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1 Page 1 of 13 SECTION : Instrumentation, Message Center, and Warning Chimes 2005 Explorer/Mountaineer Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 07/17/2009 Instrumentation, Message Center and Warning Chimes Printable View (847 KB) Refer to Wiring Diagrams Cell 59, Multifunction Control Modules for schematic and connector information. 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) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool Principles of Operation The instrument cluster is a configurable, hybrid electronic cluster (HEC) that contains a microprocessor, gauges, indicator lamps, message center, warning chimes and internal ry. The instrument cluster is non-repairable, with the exception of the instrument cluster lens. The instrument cluster uses hardwired ry, the controller area network (CAN), and universal asynchronous receiver transmitter (UART)-based protocol (UBP) communication networks. Communication using the CAN s transmits and receives data between the instrument cluster, the powertrain control module (PCM), the electronic automatic temperature control (EATC), the tire pressure monitoring system (TPMS) module, and the anti-lock brake system (ABS) module. Communication using the UART-UBP network uses data transmitted and received by the instrument cluster, the vehicle security module, and the driver seat module. For additional information regarding the CAN and UART-UBP s, refer to Section It is very important to understand: where the input originates. 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 CAN or UART-UBP s to another module. which module controls the output of the feature. Instrument Cluster Instrument Cluster Prove-Out The instrument cluster carries out a display prove-out to verify that the warning/indicator lamps and monitored systems are operating correctly. The safety belt prove-outs for 60-seconds or until the safety belt is fastened. The SERVICE ENGINE SOON, the charging system warning indicator, and the CHECK GAUGE warning indicator illuminate continuously until the engine is started and operating normally. When the ignition switch is turned to the ON position with the engine off, the following indicators illuminate for 3 seconds: 4x4 LOW indicator 4x4 HIGH indicator ABS warning indicator air bag warning indicator (6-seconds) BRAKE warning indicator powertrain malfunction (wrench) warning indicator tire pressure monitoring system indicator traction control indicator HI TEMP LOW OIL warning indicator CHECK FUEL CAP warning indicator Integrated Circuit Display The integrated display is a vacuum fluorescent tube display that contains the odometer, trip odometer, outside air temperature, and compass display on base clusters and the message center display on message center clusters. The compass module and outside air temperature sensor are hardwired to the instrument cluster. The odometer information is transmitted from the PCM through the CAN s to the instrument cluster. The instrument cluster displays the appropriate message(s) upon receipt of the outside air temperature, compass heading, and odometer data received. Speedometer The powertrain control module (PCM) calculates the vehicle speed from the transmission output shaft speed (OSS) sensor input and from the tire size and axle ratio configuration in the PCM vehicle identification (VID) block. The PCM provides the instrument cluster with the vehicle speed data over the HS-CAN bus. The instrument cluster monitors the vehicle speed input and commands the speedometer with a corresponding movement of the pointer. Fuel Gauge Fuel level is determined using a variable resistance fuel level sender unit, with an approximate resistance range between 15 ohms ± 2 ohms at empty (E) and 160 ohms ± 4 ohms at full (F) on 4.6L engines and between 7 ohms ± 2 ohms at the lower stop position and 138 ohms ± 4 ohms at the upper stop position on 4.0L engines. If equipped with flex-fuel (4.0L engines), the basic fuel level indication is the same except that the flex-fuel vehicles incorporate the use of a flex-fuel module. The flex-fuel module is a DC-AC interface. To prevent electrochemical reactions with the alcohol in the fuel, the flex-fuel module applies an AC voltage to the fuel level sender to measure the fuel sender resistance. Based on current fuel level, a modified

2 Page 2 of 13 resistance matching the fuel level is returned to the instrument cluster. The flex-fuel module is part of the fuel pump module jumper harness and is installed as an assembly. The instrument cluster uses 4 different operating modes to calculate the fuel level: Anti-slosh (default mode) Key OFF fueling Key ON fueling Recovery After a fuel fill up, the time for the fuel gauge to move from empty (E) to full (F) ranges from 2 seconds to 55 minutes depending on which operating mode the fuel gauge is in. The default fuel gauge mode is called the anti-slosh mode. To prevent fuel gauge changes from fuel slosh (gauge instability due to changes in fuel sender readings caused by fuel moving around in the tank), the fuel gauge takes approximately 55 minutes to go from empty (E) to full (F). The key OFF fueling mode (2 seconds to read empty [E] to full [F]) requires 3 conditions be met: The key must be in the OFF position throughout the entire refueling of the vehicle. At least 15% of the vehicle's fuel capacity must be added to the fuel tank. The instrument cluster must receive a valid key ON fuel sender reading within 1 second of the key being put into the RUN position. The key ON sample readings are considered valid if the fuel sender reading is between 10 ohms ± 2 ohms and 180 ohms ± 4 ohms. If these conditions are not met, the fuel gauge stays in the anti-slosh mode, which results in a slow to read full (F) event. The key ON fueling mode (approximately 90 seconds to read empty [E] to full [F]) requires 3 conditions be met: The transmission is in PARK (P). The key is in the RUN position. At least 15% of the vehicle's fuel capacity must be added to the fuel tank. In key ON fueling mode, a 30-second timer activates after the transmission is put into