2002 F-Super Duty /Excursion Workshop Manual

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1 Page 1 of 56 SECTION : Instrument Cluster 2002 F-Super Duty /Excursion Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 11/18/2005 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) 418 F224, 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 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. adjustment, calibration, or maintenance is required for any gauges. Instrument Cluster Replacement CAUTION: When installing a new instrument cluster, the instrument cluster must be re-configured. For additional information, refer to Section When installing a new instrument cluster, contact a Ford authorized instrument cluster repair facility. Speedometer The instrument cluster is hardwired to the four wheel anti-lock brake system (4WABS) module. The instrument cluster micro-processor monitors the VSS data from the 4WABS module and commands the speedometer with a corresponding movement of the pointer. The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4WABS module. The 4WABS module sends the vehicle speed signal via circuit 679 (GY/BK) to all systems that require a vehicle speed signal input. Odometer A million-mile tamper-resistant odometer is standard. New speedometers have a reset table odometer. NOTE: When installing a new instrument cluster some state laws require that the new odometer must register the same as the removed odometer. If the actual vehicle mileage cannot be determined, the repair centers are able to supply odometers set to "0" miles. An odometer mileage sticker must display the estimated vehicle mileage and be affixed to the driver door jamb. The odometer mileage sticker is available through the parts distribution center.

2 Page 2 of 56 Trip Odometer The trip odometer indicates how many miles the vehicle has been driven since the last reset. Fuel Gauge NOTE: It is critical to follow the pinpoint test diagnostic methods to make sure the correct mode is being used during diagnostics. The instrument cluster receives the fuel level signal from the fuel level sensor, part of the fuel pump module. The fuel level sensor measures variable resistance in the fuel tank depending on the current fuel level. When the fuel level is low, the resistance in the unit is low (15 ohms ± 2 ohms). When the fuel level is high, the resistance in the unit is high (160 ohms ± 4 ohms). 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 full (F) to empty (E). 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 when refueling the vehicle. At least 15 percent 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 15 ohms ± 2 ohms and 160 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) (automatic transmissions), or the parking brake applied (manual transmissions). The key is in the RUN position. At least 15 percent 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 (automatic transmissions) or when the parking brake is applied (manual transmissions). When the 30 second time has elapsed and at least 15 percent 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) or the parking brake is released, the fuel gauge strategy reverts to the anti-slosh mode. This 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 message during a refueling event. Missing fuel level messages result from intermittent opens in the fuel sender or its circuits. 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. Temperature Gauge The instrument cluster is hardwired to the engine coolant temperature (ECT) sensor on vehicles equipped with the diesel engine. When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current to the instrument cluster. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow to the instrument cluster. On vehicles equipped with gasoline engines, the instrument cluster receives the temperature signal from the PCM via the standard corporate protocol (SCP) network. Transmission Temperature Gauge (Automatic Transmission Only) The instrument cluster receives the transmission temperature information from the PCM via the SCP network. The instrument cluster micro-processor monitors the transmission temperature data and commands the gauge indication with a corresponding movement of the pointer. Oil Pressure Gauge The instrument cluster is hardwired to the oil pressure sender unit. The instrument cluster micro-processor monitors the oil pressure data and commands the oil pressure gauge indication with a corresponding movement of the pointer. The oil pressure indicator sender unit consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Voltage Gauge (Manual Transmission Only) The voltage gauge displays the system voltage as measured at the instrument cluster run input. Tachometer Gasoline vehicles are equipped with a 6,000 rpm tachometer and diesel vehicles are equipped with a 4,500 rpm tachometer. The instrument cluster receives the tachometer data from the PCM via the SCP network and commands the tachometer according to the data. Warning Indicators Charging System Indicator On vehicles equipped with gasoline engines, the ignition switch contacts are closed, battery current flows through the charging system indicator and the parallel resistor (390 ohms) to the voltage regulator. Internal circuitry in the voltage regulator provides a ground path to the instrument cluster and the indicator illuminates. When the generator builds up enough voltage to energize the voltage regulator, voltage is applied to the ground side of the indicator effectively removing the ground path and turning the indicator off. On vehicles equipped with diesel engines, the ignition switch contacts are closed, battery current flows through the charging indicator and the parallel resistor (390 ohms) to the PCM. The PCM provides a ground to the instrument cluster and the charging system indicator illuminates. When the generator builds up enough voltage to energize the voltage regulator, voltage is applied to the PCM. The PCM upon receipt of the generator charging voltage, removes the ground to the instrument cluster and turns off the charging system indicator. Brake Warning Indicator The red brake warning light (BRAKE) is used to indicate a low fluid level, brake concern, a parking brake that is not fully released, or an anti-lock brake system (ABS) fault. The brake fluid

