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1 Page 1 of Instrumentation, Message Center, and Warning Chimes 2008 Explorer/Mountaineer/Explorer Sport Trac DIAGNOSIS AND TESTING Procedure revision date: 09/24/2008 Instrumentation, Message Center and Warning Chimes Printable View Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent Instrument Gauge System Tester 014-R1063 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool Flex Probe Kit 105-R025C or equivalent Principles of Operation NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM). The instrument cluster (IC) utilizes a microprocessor to control the gauge, indicator, message center and warning chime functions. Data is sent to the instrument cluster (IC) over the high speed controller area network (HS-CAN) bus lines and through hardwired circuitry from individual components. The instrument cluster (IC) uses each input to output an action to the gauges or indicators. The instrument cluster (IC) uses input messages from other modules to control the gauges, informational indicators, warning indicators and reconfigurable telltale indicators over the communication networks. If a required message is missing or invalid for less than 5 seconds, the gauge or indicator that requires the message remains at the last commanded state based upon the last known good message. For example, if the brake status message is missing for less than 5 seconds and the brake warning indicator was ON, the indicator remains in the ON state until the next good message is received. If the message remains missing or invalid for greater than 5 seconds, the instrument cluster (IC) sets a U-code DTC and the output becomes a default action for the indicator or gauge. Each indicator or gauge utilizes a different default strategy depending on the nature of the indication. Refer to the normal operation descriptions located before each individual pinpoint test for further description of the default action specific to each indicator or gauge. If the messaged input to the cluster returns at any time, the normal function of the gauge or indicator resumes. NOTE: Whenever a network message is suspected as missing and confirmed by a missing message DTC (U-code), it is important to look for other symptoms that may also be present in the instrument cluster (IC) and throughout the vehicle. Once a DTC is set in the instrument cluster (IC), it may be helpful to review the complete message list available in Section to see what other modules also rely on the same message and run the self-test for those modules. If the message is missing from other modules, the same DTC may also be set in those modules. Confirmation of missing messages common to multiple modules may indicate that the originating module is the source of the concern or the communication network may be experiencing some problems. 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. does the module which received the input control the output of the feature, or does it output a message over the communication network to another module. which module controls the output of the feature. Instrument Cluster Instrument Cluster (IC) Gateway Function The instrument cluster (IC) acts as a gateway module by receiving information in one format and transmitting it to other modules using another format. For example, the instrument cluster (IC) receives the vehicle speed data from the PCM over the high speed controller area network (HS-CAN), converts the data into a medium speed controller area network (MS- CAN) message and sends (gateways) the message to other network modules such as the heating ventilation air conditioning (HVAC) module, the audio control module (ACM), and the smart junction box (SJB). This enables network communication between modules that do not communicate using the same network (HS-CAN or the MS-CAN). Instrument Cluster (IC) Configuration The instrument cluster (IC) contains items that are configurable. While some configurable items are customer preference items, most items are configured at the end of the line production and only available for configuration using the programmable module installation (PMI) procedures. Refer to Section for additional information on the PMI procedure and programmable module parameters. NOTE: When installing a new instrument cluster (IC), it is necessary to upload the module configuration to the scan tool. Following installation of the instrument cluster (IC), download the module configuration from the scan tool into the new instrument cluster (IC). Refer to Section to carry out PMI. Following installation of a new instrument cluster (IC), the instrument cluster (IC) and the PCM need to be mated. Refer to Section to carry out a parameter reset procedure. The following are the configurable customer preference items: Auto lock Auto-unlock