the PARK (P) position. When the 30-second time has elapsed and at least 15% of the vehicle's fuel capacity has been added, the fuel gauge response time is 90 seconds to read from empty (E) to full (F). When the transmission is shifted out of PARK (P), the fuel gauge strategy reverts to the anti-slosh mode. The key ON fueling mode prevents slow to read full events from happening if the customer refuels the vehicle with the key in the RUN position. Recovery mode is incorporated into the instrument cluster strategy to recover from a missing fuel level input after a refueling event. Missing fuel level inputs result from intermittent opens in the fuel sender or its s. Recovery mode (empty [E] to full [F] approximately 20 minutes) is initiated when the following 2 conditions are met: The instrument cluster is in the anti-slosh (default) mode. The actual fuel level in the tank is greater than what is being displayed by the fuel gauge. Engine Coolant Temperature Gauge The PCM receives the engine coolant temperature status through hardwired ry to the engine coolant temperature (ECT) sensor. The instrument cluster receives the engine coolant temperature data from the PCM through the CAN s. The instrument cluster monitors the engine coolant temperature data received from the PCM and commands the temperature gauge indication with a corresponding movement of the pointer. If the instrument cluster receives no signal the temperature gauge defaults to the cold position. Oil Pressure Gauge The instrument cluster is hardwired to the engine oil pressure switch. The engine oil pressure switch consists of a diaphragm and contact points, which are normally open. When there is low or no oil pressure, the engine oil pressure switch remains open and removes the ground to the instrument cluster. When sufficient oil pressure exists, the engine oil pressure switch closes providing a ground signal to the instrument cluster. The instrument cluster monitors the oil pressure and commands a corresponding pointer movement of the oil pressure gauge. Voltage Gauge The voltage gauge displays the system battery voltage as measured at the instrument cluster RUN input. Tachometer The tachometer is electrically operated and indicates the engine speed in revolutions per minute (rpm). The tachometer range is 0 to 7,000 rpm. The tachometer receives the signal through the CAN s from the PCM. If the rpm information sent to the instrument cluster is invalid or missing, the instrument cluster defaults the tachometer to 0 rpm. Odometer The odometer and trip odometer are viewed through the message center in the integrated display on message center clusters or in the integrated display on base clusters. The odometer is tamper-resistant and accumulates and registers up to one million miles in English mode or one million kilometers in metric mode, based upon rolling count data sent from the PCM via the CAN s. The trip odometer is resettable and accumulates and registers up to 1,608 kilometers (999 miles). Air Bag Warning Indicator The instrument cluster is hardwired to the restraint control module (RCM). If an air bag system concern is detected, a diagnostic trouble code (DTC) is logged and the RCM provides a ground path to the instrument cluster, turning on the air bag indicator. Anti-Lock Brake System (ABS) Warning Indicator The ABS warning indicator is used to indicate an ABS concern or deactivation of the ABS. The instrument cluster, upon receipt of the ABS message from the ABS module through the CAN s, turns on the ABS warning indicator. BRAKE Warning Indicator The parking brake switch is hardwired to the instrument cluster and the brake fluid level switch is hardwired to the ABS module. The instrument cluster BRAKE warning indicator uses 2 inputs. The first input is provided by the parking brake switch, and when applied, provides a ground to the instrument cluster turning on the BRAKE warning indicator. The second input is controlled by the ABS module. The ABS module, upon receipt of a low brake fluid level signal or base brake system concern, provides a brake signal to the instrument cluster through the CAN s. The instrument cluster, upon receipt of the brake signal, turns the BRAKE warning indicator on or off according to the monitored data. Charging System Warning Indicator The instrument cluster receives the charge signal from the PCM through the CAN s. When the generator output is insufficient to maintain the battery state of charge, the instrument cluster illuminates the charging system indicator. Check Gauge Warning Indicator The check gauge warning indicator illuminates when the engine oil pressure drops below approximately 42 kpa (6 psi), the engine temperature exceeds approximately 118 C (244 F), or

3 Page 3 of 13 the fuel level drops below approximately 15 percent of fuel system capacity. This indicator also flashes when the vehicle is in a fail-safe cooling event (base cluster only). Door Ajar Warning Indicator (Base Cluster) The door ajar switches provide a ground signal to the vehicle security module. The vehicle security module, upon receipt of the door ajar ground data, supplies a door ajar status message to the instrument cluster through the UART-UBP communication network. The instrument cluster monitors the door ajar status and commands the door ajar indicator on or off according to the door ajar status message. Safety Belt Warning Indicator The RCM monitors the safety belt position through the safety belt switch (part of the buckle). When the safety belt is buckled, the RCM receives a ground signal and sends a signal via 1390 (DB) to the instrument cluster to turn off the safety belt warning indicator. When the safety belt is unbuckled, the ground to the RCM is removed and the RCM sends a signal via 1390 (DB) to the instrument cluster to turn on the indicator. Low Tire Warning Indicator The TPMS has the ability to monitor the air pressure of all 5 tires. The tire-mounted pressure sensors transmit signals to the TPMS module by using the valve stem as an antenna. These signals are sent approximately every 60 seconds when the vehicle speed exceeds 32 km/h (20 mph). The TPMS module compares