3 Page 3 of 56 level switch is located in the brake fluid reservoir. ABS Warning Indicator The yellow brake warning indicator is used to indicate a concern or deactivation of the ABS. It illuminates when triggered by the ABS control module and stays illuminated as long as the concern remains in the system. Malfunction Indicator Lamp (MIL) Indicator The malfunction indicator lamp (MIL) indicator is illuminated when a diagnostic trouble code (DTC) is sensed in the closed loop by the powertrain control module (PCM). The instrument cluster receives engine data from the PCM via the SCP network. Air Bag Warning Indicator The instrument cluster is hardwired to the restraint control module. If an air bag system DTC is detected, the restraint control module provides a ground path to the instrument cluster and the air bag indicator is illuminated. Safety Belt Warning Indicator The safety belt warning indicator is powered through the instrument cluster and is grounded through the safety belt retractor switch. When the safety belt is extended, indicating a buckled condition, the switch will open to the instrument cluster and the safety belt indicator is extinguished. When the safety belt is retracted, indicating an unbuckled condition, the switch closes and provides a ground to the instrument cluster and the safety belt indicator is illuminated. Low Fuel Warning Indicator The low fuel warning indicator is controlled by the instrument cluster microprocessor and illuminates when the fuel level drops below approximately one-sixteenth of a tank or 4-8L (1-2 gal). Door Ajar Indicator On vehicles that are equipped with remote keyless entry, the door ajar switches provide a ground signal to the body security module which subsequently provides a ground signal to the instrument cluster via the UBP network and illuminates the door ajar indicator. On vehicles not equipped with remote keyless entry, the door ajar switches are hardwired to the instrument cluster and provide the ground to illuminate the door ajar indicator. High Beam Indicator The instrument cluster provides a ground for the high beam indicator. The multifunction switch provides a switched power source to the instrument cluster to illuminate the high beam indicator when in the high beam position. When the high beams are activated, the multifunction switch sends a power signal to the instrument cluster and illuminates the high beam indicator. Speed Control Indicator The instrument cluster provides power to the speed control indicator. On gasoline vehicles, the speed control indicator is controlled by the speed control module. When the speed control is engaged, the speed control module provides the instrument cluster with a ground signal and illuminates the speed control indicator. On diesel vehicles, the speed control indicator is controlled by the PCM. When the speed control is engaged, the PCM provides a ground to the instrument cluster and illuminates the speed control indicator. Water in Fuel Indicator (Diesel only) The water in fuel signal is transmitted to the instrument cluster via the SCP network from the powertrain control module (PCM). The water in fuel indicator will illuminate when 100 cc (0.2 pints) of water has accumulated in the fuel filter/water separator. Wait to Start Indicator (Diesel only) The wait to start signal is transmitted to the instrument cluster via the SCP network from the PCM. The wait to start indicator will illuminate when the ignition switch is in the ON position with the engine OFF indicating that the glow plugs are heating. Theft Indicator The instrument cluster provides the THEFT indicator with power. The theft indicator is hardwired to the PATS module and will flash when the PATS system is activated. Check Air Filter Indicator The check air filter indicator is hardwired to the air filter indicator switch (located in the air filter housing) and monitors the air flow through the air cleaner. The air filter indicator is powered by the instrument cluster and when air flow is low, the air filter indicator switch provides a ground to the instrument cluster illuminating the check air filter indicator. Check Gauge Warning Indicator The check gauge warning indicator will illuminate when any of the three following conditions exist: if the engine oil pressure drops below approximately 42 kpa (6 psi). if the engine temperature exceeds approximately 121 C (250 F). if the transmission temperature (automatic transmission only) reaches approximately 135 C (275 F). Check Fuel Cap Indicator The check fuel cap indicator is used to indicate significant leaks in the fuel tank evaporative system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM and once a leak is detected, the PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a loose fuel cap and the check fuel cap indicator is illuminated, the check fuel cap indicator will remain illuminated until the fuel cap is secured and the vehicle has been running for several minutes or the ignition has been cycled once. For additional information, refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. 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

4 Page 4 of 56 the engine temperature reaches 121 C (249.8 F) or higher, or if the engine oil pressure is low. Inspection and Verification 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Engine oil filter Door adjustment Engine coolant level Fuel tank Fuel evaporative system Low alternative fuel or gasoline Alternative fuel or gasoline tank(s) Electrical Central junction box (CJB) fuse(s): 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 (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 NO RESP/NOT EQUIP for body security module, refer to Section ; for anti-lock brake system (ABS), refer to Section ; or for restraint control module, 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 the Restraint Control Module (RCM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 8. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics. Instrument Cluster Diagnostic Trouble Code (DTC) Index DTC Description Source Action B1201 Fuel Sender Circuit Failure Instrument Cluster B1204 Fuel Sender Circuit Short To Ground Instrument Cluster B1205 EIC Switch-1 Assembly Circuit Failure Instrument Cluster B1317 Battery Voltage High Instrument Cluster B1318 Battery Voltage Low Instrument Cluster B1320 Driver Door Ajar Circuit Open Instrument Cluster B1328 Passenger Door Ajar Circuit Open Instrument Cluster B1342 ECU is Defective Instrument Cluster B1360 Ignition Run/Acc Circuit Open Instrument Cluster B2143 NVM Memory Failure Instrument Cluster B2658 Wait To Start Warning Indicator Circuit Open Instrument Cluster C1284 Oil Pressure Switch Failure Instrument Cluster U1027 Invalid or Missing Data for Engine RPM Instrument Cluster U1051 Invalid or Missing Data for Brakes Instrument Cluster U1073 Invalid or Missing Data for Engine Coolant Instrument Cluster U1059 Invalid or Missing Data for Transmission PRNDL Instrument Cluster GO to Pinpoint Test B. GO to Pinpoint Test B. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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. GO to Pinpoint Test D. GO to Pinpoint Test I. GO to Pinpoint Test M. GO to Pinpoint Test E. GO to Pinpoint Test F. For a complete list of instrument cluster DTCs, refer to Section