2 Page 2 of 58 Belt-Minder Language Oil life warning threshold Instrument Cluster (IC) Network Messages The instrument cluster (IC) and other vehicle modules carry out a display prove-out to verify that all module controlled warning/indicator lamps and monitored systems are functioning correctly within the instrument cluster (IC). When the ignition switch is cycled to the ON position with the engine off, the indicators illuminate to prove-out according the following table: Indicator Controlling Module Indicator Type Prove-Out Duration Air bag Instrument cluster (IC) Warning 6 seconds ABS Instrument cluster (IC) Warning 3 seconds Brake Instrument cluster (IC) Warning 3 seconds Charge PCM Informational Engine start up Check fuel cap (Sport Trac base cluster only) Instrument cluster (IC) Informational 3 seconds Door ajar Instrument cluster (IC) Warning prove-out Engine coolant over temperature Instrument cluster (IC) Warning 3 seconds Four wheel drive (4WD) low Instrument cluster (IC) Informational 3 seconds (if equipped) 4WD high Instrument cluster (IC) Informational 3 seconds (if equipped) High beam SJB Informational prove-out Low engine oil pressure Instrument cluster (IC) Warning Engine startup Malfunction indicator lamp (MIL) PCM Warning Engine startup Overdrive (O/D) off PCM Informational prove-out Powertrain malfunction (wrench) (base cluster) Instrument cluster (IC) Informational 3 seconds RH/LH turn signals SJB Informational prove-out Safety belt RCM Warning 60 seconds if the safety belt is unbuckled, turns off when the safety belt is buckled Speed control PCM Informational prove-out Traction control/stability assist Instrument cluster (IC) Informational 3 seconds Tire pressure monitoring system (TPMS) Instrument cluster (IC) Warning 3 seconds Information And Message Center The message center information can be selected through the SELECT/RESET button (base cluster) and by the INFO, SETUP, and RESET buttons (high series cluster). The message center is an integral part of the instrument cluster (IC) that receives and acts upon much of the same information that is input and used to operate the instrument cluster (IC) gauges, informational indicators, and warning indicators. The message center, located in the center of the instrument cluster (IC) is a liquid crystal display (LCD). The message center electronic functions use both hardwired and the controller area network (CAN) circuitry to transmit and receive information. Whenever conditions are present that require a warning message, the message center replaces the last selected display with the new warning display. Once the message is reset or cleared, the message center returns to the last selected display. If multiple warnings are present, the message center displays each warning for approximately 4 seconds. Warning messages are also generally associated with other observable instrument cluster (IC) indications. For example, when the LH front door is opened, the message center displays the message DRIVER DOOR AJAR along with the door ajar warning indicator. This allows the message center to be a more informative supplement to the instrument cluster (IC) gauges and indicators. Message Center Features The message center provides the following features: Information displays Setup displays System check messages Warning messages Information Displays (Base Instrument Cluster [IC]) The information displays are non-timed modes. The selected mode remains on until the driver presses the SELECT/RESET switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings Outside air temperature display (if equipped) Distance to empty Average fuel economy Setup menu Information Displays (High Series Instrument Cluster [IC]) 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 headings, outside air temperature display Distance to empty Average fuel economy Instantaneous fuel economy Fuel used Trip elapsed drive time Blank

3 Page 3 of 58 Setup Displays (Base Instrument Cluster [IC]) The setup displays are timed modes and terminate after a finite interval. Press the SELECT/RESET button to scroll through the SETUP MENU display sequence. If the SELECT/RESET button is not pressed within 4 seconds, the message center returns to the INFO MENU. The setup display modes are: System check Units (English/metric) Language Autolamp Autolock Auto-unlock Parking aid (if equipped) Oil life reset and start value Setup Displays (High Series Instrument Cluster [IC]) The setup displays are timed modes and terminate after a finite interval. Press the SETUP button for the following displays: System check Units (English/metric) Language Autolamp Autolock Auto-unlock Running boards (if equipped) Easy entry/exit seat (if equipped) Parking aid (if equipped) Compass zone Compass calibration Oil life reset and start value System Check Displays Selecting this function from the SETUP MENU causes the message center to cycle through each of the systems being monitored. For each of the monitored systems, the message center indicates either an OK message or a warning message for 2 seconds. For base instrument clusters (IC), the SELECT/RESET button must be held down after pressing the SELECT/RESET button to cycle the messages through each of the systems being monitored. For high series instrument clusters (IC), pressing the RESET control switch cycles the message center through each of the systems being monitored. The system check report is as follows: OIL LIFE CHARGING SYSTEM WASHER FLUID DOOR AJAR EXTERIOR LAMPS BRAKE FLUID LEVEL PARK BRAKE FUEL LEVEL AND DISTANCE TO EMPTY (high series instrument cluster [IC]) MILES TO EMPTY (base instrument cluster [IC]) FUEL LEVEL LOW (base instrument cluster [IC]) System Warnings The system warnings alert the operator to possible problems or malfunctions in the vehicle operating systems. The message center displays the last selected feature if there are no more warning messages. This allows the operator full functionality of the message center after acknowledgement of the warning message by pressing