each tire pressure sensor signal against low and high pressure limits. If the TPMS module determines that the tire pressure has exceeded the limit, the TPMS module communicates on the CAN s to the vehicle message center, which then displays a warning message. The system is not affected by wheel and tire rotation. CHECK FUEL CAP Indicator (Base Cluster) The check fuel cap indicator is used to indicate significant leaks in the fuel tank evaporative emission system due to a loose fuel cap or other fuel evaporative emission system concern. The fuel tank pressure is monitored by the PCM and, once a leak is detected, the PCM signals a fault to the instrument cluster through the CAN s. Once the PCM has detected a loose fuel cap and the check fuel cap indicator is illuminated, the check fuel cap indicator remains 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 the Powertrain Control/Emissions Diagnosis (PC/ED) manual. High Beam Indicator The instrument cluster provides a ground for the high beam indicator. When the high beam headlamps are turned on, the multifunction switch provides a power signal to the instrument cluster through hardwired ry and illuminates the high beam indicator. O/D OFF Indicator The instrument cluster receives the overdrive off signal from the PCM through the CAN s. The overdrive off switch is hardwired to the PCM. When the transmission overdrive is turned off, the overdrive off switch provides a ground signal to the PCM. The PCM, upon receipt of the overdrive off ground signal, provides a CAN overdrive off signal to the instrument cluster and the instrument cluster turns on the O/D OFF indicator. RH and LH Turn Indicators The instrument cluster provides a ground for the RH and LH turn indicators. When the multifunction switch is in the RH or LH turn position, power is supplied to the instrument cluster through hardwired ry and the RH or LH turn indicators flash on and off. SERVICE ENGINE SOON Indicator The malfunction indicator lamp (MIL) is illuminated when a DTC is detected by the PCM. The instrument cluster receives the MIL data from the PCM through the CAN s. Speed Control Indicator The instrument cluster receives the speed control signal from the PCM through the CAN s. The PCM communicates to the instrument cluster to illuminate the speed control indicator when the speed control is engaged. Traction Control Indicator (Message Center Cluster) The traction control indicator flashes when the vehicle traction control is in active mode or is being controlled by the ABS module. The instrument cluster receives the traction control signal from the ABS module through the UART-UBP communication network. The instrument cluster monitors the traction control signal, and when the ABS module detects a traction control concern, the instrument cluster turns on the traction control indicator. HI TEMP LOW OIL (Message Center Cluster) The HI TEMP LOW OIL indicator illuminates when the engine coolant temperature is high or the engine oil pressure is low. 4x4 HIGH and 4x4 LOW Indicators The instrument cluster receives the 4x4 HIGH and 4x4 LOW information from the PCM through the CAN s. When either 4x4 high or 4x4 low are selected, the PCM provides a 4x4 status signal to the instrument cluster and turns on the appropriate indicator. AWD LOCK (if equipped) The instrument cluster receives the AWD indicator status from the PCM. When all-wheel drive is selected, the PCM provides an indicator on command over the CAN s to the instrument cluster to illuminate the AWD LOCK indicator. Powertrain Malfunction (Wrench) Warning Indicator The instrument cluster receives the electronic throttle control status from the PCM over the CAN s. When a system concern is detected, the PCM sends the instrument cluster a command signal to illuminate the powertrain malfunction (wrench) warning indicator. Information And Message Center The message center electronic functions use both hardwired inputs and CAN, and UART-UBP communication networks to transmit and receive information. The message center provides the following features: information displays setup displays warning messages system check messages The message center information can be selected through a set of 3 switches:

4 Page 4 of 13 INFO SETUP RESET Tire Pressure Monitoring System (TPMS) The following messages can appear with a TPMS: CHECK TIRE PRESSURE CHECK SPARE TIRE PRESSURE WARNING TIRE VERY LOW TIRE PRESSURE SYSTEM OFF TIRE PRESSURE SYSTEM FAULT TIRE PRESSURE SENSOR FAULT For additional information and diagnosis of these messages, refer to Section General information on these messages may also be found in the Owner's Literature. Information Displays The information displays are non-timed modes. The selected mode remains on until the driver presses a message center switch to change the mode, or until it is overridden by another mode. The information display modes are: odometer trip odometer compass distance to empty average fuel economy Setup Displays The setup displays are timed modes and terminate after a finite interval. The setup display modes are: language English/metric units system check oil life status oil life in xx% charge system status oil pressure status engine temp status washer fluid level brake fluid level fuel level status distance to empty tire warning Every 180 days or 8,000 km (5,000 miles) the oil life display in the message center SYSTEM CHECK will decrease gradually from 100% to 0%. At 5% oil life, the CHANGE OIL SOON warning indicator illuminates. At 0% oil life, the OIL CHANGE REQUIRED warning indicator illuminates. Oil life status is continually displayed in the SYSTEM CHECK portion of the message center and oil life warnings appear if the oil life is low. For additional information, refer to the Owner's Literature. Warning Messages The warning messages are single cycle, non-resettable, and repetitive warning messages. The single cycle warning messages are: CHANGE OIL SOON OIL CHANGE REQUIRED LOW WASHER FLUID LEVEL LOW BRAKE FLUID LEVEL The single cycle warning messages display once whenever the ignition switch is turned to the ON position or a fault occurs in a system and can be cleared