5 Page 5 of 56 Restraint Control Module (RCM) Diagnostic Trouble Code (DTC) Index DTC Description Source Action B1869 Lamp Air Bag Warning Indicator Circuit Open Restraint Control Module GO to Pinpoint Test P. B1870 Lamp Air Bag Warning Indicator Circuit Short to Battery Restraint Control Module GO to Pinpoint Test P. For a complete list of RCM DTCs, refer to Section B. Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index DTC Description Source Action C1226 Brake Warning Lamp Output Short to Ground ABS GO to Pinpoint Test M. For a complete list of ABS control module DTCs, refer to Section Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index DTC Description Source Action P4057 Fuel Fill Cap Off PCM GO to Pinpoint Test Z. P0381 Glow Plug Indicator Circuit Malfunction PCM GO to Pinpoint Test V. For a complete list of the PCM DTCs, refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. 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. Instrument Cluster Self-Diagnostic Mode Odometer display GAGE All segments illuminated. bulb r #### nr#### EE ## dt #### ###C dtc #### EnG m tac FUEL OIL br bat ##.# rheo rhi, rhs, rho Cr PA, Pb, PC, and Pd PE0-PE7 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. Symptom Chart Symptom Chart Condition Possible Sources Action communication with the instrument cluster Central junction box (CJB) fuse (s): 33 (15A). 35 (10A). 41 (10A). 45 (10A). J1850 standard corporate protocol (SCP) communication network. GO to Pinpoint Test A.

6 Page 6 of 56 Incorrect fuel gauge indication Incorrect voltage gauge indication manual transmission only Incorrect oil pressure gauge indication Incorrect temperature gauge indication Incorrect transmission temperature gauge indication automatic transmission only The low fuel warning indicator is never/always on The speedometer is inoperative The tachometer is inoperative 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 The ABS warning indicator is never/always on The brake warning indicator is never on The brake warning indicator is always on Malfunction indicator lamp (MIL) indicator is never on Malfunction indicator lamp (MIL) indicator is always on The charging system indicator is never on The charging system indicator is always on The air bag indicator warning is never/always on Fuel sender. Fuel tank. Oil pressure switch. Coolant temperature sender (diesel only). J1850 standard corporate protocol (SCP) communication network. Powertrain control module (PCM). Transmission temperature sensor. Powertrain control module (PCM). Low fuel indicator bulb. Anti-lock brake system (ABS) module. Generator (diesel only). Indicator bulb. Body security module. Indicator bulb. Safety belt switch (part of the safety belt retractor). Anti-lock brake system (ABS) module. Tires. Indicator bulb. Anti-lock brake system (ABS) module. Indicator bulb. Brake warning indicator relay. Anti-lock brake system (ABS) module. Brake fluid level switch. Parking brake switch. Brake fluid level switch. Parking brake switch. Anti-lock brake system (ABS) module. Hydromax module (if equipped). Indicator LED. J1850 standard corporate protocol (SCP) communication network. Powertrain control module (PCM). Diagnostic trouble code (DTC) related concern(s). Central junction box (CJB) fuse 29 (5A). Charging system. Indicator LED. Generator (charging system). Indicator bulb. GO to Pinpoint Test B. GO to Pinpoint Test C. GO to Pinpoint Test D. GO to Pinpoint Test E. GO to Pinpoint Test F. GO to Pinpoint Test G. GO to Pinpoint Test H. GO to Pinpoint Test I. 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. GO to Pinpoint Test K. GO to Pinpoint Test H. GO to Pinpoint Test L. GO to Pinpoint Test M. REFER to Section GO to Pinpoint Test N. REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. GO to Pinpoint Test O. REFER to Section GO to Pinpoint Test P.

7 Page 7 of 56 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 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 CHECK GAGE warning indicator is inoperative/always on The check air filter indicator is never/always on diesel only The CK SUSP indicator is never/always on The instrument cluster is inoperative Air bag diagnostic monitor. Indicator bulb. Indicator bulb. Indicator bulb. 4X4 range select switch. Indicator bulb. 4X4 range select switch. Powertrain control module (PCM). Indicator bulb. Water in fuel switch. Indicator bulb. Speed control servo. Indicator bulb. Passive anti-theft (PATS) module. Evaporative system. Powertrain control module (PCM). CHECK GAGE indicator bulb. Check air filter indicator bulb. Check air filter switch. Air suspension module. Central junction box (CJB) fuse (s): 33 (15A). 35 (10A). 41 (10A). 45 (10A). 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. GO to Pinpoint Test X. GO to Pinpoint Test Y. GO to Pinpoint Test Z. GO to Pinpoint Test AA. GO to Pinpoint Test AB. GO to Pinpoint Test AC. GO to Pinpoint Test AD. Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE INSTRUMENT CLUSTER CAUTION: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. A1 CHECK THE INSTRUMENT CLUSTER POWER SUPPLY Instrument Cluster C220c Using the following table, measure the voltage between the instrument cluster C220c, harness side and ground. Pin Circuit (LG/OG) (BK/LG)

