal operation. 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.
PINPOINT TEST X: THE SPEED CONTROL INDICATOR IS NEVER/ALWAYS ON 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. 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 .
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If the speed control indicator is always on, GO to X4 . No REFER to Section 310-03 . 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).
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Does the indicator illuminate? Yes If gasoline, INSTALL a new speed control servo. REFER to Section 31003 . 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).
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Is the resistance less than 5 ohms? Yes GO to X6 . No REPAIR the circuit. TEST the system for normal operation. X4 CHECK SPEED CONTROL SERVO (GASOLINE ONLY) OR PCM (DIESEL ONLY)
PCM (Diesel Only) C175
Speed Control Servo (Gasoline Only) C122
Does the indicator illuminate? Yes GO to X5 . No INSTALL a new PCM. REFER to Powertrain Control/Emissions
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Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDIIBi-Fuel ) (diesel only) or speed control servo. REFER to Section 31003 (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.
Is the resistance greater than 10,000 ohms? Yes GO to X6 . No REPAIR the circuit. TEST the system for normal operation. X6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors. Check for:
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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. 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.
PINPOINT TEST Y: THE THEFT INDICATOR IS NEVER/ALWAYS ON 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. Y1 CHECK THE THEFT INDICATOR OPERATION
Is the indicator always on? Yes GO to Y2 . No GO to Y3 . Y2 CHECK THE PATS MODULE
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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
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PATS Module C252
Measure the voltage between the instrument cluster C220c pin 3, circuit 1269 (OG/RD), harness side and ground.
Is voltage present? Yes REPAIR the circuit. TEST the system for normal operation. 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,
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circuit 1269 (OG/RD), harness side; and between the instrument cluster C220c pin 3, circuit 1269 (OG/RD), harness side and ground.
Is the resistance less than 5 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 . No REPAIR the circuit. TEST the system for normal operation. 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. Operate the system and verify the concern is still present. Is the concern still present? 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
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connector. CLEAR the DTCs. REPEAT the self-test. Y6 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. 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.
PINPOINT TEST Z: THE CHECK FUEL CAP INDICATOR IS INOPERATIVE/ALWAYS ON CONDITIONS DETAILS/RESULTS/ACTIONS
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 .
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Z2 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 check fuel cap indicator. Does the check fuel cap indicator illuminate when triggered on and turn off when triggered off? Yes REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual ( OBDII Early release , OBDII-Diesel , OBDII-Bi-Fuel ). No GO to Z3 . Z3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors.
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Check for: corrosion pushed-out pins Connect all instrument cluster connectors and make sure they are seated 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. 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.
PINPOINT TEST AA: THE CHECK GAGE WARNING INDICATOR IS INOPERATIVE/ALWAYS ON CONDITIONS DETAILS/RESULTS/ACTIONS
AA1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL
Diagnostic Tool
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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 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?
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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. REPEAT the self-test.
PINPOINT TEST AB: THE CHECK AIR FILTER INDICATOR IS NEVER/ALWAYS ONDIESEL ONLY CONDITIONS DETAILS/RESULTS/ACTIONS
AB1 VERIFY THE CHECK AIR FILTER INDICATOR OPERATION
Air Filter Switch C1210
Monitor the check air filter indicator. Does the check air filter indicator illuminate? Yes GO to AB2 . No GO to AB3 . AB2 CHECK CIRCUIT 142 (LB/RD) FOR SHORT TO GROUND
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Measure the resistance between the instrument cluster C220a pin 6, circuit 142 (LB/RD), harness side and ground.
Is the resistance greater than 10,000 ohms? Yes GO to AB6 . No REPAIR the circuit. TEST the system for normal operation. 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.
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Observe the check air filter indicator. Does the check air filter indicator illuminate? 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.
Is the resistance less than 5 ohms? Yes
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INSTALL a new air filter switch. TEST the system for normal operation. No REPAIR the circuit. 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.
Is the resistance less than 5 ohms? Yes GO to AB6 . No REPAIR the circuit. TEST the system for normal operation. AB6 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 are seated correctly. Operate the system and verify the
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concern is still present. Is the concern still present? Yes INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. 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.
PINPOINT TEST AC: THE CK SUSP INDICATOR IS NEVER/ALWAYS ON CONDITIONS AC1 CHECK THE AIR SUSPENSION INDICATOR DETAILS/RESULTS/ACTIONS
Monitor the air suspension indicator during prove-out. Is the air suspension indicator always on? Yes REFER to Section 204-00 . No GO to AC2 . AC2 CHECK THE INSTRUMENT CLUSTER INPUT
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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 indicator illuminate? Yes REFER to Section 204-00 . No GO to AC3 . AC3 CHECK CIRCUIT 419 (DG/LG) FOR AN OPEN
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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.
Is the resistance less than 5 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.
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Is any voltage indicated? 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: corrosion pushed-out pins Connect all instrument cluster connectors and make sure they seat correctly. Make sure all other system connectors are fully seated. 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. 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.
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REPEAT the self-test.
PINPOINT TEST AD: THE INSTRUMENT CLUSTER IS INOPERATIVE 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. AD1 CHECK THE INSTRUMENT CLUSTER POWER SUPPLY
Using the following table, measure the voltage between the instrument cluster C220c, harness side and ground. Pin 12 20 Circuit 785 (BK/LG) 640 (RD/YE)
11 705 (LG/OG) 19 1002 (BK/PK)
Are the voltages greater than 10 volts?
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Yes GO to AD2 . No REPAIR the circuit(s) in question. TEST the system for normal operation. 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.
Are the resistances less than 5 ohms? Yes GO to AD3 . No REPAIR the circuit(s) in question. TEST the system for normal operation. AD3 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.
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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. 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. REPEAT the self-test.
6/17/2009