by pressing the RESET button. The repetitive warning messages are: CHECK CHARGING SYSTEM TRANSMISSION OVERHEATED CHECK TRANSMISSION LOW FUEL LEVEL LOW OIL PRESSURE CHECK ENGINE TEMPERATURE CHECK TIRE PRESSURE CHECK FUEL CAP The repetitive warning messages are displayed at a fixed interval whenever the ignition switch is turned to the ON position or the ACC position. To remove a repetitive warning message, press the RESET button. The message reoccurs after 10 minutes until the warning condition is corrected. The tire pressure warning is displayed whenever the tire pressure module receives a signal from a tire pressure sensor indicating that the tire pressure is out of range. For additional information on the tire pressure warning system, refer to Section The non-resettable warning messages display whenever the ignition switch is turned to the ON position and a fault occurs in a system. The fault must be corrected to clear the nonresettable warning messages. The non-resettable warning messages are: DOOR AJAR BACKUP AID

5 Page 5 of 13 Warning Chimes The instrument cluster controls the following warnings and chimes: driver safety belt not fastened warning chime (warning times out) key-in-ignition warning (repetitive chime) headlamp-on warning (repetitive chime) door ajar warning (repetitive chime) safety belt warning chime (repetitive chime) Belt-Minder warning chime (repetitive chime after a delay and the safety belt chime has completed) Safety Belt Warning Chime The safety belt warning chime warns that the driver safety belt is not fastened. The safety belt warning chime sounds when the driver safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC positions to the RUN or START position. The safety belt warning chime stops sounding when the safety belt is fastened, when the ignition switch is turned from the RUN or START position to the OFF/LOCK or ACC position, or when the chime has sounded for approximately 6 seconds. The safety belt warning chime inputs are: the ignition switch START position, with voltage applied on START 489 (PK/BK). the ignition switch RUN position, with voltage applied on RUN 295 (LB/PK). the driver safety belt switch data communicated by the restraint control module (RCM) to the instrument cluster on 1390 (DB). The safety belt warning indicator, along with the chime, warns that the safety belt is not fastened. The safety belt warning indicator is illuminated when the safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC position to the RUN or START position. The safety belt warning indicator turns off when the safety belt is fastened, the ignition switch is moved from the RUN or START position to the OFF/LOCK or ACC position, or if the indicator is illuminated for approximately 6 seconds. The safety belt warning indicator inputs are: the ignition switch START position, with voltage applied on START 489 (PK/BK). the ignition switch RUN position, with voltage applied on RUN 295 (LB/PK). the driver safety belt switch data communicated by the RCM to the instrument cluster on 1390 (DB). Belt-Minder The Belt-Minder feature supplements the current safety belt warning function. The Belt-Minder is enabled after the current safety belt warning is complete. The Belt-Minder reminds the driver that the driver safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. While activated, the Belt-Minder alternates the chime and indicator from on for 6 seconds to off for 30 seconds. NOTE: The Belt-Minder is configurable. For additional information, refer to Section To configure without using a diagnostic tool, refer to Belt-Minder Deactivating/Activating in this section. Door Ajar Warning Indicator The door ajar warning chime warns that a door is not fully closed. The chime sounds when any door or the liftgate becomes ajar while the ignition switch is in the RUN position. The door ajar warning indicator warns that a door is not fully closed. The door ajar warning indicator illuminates when any door or the liftgate initially becomes ajar while the ignition switch is in the RUN or START position. The door ajar warning indicator turns off when all doors and the liftgate are closed, or the ignition switch is turned to the OFF/LOCK or ACC position. The door ajar warning indicator/chime inputs are: the ignition switch START position, with voltage applied on START 489 (PK/BK). the ignition switch RUN position, with voltage applied on RUN 295 (LB/PK). the door ajar data communicated by the vehicle security module to the instrument cluster on the UART-UBP communication 693 (OG). Key-In-Ignition Warning Chime The key-in-ignition warning chime warns that the key is still in the ignition lock cylinder when the driver door is ajar. The key-in-ignition warning chime sounds when the driver door is ajar, the ignition switch is in the OFF/LOCK or ACC position, and the key is in the ignition lock cylinder. The key-in-ignition warning chime stops sounding when the driver door is closed, the key is removed from the ignition lock cylinder, or the ignition switch is turned to the RUN position. The key-in-ignition warning chime inputs are: the ignition switch START position, with no voltage on START 489 (PK/BK). the ignition switch RUN position, with no voltage on RUN 295 (LB/PK). the key-in-ignition switch 1414 (LG/VT), with voltage applied with the key in the ignition. Headlamp On Warning Chime The headlamp on warning chime warns that the headlamps are on when the driver door is ajar and the key is removed from the ignition. The headlamps on warning chime sounds if the driver door is ajar, the headlamp switch is in the PARK or HEAD position, and the ignition switch is in the OFF/LOCK position with the key out. The headlamp on warning chime stops sounding when any one of the above conditions are removed. The headlamp on warning chime inputs are: the ignition switch in the START position, with no voltage on the START 489 (PK/BK). the ignition switch the RUN position, with no voltage on the RUN 295 (LB/PK). the key in the ignition switch 1414 (LG/VT), with no voltage applied with the key removed from the ignition. voltage applied on the instrument illumination 235 (RD/BK).