8 Page 8 of (BK/PK) (RD/YE) Are the voltages greater than 10 volts? GO to A2. A2 CHECK INSTRUMENT CLUSTER GROUND CIRCUITS 57 (BK) AND 676 (PK/OG) REPAIR the circuit(s) in question. TEST the system for normal operation. 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? REFER to Section REPAIR the circuit(s) in question. TEST the system for normal operation. PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION 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 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%? GO to B2. B2 CHECK THE FUEL GAUGE OPERATION GO to B8. NOTE: The fuses must be removed to reset the fuel gauge timers. Failure to complete this step may result in erroneous test results.

9 Page 9 of 56 Remove the central junction box (CJB) fuses 35 (10A) and 41 (10A). Wait 1 minute and reinstall the fuses. 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. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Set the tester to 160 ohms. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Set the tester to 15 ohms. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Observe the fuel gauge. The fuel gauge should read E (empty) or below. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Set the tester to 160 ohms. NOTE: Wait 1 minute for the fuel gauge to respond. Observe the fuel gauge. The fuel gauge should read F (full ) or above. Does the fuel gauge operate correctly? DISCONNECT the instrument gauge system tester. GO to B3. B3 CHECK THE FUEL TANK DISCONNECT the instrument gauge system tester. GO to B5. Check the fuel tank for any damage or deformation.

10 Page 10 of 56 Is the fuel tank OK? GO to B4. B4 INSPECT THE FUEL PUMP ASSEMBLY INSTALL a new fuel tank. REFER to Section TEST the system for normal operation. Check the fuel pump assembly in-tank mounting, float, float rod, wiring and connections for damage or obstruction. Are the fuel pump assembly and wiring OK? INSTALL a new fuel sender. TEST the system for normal operation. B5 CHECK CIRCUIT 29 (YE/WH) FOR SHORT TO POWER REPAIR or INSTALL a new fuel pump assembly as necessary. TEST the system for normal operation. 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? 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? GO to B7. 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.

11 Page 11 of 56 Is the resistance less than 5 ohms? GO to B8. B8 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. REPEAT the Instrument Cluster self-test. 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 INDICATION MANUAL TRANSMISSION ONLY 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 on-demand self-tests. Are any instrument cluster DTCs recorded? If instrument cluster DTC B1317 or B1318 is retrieved, REFER to Section All other instrument cluster DTCs, REFER to the Instrument Cluster Diagnostic Trouble Code (DTC) Index. 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%? REFER to Section

12 Page 12 of 56 GO to C3. C3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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 on-demand self-tests. Are any instrument cluster DTCs recorded? 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. GO to D2. D2 CARRY OUT THE OIL PRESSURE GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command Select the instrument cluster oil pressure gauge active command. Trigger the oil pressure gauge active command. Scroll in three increments 0%, 50% and 100%. Did the engine oil pressure gauge start at L (low) when at 0%, move to half at 50% and H (high) at 100%? GO to D3. D3 CHECK THE ENGINE OIL PRESSURE GO to D6. Carry out the engine oil pressure test. Refer to Section Is the oil pressure within specification? GO to D4. D4 CHECK CIRCUIT 31 (WH/RD) FOR OPEN OR SHORT TO GROUND REFER to Section

13 Page 13 of 56 Instrument Cluster C220c 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 switch, and greater than 10,000 ohms between the instrument cluster and ground? GO to D5. D5 CHECK CIRCUIT 31 (WH/RD) FOR SHORT TO POWER Measure the voltage between the instrument cluster C220c pin 8, circuit 31 (WH/RD), harness side and ground. Is the resistance greater than 10,000 ohms? D6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION INSTALL a new oil pressure switch. TEST the system for normal operation. Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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

14 Page 14 of 56 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 on-demand self-tests. Are any instrument cluster DTCs recorded? If instrument cluster DTC U1073 is retrieved, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. All other instrument cluster DTCs REFER to the Instrument Cluster Diagnostic Trouble Code (DTC) Index. GO to E2. E2 CARRY OUT THE COOLANT TEMPERATURE GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command 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%? For gasoline engines, REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. For diesel engines, REFER to GO to E3. GO to E7. E3 CHECK CIRCUIT 45 (YE/RD) FOR OPEN OR SHORT TO GROUND Instrument Cluster C220c 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? GO to E4. E4 CHECK CIRCUIT 45 (YE/RD) FOR SHORT TO POWER Measure the voltage between the instrument cluster C220c pin 6, circuit 45 (YE/RD), harness side and ground.