the reset button and clearing the message. The warning messages are divided into 4 categories: They cannot be cleared until the condition is corrected. They reappear on the display 10 minutes from the reset if the condition has not been corrected. They do not reappear until an ignition OFF-ON cycle has been completed. They reappear if the condition clears then reoccurs within the same ignition ON-OFF cycle. The warning displays that cannot be reset are: DOOR AJAR The warning messages that reoccur after 10 minutes are: FUEL LEVEL LOW PARK BRAKE ENGAGED CHECK BRAKE SYSTEM The warning messages that display whenever the ignition switch is turned from the OFF position to the ON position are: CHECK PARK AID (if equipped) BRAKE FLUID LEVEL LOW CHECK HEADLAMP CHECK HIGHBEAM CHECK TURN LAMP WASHER FLUID LOW LEVEL OIL CHANGE REQUIRED ENGINE OIL CHANGE SOON The warning messages that return after a condition has cleared then reoccurs within the same ignition ON-OFF cycle are: LIFTGATE/GLASS AJAR CLEAR OBJECTS BY PASS SEAT

4 Page 4 of 58 CHECK CHARGING SYSTEM LOW TIRE PRESSURE TIRE MONITOR FAULT TIRE SENSOR FAULT The message center displays messages that indicate a system state during the operation of the four wheel drive (4WD) system. The displayed warning messages are as follows: FOR 4X4 LOW STOP VEHICLE (if equipped) FOR 4X4 LOW SHIFT TO N (if equipped) TO EXIT 4X4 LOW STOP VEHICLE (if equipped) TO EXIT 4X4 LOW SHIFT TO N (if equipped) The message center displays messages that indicate a system state during repair procedures related to the tire pressure monitoring system (TPMS). The displayed warning messages are as follows: TRAIN TIRES TIRES TRAINED TIRES NOT TRAINED The message center displays messages that indicate a system state during repair procedures related to the compass display. The displayed warning messages are as follows: COMPASS ZONE XX (base instrument cluster [IC]) RESET FOR ZONE SETTING (high series instrument cluster [IC]) ZONE XX RESET TO CHANGE (high series instrument cluster [IC]) ZONE XX IS SET PRESS RESET FOR CALIBRATION (high series instrument cluster [IC]) CIRCLE SLOW TO CALIBRATE (base instrument cluster [IC]) CIRCLE SLOWLY TO CALIBRATE (high series instrument cluster [IC]) CALIBRATION COMPLETED The message center displays messages that indicate a system state during repair procedures related to the oil life and oil life start value. The displayed warning messages are as follows: HOLD RESET IF NEW OIL OIL LIFE SET TO 100% OIL LIFE START VALUE SET TO XXX% (high series instrument cluster [IC]) OIL LIFE SET TO XXX% (base instrument cluster [IC]) Outside Air Temperature Sensor (Instrument Cluster [IC] Without Electronic Automatic Temperature Control [EATC]) The instrument cluster (IC) receives the outside air temperature data from the outside air temperature sensor. This data is then displayed on the message center. The outside air temperature sensor is located on the radiator core support behind the front grill assembly and is fastened with a pin-type retainer. If equipped with electronic automatic temperature control (EATC), the outside air temperature data from the outside air temperature sensor is displayed in the heating ventilation air conditioning (HVAC) module. Refer to Section for the outside air temperature display in the EATC. Compass The compass heading is displayed as one of N, NE, E, SE, S, SW, W and NW in the message center display. The compass reading may be affected when you drive near large buildings, bridges, power lines and powerful broadcast antenna. Magnetic or metallic objects placed in, on or near the vehicle may also affect compass accuracy. The compass sensor module is mounted behind the interior rear view mirror. Warning Chimes The instrument cluster (IC) uses different chimes to alert the driver of various vehicle conditions as follows: Safety belt warning (repetitive chime) Belt-Minder warning (repetitive chime after a delay and after the safety belt chime is completed) Key-in-ignition warning (repetitive chime) Headlamps on warning (repetitive chime) Turn signal on warning (single tone chime after 3.2 km [2 miles]) Turn signal tone (tic-tock chime) Parking brake warning (repetitive chime) Air bag secondary warning chime (repetitive chime) Message center general tone (single tone) Safety Belt Warning Chime The safety belt warning chime warns that the safety belt is not fastened. The safety belt warning chime sounds when the driver or passenger safety belt is not fastened and the ignition key is turned from the OFF/LOCK or ACC to the ON or START position. The safety belt warning chime stops sounding when the safety belt is fastened, when the ignition key is turned from the ON 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: Ignition switch position Driver or passenger safety belt switch data communicated by the restraints control module (RCM) to the instrument cluster (IC) through the controller area network (CAN) Belt-Minder The Belt-Minder is configurable. To configure using a scan tool, refer to Section To configure without using a scan tool, refer to Belt-Minder Deactivating/Activating in this section. 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 or passenger safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster (IC) once the vehicle speed has exceeded 5 km/h (3 mph). While activated, the Belt-Minder alternates the chime and indicator from on for 6 seconds to off for 60 seconds.