6 Page 6 of 13 Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Accessory drive belt Brake fluid level Door adjustment Engine coolant level Engine oil level Fuel evaporative emission system Fuel tank Washer fluid level Tire pressure Electrical Battery junction box (BJB) fuses: 15 (15A) 16 (15A) 23 (30A) Central junction box (CJB) fuses: 6 (10A) 15 (5A) 19 (10A) 21 (5A) Miniature bulb(s) Message center switches Safety belt switch (part of the buckle) Key-in-ignition warning switch (part of the ignition switch) Headlamp switch Door ajar switch(es) 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 cause is not visually evident, connect the diagnostic tool to the data link connector 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 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 diagnostic tool data link test. If the diagnostic tool responds with: ISO, UART-UBP or CAN fault; all electronic control units no response/not equipped, refer to Section No response/not equipped for the instrument cluster, Go To Pinpoint Test A. For the vehicle security module, refer to Section For the anti-lock brake system (ABS), refer to Section For the restraint control module (RCM), refer to Section B. 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 Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. For all other DTCs, refer to Section If no DTCs related to the concern are retrieved, GO to Symptom Chart - Instrument Cluster, GO to Symptom Chart - Information And Message Center or GO to Symptom Chart - Warning Chimes. Instrument Cluster Diagnostic Trouble Code (DTC) Index DTC Description Action B1201 Fuel Sender Circuit Failure Go To Pinpoint Test B. B1204 Fuel Sender Circuit Short to Ground Go To Pinpoint Test B. B1205 EIC Switch-1 Assembly Circuit Failure Go To Pinpoint Test AF. B1317 Battery Voltage High REFER to Section to continue diagnosis of the charging system. B1318 Battery Voltage Low REFER to Section to continue diagnosis of the charging system. B1342 ECU is Defective INSTALL a new instrument cluster. REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. B1352 Ignition Key-In Circuit Failure Go To Pinpoint Test AM. B1360 Ignition RUN/ACC Circuit Open Go To Pinpoint Test A. B2143 NVM Memory Failure INSTALL a new instrument cluster. REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. B2477 Module Configuration Failure REFER to Section to continue diagnosis on the module configuration. C1284 Engine Oil Pressure Switch Failure Go To Pinpoint Test D. U1900 CAN Communication Bus Fault REFER to Section to continue communication diagnosis. U1950 UBP Communication Bus Fault REFER to Section to continue communication diagnosis. U2013 Compass Module Is Not Responding Go To Pinpoint Test AD. All other DTCs REFER to Section Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index DTC Description Action P0457 Fuel Fill Cap Off REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual to continue diagnosis of the fuel tank evaporative emission system. P0460 Fuel Level Sensor A Circuit REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual first. If sent here from the PC/ED manual, Go To Pinpoint Test B. P0461 Fuel Level Sensor A Circuit Range/Performance REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual first. If sent here from the PC/ED manual, Go To Pinpoint Test B. P0462 Fuel Level Sensor A Circuit Low REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual first. If sent here from the PC/ED manual, Go To Pinpoint Test B. P0463 Fuel Level Sensor A Circuit High REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual first.

7 Page 7 of 13 All other DTCs If sent here from the PC/ED manual, Go To Pinpoint Test B. REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. Instrument Cluster Self-Diagnostic Mode To enter the instrument cluster self diagnostic mode with the engine off, press and hold the odometer RESET button (base cluster) or the message center RESET button (message center cluster). Turn the ignition switch to the RUN position and hold until the display indicates test (base cluster) or TEST (message center cluster) usually within 3 to 5 seconds. Press the reset button once to advance through each stage of the self-test. To exit the instrument cluster self-test mode, turn the ignition to the OFF position. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics. Instrument Cluster Self-Diagnostic Mode Base Cluster Display Message Center Cluster Display Description test TEST Initial entry display into the self-test mode. GAGE SWEEP GAUGES Carries out a gauge sweep of all the gauges, then displays the present gauge values. Also carries out the checksum test on ROM and EEPROM. All segments illuminated All segments illuminated Illuminates all odometer segments. bulb TEST TELLTALES Illuminates all the micro-controlled lamps and LEDs. PART NUMBER, #### ## Displays the alpha-numeric part number. #### Displays the alpha-numeric part number prefix (first 4 digits). #### Suffix (last 2 digits of the part number are displayed as a 2 byte hexadecimal number). ###### SERIAL NUMBER ###### Displays the serial number in decimal. i9nin# IGNITION KEY, # Displays the key-in-ignition status. r #### nr#### ROM LEVEL ####, CHKSUM #### NVM LEVEL ##, CHKSUM #### Returns to normal operation of all the micro-controlled lamps and the LEDs and displays the hexadecimal value for the read-only memory (ROM) level. Displays the hexadecimal ROM level and type as stored in the non-volatile memory (NVM). EE ## Displays the hexadecimal value for the EE level. dt #### FINAL DATE, #### Displays the hexadecimal coding of the final manufacturing test date. CF1-CF4 MODULE CONFIG, BYTE1- BYTE4=## Displays the hexadecimal of bytes 1-4 of the module configuration settings. dtc #### DIAG TROUBLE, CODE: #### Displays a 16-bit DTC in hexadecimal format. DTCs displayed are those detected in continuous operation, not during the self-test. E ###.# VEHICLE SPEED, ###.# MPH Displays the English speed value being input. The speedometer indicates the present speed. ###.# VEHICLE SPEED, ###.