15 Page 15 of 56 Is any voltage indicated? GO to E5. E5 CHECK CIRCUIT 39 (RD/WH) FOR OPEN OR SHORT TO GROUND Measure the resistance between the instrument cluster C220c pin 7, circuit 39 (RD/WH), harness side and the engine coolant temperature sensor C1064 pin 1, circuit 39 (RD/WH), harness side; and between the instrument cluster C220c pin 7, circuit 39 (RD/WH), harness side and ground. 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? GO to E6. 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? E7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION INSTALL a new engine coolant temperature sensor. REFER to Section B. TEST the system for normal operation. Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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.

16 Page 16 of 56 PINPOINT TEST F: INCORRECT TRANSMISSION TEMPERATURE GAUGE INDICATION AUTOMATIC TRANSMISSION ONLY F1 RETRIEVE THE RECORDED DTCS FROM BOTH CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS Use the recorded instrument cluster DTCs from the continuous and on-demand self-tests. Are any instrument cluster DTCs recorded? If instrument cluster DTC U1059 is retrieved, GO to F4. All other instrument cluster DTCs, REFER to the Instrument Cluster Diagnostic Trouble Code (DTC) Index. If any PCM DTCs are present, REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. GO to F2. F2 CARRY OUT THE TRANSMISSION TEMPERATURE GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command Select the instrument cluster transmission temperature gauge active command. Trigger, monitor, and scroll the transmission temperature gauge at: 0%, 50%, and 100%. Does the transmission temperature gauge display: low (L) with 0%, half with 50%, and high (H) with 100%? GO to F4. GO to F3. F3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. F4 CHECK FOR CORRECT PCM OPERATION INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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. Disconnect all PCM connectors. Connect all PCM connectors and make sure they seat correctly. INSTALL anew PCM. REFER to Section A for gasoline engines or Section B for diesel engines. TEST the system for normal operation. 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.

17 Page 17 of 56 PINPOINT TEST G: THE LOW FUEL WARNING INDICATOR IS NEVER/ALWAYS ON G1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on and off. Observe the low fuel warning indicator. Does the low fuel warning indicator illuminate when commanded on and turn off when commanded off? G2 CHECK THE FUEL GAUGE GO to G2. GO to G3. Check the fuel gauge. Does the fuel gauge operate correctly? GO to G3. GO to Pinpoint Test B. G3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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

18 Page 18 of 56 Instrument Cluster Active Command 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? GO to H2. GO to H4. H2 CHECK THE CIRCUIT 679 (GY/BK) FOR OPEN OR SHORT TO GROUND Instrument Cluster C220b 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? H3 CHECK THE CIRCUIT 679 (GY/BK) FOR SHORT TO POWER GO to H3. Measure the voltage between the instrument cluster C220b pin 3, circuit 679 (GY/BK), harness side and ground. Is any voltage indicated? H4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION REFER to Section

19 Page 19 of 56 Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 I: THE TACHOMETER IS INOPERATIVE 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 on-demand self-tests. Are any instrument cluster DTCs recorded? If instrument cluster DTC U1027 is retrieved, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. All other instrument cluster DTCs REFER to the Instrument Cluster Diagnostic Trouble Code (DTC) Index. GO to I2. I2 CARRY OUT THE TACHOMETER ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command Select the instrument cluster tachometer active command. Trigger the tachometer and scroll in increments of 10%. Monitor the tachometer gauge. The tachometer should increase in increments of approximately 600 rpm for each 10% change. Does the tachometer gauge increase within specifications? REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. GO to I3. I3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 CAUTION: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

20 Page 20 of 56 J1 CHECK THE INTERIOR LAMPS OPERATION Open and close each door while monitoring the interior lamps. Do the interior lamps operate correctly? GO to J2. REFER to Section J2 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command 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? With remote keyless entry system, GO to J5. Without remote keyless entry system, GO to J3. GO to J6. J3 CHECK CIRCUIT 759 (LG/YE) FOR OPEN OR SHORT TO GROUND Driver Door Ajar Switch C526 Instrument Cluster C220b 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? GO to J4. J4 CHECK CIRCUIT 760 (PK/LB) FOR OPEN OR SHORT TO GROUND

21 Page 21 of 56 Door Ajar Switch C715 (LR), C820 (RR), and C602 (RF) Instrument Cluster C220b 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? GO to J6. J5 CHECK FOR CORRECT BODY SECURITY MODULE OPERATION REPAIR the circuit. TEST the system for normal operation Disconnect all body security module connectors. Connect all body security module connectors and make sure they seat correctly. J6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION INSTALL a new body security module. REFER to Section TEST the system for normal operation. 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. Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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

22 Page 22 of 56 Safety Belt Retractor Switch C323 Connect a fused (10A) jumper wire between the safety belt retractor switch C323 pin 1, circuit 85 (BN/LB), harness side and ground. Observe the safety belt warning indicator. Is the safety belt warning indicator illuminated? GO to K2. K2 CHECK CIRCUIT 57 (BK) FOR OPEN GO to K3. 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? INSTALL a new safety belt retractor switch. REFER to Section A. TEST the system for normal operation. K3 CHECK CIRCUIT 85 (BN/LB) FOR OPEN Instrument Cluster C220b Measure the resistance between the instrument cluster C220b pin 6, circuit 85 (BN/LB), harness side and the safety belt retractor switch C323 pin 1, circuit 85 (BN/LB), harness side. Is the resistance less than 5 ohms? GO to K4. K4 CHECK CIRCUIT 85 (BN/LB) FOR SHORT TO POWER Measure the voltage between the instrument cluster C220b pin 6, circuit 85 (BN/LB), harness side and ground.