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2002 F-Super Duty, Excursion Workshop Manual

SECTION 413-01: Instrument Cluster DIAGNOSIS AND TESTING

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

2002 F-Super Duty, Excursion Workshop Manual

2002 F-Super Duty, Excursion Workshop Manual

2002 F-Super Duty, Excursion Workshop Manual

2002 F-Super Duty, Excursion Workshop Manual

2002 F-Super Duty, Excursion Workshop Manual

2002 F-Super Duty, Excursion Workshop Manual

B1360 B2143 B2658

2002 F-Super Duty, Excursion Workshop Manual

C1284 U1027 U1051 U1073

Instrument Cluster Instrument Cluster Instrument Cluster Instrument Cluster

Go To Pinpoint Test D . Go To Pinpoint Test I . Go To Pinpoint Test M . Go To Pinpoint Test E .

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 .

P0381 Glow Plug Indicator Circuit Malfunction

2002 F-Super Duty, Excursion Workshop Manual

Symptom Chart Symptom Chart

2002 F-Super Duty, Excursion Workshop Manual

Condition No communication with the instrument cluster

Action Go To Pinpoint Test A .

Incorrect fuel gauge indication

Incorrect temperature gauge indication

Incorrect transmission temperature gauge indicationautomatic transmission only

The low fuel warning indicator is never/always on The speedometer is inoperative

2002 F-Super Duty, Excursion Workshop Manual

Trip odometer inoperative, speedometer OK

The ABS warning indicator is never/always on

The brake warning indicator is never on

The brake warning indicator is always on

REFER to Section 206-00 .

2002 F-Super Duty, Excursion Workshop Manual

Malfunction indicator lamp (MIL) indicator is never on

Malfunction indicator lamp (MIL) indicator is always on

The charging system indicator is never on

REFER to Section 414-00 .

2002 F-Super Duty, Excursion Workshop Manual

never/always on diesel only The speed control indicator is never/always on

The theft indicator is never/always on

The check fuel cap indicator is inoperative/always on

The CK SUSP indicator is never/always on

The instrument cluster is inoperative

PINPOINT TEST A: NO COMMUNICATION WITH THE INSTRUMENT CLUSTER CONDITIONS DETAILS/RESULTS/ACTIONS

2002 F-Super Duty, Excursion Workshop Manual

Instrument Cluster C220c

11 705 (LG/OG) 19 1002 (BK/PK)

2002 F-Super Duty, Excursion Workshop Manual

PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION CONDITIONS DETAILS/RESULTS/ACTIONS

2002 F-Super Duty, Excursion Workshop Manual

Fuel Pump Assembly C433 or C4033 (California)

2002 F-Super Duty, Excursion Workshop Manual

Set the tester to 15 ohms.

2002 F-Super Duty, Excursion Workshop Manual

Set the tester to 145 ohms.

2002 F-Super Duty, Excursion Workshop Manual

Instrument Cluster C220b

Is any voltage present?

2002 F-Super Duty, Excursion Workshop Manual

Is the resistance less than 5