# KPH Displays the metric speed value being input. The speedometer indicates the present speed. t #### TACH VALUE, ####RPM Displays the tachometer value being input to the instrument cluster. The tachometer indicates the present rpm. F ### FUEL LEVEL A/D, ### Displays the present fuel level analog/digital ratio input in decimal. The instrument cluster indicates the present fuel level. FP ### FUEL LEVEL %, ### Displays the present fuel level percent status in decimal. ### C COOLANT TEMP, ### Displays the last temperature gauge input value from CAN. The temperature gauge indicates the present temperature. odo### ODO CAN INPUT, ### Displays the odometer input received through the CAN in decimal. OIL### OIL PRESSURE, ### Displays the last analog/digital reading of the engine oil pressure switch contact resistance. The oil gauge indicates the present level. br # BRAKE FLUID AD, # Displays the brake fluid level received from the ABS module. bat ##.# BATTERY VOLTS, ##.# Displays the present SBATT reading in 10th of volt. PWM DIM STEP, ## Displays the dimming step in decimal. rho ### PWM DIM INPUT, ### Displays the present hexadecimal pulse width modulation (PWM) dimming input. Prnd## PRNDL, ## Displays the hexadecimal value of the PRNDL inputs packed into a single byte. Par-# PARK BRAKE, # Displays the input status of the parking brake switch. door1-# DOOR AJAR, # Displays the input status of any door ajar input. door2-# LIFTGATE AJAR, # Displays the input status of the liftgate ajar input. Stbt-# SEATBELT, # Displays the input status of the safety belt switch. RUN/START, # RUN/START sense check. RUN/ACC, # RUN/ACC sense check. CHE ## CHECK ENGINE, ### Displays the 8-bit hexadecimal value of the CAN malfunction indicator lamp (MIL) telltale command. PA, Pb, PE, PG ## PORT A, B, E and J, ## Displays the 8-bit hexadecimal value for the ports A, b, E, and G (base clusters) or J (message center clusters) readings. PP, PS, PT, PCAn, PAD0 and PAD1 ## PORT H, IB, P, S and T, ## Displays the 8-bit hexadecimal value for the ports P, S, T, CAn, AD0, and AD1 (base clusters) or H, IB, P, S, and T (message center clusters) in analog/digital readings. AD00-AD17 ## PORT AD00-AD17 Displays the 8-bit hexadecimal value for the ports AD00-AD17 in analog/digital readings. Symptom Charts Symptom Chart Instrument Cluster Condition Possible Sources Action No communication with the instrument cluster Go To Pinpoint Test A. Incorrect fuel gauge indication Go To Pinpoint Test B. Flex-fuel module (4.0L engines) (part of

8 Page 8 of 13 Incorrect voltage gauge indication Incorrect oil pressure gauge indication Incorrect temperature gauge indication The speedometer/odometer is inoperative Incorrect speedometer indication The tachometer is inoperative 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 The CHECK FUEL CAP indicator is never on The CHECK FUEL CAP indicator is always on The anti-lock brake system (ABS) warning indicator is never on The anti-lock brake system (ABS) warning indicator is always on The brake warning indicator is never/always on The SERVICE ENGINE SOON indicator is never on The SERVICE ENGINE SOON indicator is always on The charging system warning indicator is never/always on The air bag indicator warning is never/always on The high beam indicator is never on The LH turn indicator is never on The RH turn indicator is never on The 4X4 HIGH/AWD LOCK indicator is never/always on The 4X4 LOW range indicator is never/always on The speed control indicator is never/always on The check gauge warning indicator is never/always on The O/D OFF indicator is never/always on The traction control indicator is never/always on The integrated display is inoperative The instrument cluster is inoperative The low tire warning indicator is never on The powertrain malfunction (wrench) warning indicator is never/always on the fuel pump module jumper harness). Fuel level sensor. Fuel pump module. Fuel tank. Charging system. Engine oil pressure switch. Tire size configuration. Axle ratio configuration. Powertrain control module (PCM) concern. Vehicle security module. Restraint control module (RCM). Safety belt switch (part of the driver safety belt buckle). Fuel evaporative system. ABS module. ABS module. Brake fluid level switch. Parking brake switch. Anti-lock brake system (ABS) module. Diagnostic trouble code (DTC) related concern(s). Charging system. Restraint control module (RCM). Go To Pinpoint Test C. Go To Pinpoint Test D. Go To Pinpoint Test E. Go To Pinpoint Test F. Go To Pinpoint Test AT. Go To Pinpoint Test G. Go To Pinpoint Test H. Go To Pinpoint Test I. Go To Pinpoint Test J. REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual to continue the diagnosis. Go To Pinpoint Test K. REFER to Section to continue diagnosis of the ABS. Go To Pinpoint Test L. Go To Pinpoint Test M. REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual to continue diagnosis. Go To Pinpoint Test N. Go To Pinpoint Test O. Go To Pinpoint Test P. 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. Anti-lock brake system (ABS) module. Tire pressure monitoring system (TPMS) module. Go To Pinpoint Test W. Go To Pinpoint Test X. If the integrated display or the temperature display is inoperative, Go To Pinpoint Test Y. If the compass is inoperative, Go To Pinpoint Test AD. Go To Pinpoint Test Z. Go To Pinpoint Test AA. Go To Pinpoint Test AB. Symptom Chart Information And Message Center

9 Page 9 of 13 Condition Possible Sources Action No communication with the instrument cluster The message center is not operating correctly The compass is inoperative The compass is inaccurate Message center switch Compass sensor module Zone setting Calibration Compass sensor module Go To Pinpoint Test A. Go To Pinpoint Test AC. Go To Pinpoint Test AD. Go To Pinpoint Test AE. The message center display is blank INSTALL a new instrument cluster. REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. The charging system warning display is inoperative The message center switch does not operate correctly The low washer fluid level display does not operate correctly The door ajar display does not operate correctly The low fuel level display does not operate correctly The distance to empty, average fuel economy display does not operate correctly The low brake fluid level display does not operate correctly The low oil pressure display does not operate