23 Page 23 of 56 Is any voltage indicated? GO to K5. K5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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 lamp prove out? If the ABS warning indicator is always on, GO to L2. L2 CHECK ABS INDICATOR LAMP OPERATION If the ABS warning indicator is inoperative, GO to L4. ABS Module C135 Observe the ABS indicator lamp. Is the ABS indicator lamp illuminating?

24 Page 24 of 56 GO to L3. L3 CHECK CIRCUIT 603 (DG) FOR SHORT TO GROUND REFER to Section 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? L4 CHECK THE ABS WARNING INDICATOR CONTROL CIRCUIT GO to L7. 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? REFER to Section L5 CHECK CIRCUIT 603 (DG) FOR OPEN GO to L5. Instrument Cluster C220c 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.

25 Page 25 of 56 Is the resistance less than 5 ohms? GO to L6. L6 CHECK CIRCUIT 603 (DG) FOR SHORT TO POWER Measure the voltage between the 4WABS module C135 pin 15, circuit 603 (DG), harness side and ground. Is there any voltage indicated? GO to L7. L7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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? GO to M2. M2 CHECK PARKING BRAKE SWITCH DISENGAGE the parking brake control and FILL the brake fluid to the correct level as necessary. TEST the system for normal operation.

26 Page 26 of 56 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? GO to M3. M3 CHECK CIRCUIT 162 (LG/RD) FOR OPEN OR SHORT TO GROUND INSTALL a new parking brake switch. REFER to Section TEST the system for normal operation. Instrument Cluster C220b 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? GO to M4. M4 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE ABS Module C135 Instrument Cluster C220b Check the red BRAKE warning indicator for illumination. Does the red BRAKE warning indicator illuminate?

27 Page 27 of 56 GO to M5. M5 CHECK BRAKE FLUID LEVEL SWITCH NOTE: Verify that the brake fluid level is full. REFER to Section 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). 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? GO to M6. M6 CHECK CIRCUIT 531 (DG/YE) AND CIRCUIT 512 (TN/LG) FOR SHORT TO GROUND INSTALL a new brake fluid level switch. TEST the system for normal operation. Instrument Cluster C220c 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? GO to M7. M7 CHECK CIRCUIT 531 (DG/YE) AND CIRCUIT 512 (TN/LG) FOR AN OPEN REPAIR circuit 531 (DG/YE) and circuit 512 (TN/LG) as necessary. TEST the system for normal operation. 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?

28 Page 28 of 56 GO to M8. M8 CHECK CIRCUIT 57 (BK) FOR AN OPEN REPAIR the circuit in question. TEST the system for normal operation. 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? GO to M9. M9 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Correct all instrument cluster connectors and make sure they seat correctly. Operate the system and verify that concern is still present. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 N1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Connect the diagnostic tool. Instrument Cluster Active Command Select the ICM WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command. Observe the SERVICE ENGINE SOON indicator. Is the SERVICE ENGINE SOON indicator illuminating? REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. GO to N2. N2 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION

29 Page 29 of 56 Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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. Does the charging system warning indicator illuminate? For gasoline engine, INSTALL a new generator. REFER to Section TEST the system for normal operation. For diesel engine, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. For gasoline engine, GO to O2. O2 CHECK CIRCUIT 904 (LG/RD) FOR OPEN For diesel engine, GO to O3. Instrument Cluster C220b 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.

30 Page 30 of 56 Is the resistance less than 5 ohms? GO to O4. O3 CHECK INDICATOR CONTROL CIRCUIT 904 (LG/RD) FOR OPEN Instrument Cluster C220b 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. Is the resistance less than 5 ohms? O4 CHECK CIRCUIT 904 (LG/RD) FOR SHORT TO POWER GO to O4. Measure the voltage between the instrument cluster C220b pin 12, circuit 904 (LG/RD), harness side and ground. Is any voltage indicated? GO to O5. O5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly.

31 Page 31 of 56 INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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 prove out correctly? System is OK. If the air bag indicator is never on, GO to P2. P2 CHECK CIRCUIT 608 (BK/YE) If the air bag indicator is always on, GO to P4. Deactivate the restraint control supplemental air bag system. Refer to Section B. Restraint Control Module C1041 Connect a fused (10A) jumper wire between the restraint control module C1041 pin 20, circuit 608 (BK/YE), harness side and ground. Does the air bag indicator lamp illuminate? REFER to Section B. P3 CHECK CIRCUIT 608 (BK/YE) FOR OPEN GO to P3.