correctly The check engine temperature display does not operate correctly Generator Powertrain control module (PCM) Message center switch Washer fluid level switch Vehicle security module Go To Pinpoint Test N. Go To Pinpoint Test AF. Go To Pinpoint Test AG. Go To Pinpoint Test AH. Go To Pinpoint Test AI. CHECK the operation of the speedometer, the fuel gauge and the odometer. If the speedometer, the fuel gauge or the odometer do not operate correctly, Go To Pinpoint Test F (speedometer/odometer) or Go To Pinpoint Test B (fuel gauge). If the speedometer, the fuel gauge or the odometer operate correctly, INSTALL a new instrument cluster. REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. Go To Pinpoint Test AJ. Go To Pinpoint Test AK. Go To Pinpoint Test AL. Symptom Chart Warning Chimes Condition Possible Sources Action The key-in-ignition warning chime is inoperative The headlamps on reminder chime is inoperative The door ajar warning chime is inoperative The safety belt warning chime does not operate correctly The air bag warning chime is inoperative Key-in-ignition warning switch Vehicle security module Vehicle security module Go To Pinpoint Test AM. Go To Pinpoint Test AN. Go To Pinpoint Test AO. Go To Pinpoint Test AP. Go To Pinpoint Test AP. The message center warning chime is inoperative INSTALL a new instrument cluster. REFER to Instrument Cluster (IC) in this section. The message center switch tone chime is inoperative INSTALL a new instrument cluster. REFER to Instrument Cluster (IC) in this section. All the chimes are inoperative Go To Pinpoint Test AQ. The chime sounds when the driver door is ajar (no key in ignition and headlamps OFF) The Belt-Minder feature does not operate correctly Key-in-ignition warning switch Safety belt switch(es) Restraint control module (RCM) Go To Pinpoint Test AR. Go To Pinpoint Test AS. Connector Circuit Reference Engine Oil Pressure Switch C103

10 Page 10 of (WH/RD) oil pressure signal 0 volts, less than 5 ohms between the engine oil pressure switch and the instrument cluster. Greater than 10,000 ohms between the engine oil pressure switch and ground. Brake Fluid Level Switch C (BK) switch ground 0 volts, less than 5 ohms between the brake fluid level switch and ground (TN/LG) brake fluid level return (VT/WH) brake fluid level signal 0 volts, less than 5 ohms between the brake fluid level switch and the anti-lock brake system (ABS) module. 0 volts, less than 5 ohms between the brake fluid level switch and the ABS module. Greater than 10,000 ohms between the brake fluid level switch and ground. Outside Air Temperature Sensor C (DB/WH) outside air temperature signal (DB/YE) outside air temperature sensor return 0 volts, less than 5 ohms between the outside air temperature sensor and the instrument cluster. Greater than 10,000 ohms between the outside air temperature sensor and ground. 0 volts, less than 5 ohms between the outside air temperature sensor and the instrument cluster. Greater than 10,000 ohms between the outside air temperature sensor and ground. Washer Fluid Level Switch C (RD/LG) signal from the washer fluid level switch to the instrument cluster 0 volts, less than 5 ohms between the instrument cluster and the washer fluid level switch. Greater than 10,000 ohms between the washer fluid level switch and ground (BK/LB) signal return ground 0 volts, less than 5 ohms between the washer fluid level switch and ground. Anti-Lock Brake System (ABS) Module C155

11 Page 11 of (TN/LG) brake fluid level return (VT/WH) brake fluid level signal 0 volts, less than 5 ohms between the ABS module and the brake fluid level switch. Greater than 10,000 ohms between the ABS module and ground. 0 volts, less than 5 ohms between the ABS module and the brake fluid level switch. Greater than 10,000 ohms between the ABS module and ground. Instrument Cluster C220a Pin Number (BK/LG) B+ keep alive power feed Greater than 10 volts at all times. Less than 5 ohms between the instrument cluster and the battery junction box (BJB) fuse 15 (15A). Greater than 10,000 ohms between the instrument cluster and ground (BK/LB) logic ground 0 volts, less than 5 ohms between the instrument cluster and ground (RD/LG) low washer fluid switch input 0 volts, less than 5 ohms between the instrument cluster and the low washer fluid switch. Greater than 10,000 ohms between the instrument cluster and ground (PK/BK) B+ power feed, hot in the START/RUN positions (GY/OG) signal return from the message center switch to the instrument cluster Greater than 10 volts with the ignition switch in the RUN or START position. Less than 5 ohms between the instrument cluster and the central junction box (CJB). Greater than 10,000 ohms between the instrument cluster and ground. 0 volts, less than 5 ohms between the message center switch and the instrument cluster. Greater than 10,000 ohms between the message center switch and ground (DB) safety belt warning indicator control 0 volts, less than 5 ohms between the instrument cluster and the restraint control module (RCM). Greater than 10,000 ohms between the instrument cluster and ground (LG/RD) parking brake switch input 0 volts, less than 5 ohms between the instrument cluster and the parking brake switch. Greater than 10,000 ohms between the instrument cluster and ground with the parking brake released (LG/OG) RH turn indicator power input Alternating voltage between 0 volts and 10 volts in the RH turn position. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground. Instrument Cluster C220b Pin Number (LB/RD) LH turn indicator power input Alternating voltage between 0 volts and 10 volts in the LH turn position. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground (LB/YE) fuel level signal return 0 volts, less than 5 ohms between the instrument cluster and the fuel pump module. Greater than 10,000 ohms between the instrument cluster and ground (BK/YE) air bag warning indicator control. 0 volts, less than 5 ohms between the instrument cluster and the restraint control module (RCM). Greater than 10,000 ohms between the instrument cluster and ground (LG/VT) fuel level variable input signal 0 volts, less than 5 ohms between the instrument cluster and the fuel pump module. Greater than 10,000 ohms between the instrument cluster and ground (WH/RD) oil pressure switch input 0 volts, less than 5 ohms between the instrument cluster and the engine oil pressure switch. Greater than 10,000 ohms between the instrument cluster and ground (BK/YE) signal from the instrument cluster to the message center switch 0 volts, less than 5 ohms between the message center switch and the instrument cluster. Greater than 10,000 ohms between the message center switch and ground (BK) bulb ground 0 volts, less than 5 ohms between the instrument cluster and ground (RD/BK) illumination input Greater than 10 volts with the parking lamps or headlamps on (LG/BK) high beam indicator input 0 volts with the high beam headlamps OFF, greater than 10 volts with the high beam headlamps ON. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground (DB/YE) outside air temperature signal 0 volts, less than 5 ohms between the instrument cluster and the outside air temperature sensor. Greater than 10,000 ohms between the instrument cluster and ground (LG/VT) key-in-ignition warning switch input (WH/OG) compass sensor module data line to the message center (WH/BK) compass sensor module data line to the message center (LB/PK) B+ power feed in the RUN/ACC position (DB/WH) outside air temperature return Greater than 10 volts with the key in the ignition switch. 0 volts without the key in the ignition switch. Greater than 10,000 ohms between the instrument cluster and ground. 0 volts, less than 5 ohms between the compass sensor module and the instrument cluster. Greater than 10,000 ohms between the compass sensor module and ground. 0 volts, less than 5 ohms between the compass sensor module and the instrument cluster. Greater than 10,000 ohms between the compass sensor module and ground. Greater than 10 volts with the ignition switch in the RUN or ACC position. Less than 5 ohms between the instrument cluster and the central junction box (CJB). Greater than 10,000 ohms between the instrument cluster and ground. 0 volts, less than 5 ohms between the instrument cluster and the outside air temperature sensor. Greater than 10,000 ohms between the instrument cluster and ground.

12 Page 12 of 13 Ignition Switch C (YE) ignition switch power input Greater than 10 volts at all times (LG/VT) key-in-ignition warning switch input 0 volts, less than 5 ohms between the ignition switch and the instrument cluster. Greater than 10,000 ohms between the ignition switch and ground. Message Center Switch C253 Pin Number (BK/YE) signal from the instrument cluster to the message center switch (GY/OG) signal return from the message center switch to the instrument cluster 0 volts, less than 5 ohms between the message center switch and the instrument cluster. Greater than 10,000 ohms between the message center switch and ground. 0 volts, less than 5 ohms between the message center switch and the instrument cluster. Restraint Control Module (RCM) C310a (BK/YE) air bag warning indicator control (DB) safety belt warning indicator control 0 volts, less than 5 ohms between the RCM and the instrument cluster. Greater than 10,000 ohms between the RCM and ground. 0 volts, less than 5 ohms between the RCM and the instrument cluster. Greater than 10,000 ohms between the RCM and ground. Fuel Pump Module In-Line C431 (4.0L Engines) Pin Number (RD/YE) flex-fuel module B+ power Greater than 10 volts with the ignition switch in the RUN position. Less than 5 ohms between the fuel pump module and the instrument cluster. Greater than 10,000 ohms between the fuel pump module and ground (LB/YE) fuel level signal return 0 volts, less than 5 ohms between the fuel pump module and the instrument cluster. Greater than 10,000 ohms between the fuel pump module and ground (LG/VT) fuel level variable input signal 0 volts, less than 5 ohms between the fuel pump module and the instrument cluster. Greater than 10,000 ohms between the fuel pump module and ground. Fuel Pump Module In-Line C438 (4.6L Engines)

13 Page 13 of (LB/YE) fuel level signal return 0 volts, less than 5 ohms between the fuel pump module and the instrument cluster. Greater than 10,000 ohms between the fuel pump module and ground (LG/VT) fuel level variable input signal 0 volts, less than 5 ohms between the fuel pump module and the instrument cluster. Greater than 10,000 ohms between the fuel pump module and ground. Compass Sensor Module C (BK/LB) compass sensor module ground 0 volts, less than 5 ohms between the compass sensor module and ground (GY/YE) compass sensor module power Greater than 10 volts with the ignition switch in the RUN position. Greater than 10,000 ohms between the compass sensor module and ground (WH/OG) compass sensor module data line to the message center (WH/BK) compass sensor module data line to the message center 0 volts, less than 5 ohms between the compass sensor module and the instrument cluster. Greater than 10,000 ohms between the compass sensor module and ground. 0 volts, less than 5 ohms between the compass sensor module and the instrument cluster. Greater than 10,000 ohms between the compass sensor module and ground. Parking Brake Switch C (LG/RD) parking brake switch input. 0 volts, less than 5 ohms between the parking brake switch and the instrument cluster. Greater than 10,000 ohms between the parking brake switch and ground (BK) brake switch ground. 0 volts, less than 5 ohms between the parking brake switch and ground. Pinpoint Test A: No Communication With The Instrument Cluster Normal Operation The instrument cluster communicates interactively with other electronic modules using the communication network. For additional information about the communications network, refer to Section With the ignition switch in the START/RUN position, the instrument cluster receives power from 489 (PK/BK). When in the RUN/ACC position, power is received from 295 (LB/PK). With the ignition switch is in the OFF position, the instrument cluster receives its keep-alive memory (KAM) power from 3049 (BK/LG). The instrument cluster grounding is accomplished through 1203 (BK/LB) and the bulb grounding is accomplished through 1205 (BK). Possible Causes 295 (LB/PK) open 489 (PK/BK) open 1203 (BK/LB) open 1205 (BK) open 3049 (BK/LG) open