32 Page 32 of 56 Instrument Cluster C220c 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? GO to P6. P4 ISOLATE AIR BAG DIAGNOSTIC MODULE Deactivate the restraint control supplemental air bag system. Refer to Section B. Restraint Control Module C1041 Observe the air bag warning indicator. Does the air bag warning indicator illuminate? P5 CHECK CIRCUIT 608 (BK/YE) FOR SHORT TO GROUND GO to P5. REFER to Section B. Instrument Cluster C220c 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? GO to P6. P6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION

33 Page 33 of 56 Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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? GO to Q2. Q2 CHECK CIRCUIT 12 (LG/BK) FOR VOLTAGE REFER to Section Instrument Cluster C220c NOTE: Headlamps must be on for this test. Place the multifunction switch in the high beam position. Measure the voltage between the instrument cluster C220c pin 5, circuit 12 (LG/BK), harness side and ground. Is the voltage greater than 10 volts? GO to Q4. 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.

34 Page 34 of 56 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? INSTALL a new multifunction switch. REFER to Section 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? GO to Q5. Q5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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? GO to R2. R2 CHECK CIRCUIT 3 (LG/WH) FOR VOLTAGE REFER to Section Instrument Cluster C220a Place the multifunction switch in the LH turn signal position. Measure the voltage between instrument cluster C220a pin 5, circuit 3 (LG/WH), harness side and ground.

35 Page 35 of 56 Does the voltage fluctuate between 0 and greater than 10 volts? GO to R4. 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 ohms between the instrument cluster and the multifunction switch, and greater than 10,000 ohms between the instrument cluster and ground? INSTALL a new multifunction switch. REFER to Section TEST the system for normal operation. R4 CHECK CIRCUIT 57 (BK) FOR OPEN Instrument Cluster C220c Measure the resistance between instrument cluster C220c pin 15, circuit 57 (BK), harness side and ground. Is the resistance less than 5 ohms? GO to R5. R5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION

36 Page 36 of 56 Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 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? GO to S2. S2 CHECK CIRCUIT 2 (WH/LB) FOR VOLTAGE REFER to Section Instrument Cluster C220c 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? GO to S4. GO to S3. S3 CHECK CIRCUIT 2 (WH/LB) FOR OPEN OR SHORT TO GROUND Multifunction Switch C202b Measure the resistance between the instrument cluster C220c pin 4, circuit 2 (WH/LB), harness side and the multifunction switch C202b pin 7, circuit 2 (WH/LB), harness side; and between the instrument cluster C220c pin 4, circuit 2 (WH/LB), harness side and ground.

37 Page 37 of 56 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? INSTALL a new multifunction switch. REFER to Section 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. Is the resistance less than 5 ohms? GO to S5. S5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 T: THE 4X4 HIGH/4X4 LOW RANGE INDICATOR IS NEVER/ALWAYS ON ELECTRONIC 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

38 Page 38 of 56 Instrument Cluster Active Command 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? 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. T2 CHECK CIRCUIT 210 (LB) FOR OPEN GO to T9. 4x4 Control Module C281b Instrument Cluster C220b 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. Is the resistance less than 5 ohms? GO to T3. T3 CHECK CIRCUIT 210 (LB) FOR SHORT TO POWER Measure the voltage between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground. Is any voltage indicated? T4 CHECK CIRCUIT 975 (BN/YE) FOR OPEN GO to T8.

39 Page 39 of 56 Instrument Cluster C220b 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? GO to T5. T5 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO POWER Measure the voltage between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side and ground. Is any voltage indicated? T6 CHECK CIRCUIT 210 (LB) FOR SHORT TO GROUND GO to T8. Instrument Cluster C220b Measure the resistance between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground. Is the resistance greater than 10,000 ohms?

40 Page 40 of 56 T7 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO GROUND GO to T8. Instrument Cluster C220b 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? GO to T8. T8 CHECK FOR CORRECT 4X4 MODULE OPERATION Disconnect all 4x4 module connectors. Connect all 4x4 module connectors and make sure they seat correctly. T9 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION INSTALL a new 4x4 module. REFER to Section A. TEST the system for normal operation. 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. Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 ON MANUAL SHIFT 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

41 Page 41 of 56 Connect the diagnostic tool. Instrument Cluster Active Command 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? 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. U2 CHECK CIRCUIT 210 (LB) FOR OPEN GO to U8. 4x4 Range Select Switch C1177 Instrument Cluster C220b 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? GO to U3. U3 CHECK CIRCUIT 210 (LB) FOR SHORT TO POWER Measure the voltage between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground. Is any voltage indicated? REPAIR the circuit in question. TEST the system for normal operation.

42 Page 42 of 56 U4 CHECK CIRCUIT 975 (BN/YE) FOR OPEN GO to U6. 4x4 Range Select Switch C1177 Instrument Cluster C220b 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? GO to U5 U5 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO POWER Measure the voltage between the instrument cluster C220b pin 4, circuit 975 (BN/YE), harness side ground. Is any voltage indicated? REPAIR the circuit in question. TEST the system for normal operation. U6 CHECK CIRCUIT 210 (LB) FOR SHORT TO GROUND INSTALL a new 4x4 range select switch. TEST the system for normal operation. 4x4 Range Select Switch C1177 Instrument Cluster C220b Measure the resistance between the instrument cluster C220b pin 5, circuit 210 (LB), harness side and ground.

43 Page 43 of 56 Is the resistance greater than 10,000 ohms? U7 CHECK CIRCUIT 975 (BN/YE) FOR SHORT TO GROUND INSTALL a new 4x4 select switch. REFER to Section A. TEST the system for normal operation. REPAIR the circuit in question. TEST the system for normal operation. 4x4 Range Select Switch C1177 Instrument Cluster C220b 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? U8 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION INSTALL a new 4x4 select switch. REFER to Section A. TEST the system for normal operation. REPAIR the circuit in question. TEST the system for normal operation. Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 V: THE WAIT TO START INDICATOR IS NEVER/ALWAYS ON DIESEL ONLY V1 RETRIEVE THE RECORDED PCM AND INSTRUMENT CLUSTER DTCS BOTH CONTINUOUS AND ON-DEMAND SELF-TESTS Connect the diagnostic tool.

44 Page 44 of 56 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? 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. For all other instrument cluster DTCs, REFER to Section GO to V2. V2 CHECK THE WAIT TO START INDICATOR PROVE-OUT NOTE: The wait to start indicator should prove out for approximately 1 to 10 seconds, then turn off. Monitor the wait to start indicator during prove-out. Does the wait to start indicator prove out correctly? The system is OK. GO to V3. V3 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on then off. Observe the wait to start indicators. Does the wait to start indicator illuminate when commanded on, and turn off when commanded off? GO to V4. GO to V5. V4 CHECK FOR CORRECT PCM OPERATION Disconnect all PCM connectors. Connect all PCM connectors and make sure they seat correctly. INSTALL a new PCM. REFER to Section B. TEST the system for normal operation. If the problem remains, REINSTALL the original PCM and GO to V5. 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 Connect all instrument cluster connectors and make sure they seat correctly.

45 Page 45 of 56 INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 W: THE WATER IN FUEL INDICATOR IS NEVER/ALWAYS ON DIESEL ONLY W1 RETRIEVE THE RECORDED PCM DTCS BOTH CONTINUOUS AND ON-DEMAND AND SELF-TESTS Connect the diagnostic tool. PCM and Instrument Cluster DTCs Retrieve the recorded PCM DTCs from both the continuous and on-demand self-tests. Are there any DTCs retrieved? If PCM DTC P1139 is retrieved, GO to W5. For all other PCM DTCs, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. GO to W2. W2 CHECK THE WATER IN FUEL INDICATOR PROVE-OUT Monitor the water in fuel indicator during prove-out. Does the water in fuel indicator prove out correctly? The system is OK. GO to W3. W3 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Instrument Cluster Active Command Select the instrument cluster WARNING LAMPS AND CHIME active command. Trigger the ALL LAMPS active command on then off. Observe the wait to start indicators. Does the water in fuel indicator illuminate when commanded on, and turn off when commanded off? GO to W4. GO to W5. W4 CHECK FOR CORRECT PCM OPERATION Disconnect all PCM connectors. Connect all PCM connectors and make sure they seat correctly.

46 Page 46 of 56 INSTALL a new PCM. REFER to Section B. TEST the system for normal operation. If the problem remains, REINSTALL the original PCM and GO to W5. 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. W5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Connect all instrument cluster connectors and make sure they seat correctly. INSTALL a new instrument cluster. REFER to Instrument Cluster in this section. TEST the system for normal operation. 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 X: THE SPEED CONTROL INDICATOR IS NEVER/ALWAYS ON CAUTION: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. X1 CHECK SPEED CONTROL OPERATION Test drive the vehicle and operate the speed control. Does the speed control operate correctly? If the speed control indicator is never on, GO to X2. If the speed control indicator is always on, GO to X4. X2 CHECK THE SPEED CONTROL INDICATOR CIRCUIT REFER to Section 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). Does the indicator illuminate? If gasoline, INSTALL a new speed control servo. REFER to Section If diesel, INSTALL a new PCM. REFER to Section B. TEST the system for normal operation.

47 Page 47 of 56 X3 CHECK CIRCUIT 203 (OG/LB) GO to X3. Instrument Cluster C220c Measure the resistance between the speed control servo C122 pin 1, circuit 203 (OG/LB), harness side and the instrument cluster C220c pin 17, circuit 203 (OG/LB), harness side (gasoline only); or between the PCM C175 pin 45, circuit 203 (OG/LB), harness side and the instrument cluster C220c pin 17, circuit 203 (OG/LB), harness side (diesel only). Is the resistance less than 5 ohms? GO to X6. 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? GO to X5. X5 CHECK THE SPEED CONTROL INDICATOR CIRCUIT FOR SHORT TO GROUND INSTALL a new PCM. REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual (diesel only) or speed control servo. REFER to Section (gasoline only). TEST the system for normal operation. Instrument Cluster C220c Measure the resistance between the instrument cluster C220c pin 17, circuit 203 (OG/LB), harness side and ground.

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