5 Page 5 of 58 NOTE: The Belt-Minder is disabled for 1 ignition switch ON cycle if the safety belt is buckled then unbuckled during that specific cycle. 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 key is in the ignition lock cylinder and in the OFF/LOCK or ACC position. The key-in-ignition warning chime stops sounding when the driver door is closed, the key is removed from the ignition lock cylinder, or if the ignition key is turned to the ON position. The key-in-ignition warning chime inputs are: Ignition switch position Door ajar data communicated by the smart junction box (SJB) to the instrument cluster (IC) through the CAN Key-in-ignition switch signal from the ignition switch Headlamps On Warning Chime The headlamps on warning chime warns that the headlamps are on when the driver door is ajar and the key is removed from the ignition lock cylinder. The headlamps on warning chime sounds if the driver door is ajar, the headlamp switch is in the headlamp or parking lamp on position, and the ignition switch in the OFF/LOCK position. The headlamps on warning chime stops sounding when any one of the above conditions are removed. The headlamps on warning chime inputs are: Ignition switch position Driver door ajar data communicated by the SJB to the instrument cluster (IC) through the CAN Headlamp switch data communicated by the SJB to the instrument cluster (IC) through the CAN Turn Signal On Warning Chime The turn signal on warning chime warns that the turn signal has not been cancelled. The turn signal on warning chime sounds if the left or right turn signal is on and the vehicle has traveled more than 3.2 km (2 miles). The turn signal on warning chime stops sounding if the turn signal is turned off, or if the ignition key is turned to the OFF or ACC position. The turn signal on warning chime inputs are: Turn signal data communicated by the SJB to the instrument cluster (IC) through the CAN communication Odometer count data communicated by the PCM to the instrument cluster (IC) through the CAN Parking Brake Warning Chime The parking brake warning chime warns that the parking brake is engaged when the vehicle is in motion. The parking brake warning chime sounds if the ignition key is in ON position, the parking brake is engaged, and the vehicle speed is greater than 5 km/h (3 mph). The parking brake warning chime stops sounding if the parking brake is released, the ignition key is not in the ON position, or if the vehicle speed is less than 5 km/h (3 mph). The parking brake warning chime inputs are: Ignition switch position Parking brake switch data communicated by the SJB to the instrument cluster (IC) through the CAN Vehicle speed data communicated by the PCM to the instrument cluster (IC) through the CAN Air Bag Secondary Warning Chime The air bag secondary warning chime warns that the air bag warning indicator light does not work correctly. The instrument cluster (IC) monitors the air bag warning indicator status internally. When a fault is present in the air bag warning indicator and the instrument cluster (IC) receives an air bag warning indicator on request from the RCM, the air bag secondary warning chime sounds. The air bag secondary warning chime input is: Air bag warning indicator request data communicated by the RCM to the instrument cluster (IC) Turn/Hazard On Tone The turn/hazard on tone provides an audible tic-toc in addition to the turn/hazard indicator lamps. The turn/hazard on tone sounds if the turn or hazard signals are on. The turn/hazard on tone inputs are: Left turn indicator signal from the SJB to the instrument cluster (IC) Right turn indicator signal from the SJB to the instrument cluster (IC) Message Center Warning Chime The message center warning chime sounds when a new warning message is displayed on the message center. If multiple warning messages are present, a chime tone sounds for each of the warnings that are displayed. The message center warning chime inputs are the warning messages displayed on the message center. The message center warning chime sounds to alert the driver when a concern is detected in one of the following systems: Tire pressure monitoring system (TPMS) Door ajar Low fuel level Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage.

6 Page 6 of 58 Visual Inspection Chart Mechanical Accessory drive belt Brake fluid level Door adjustment Engine coolant level Engine oil level Fuel tank Fuel evaporative system Liftgate adjustment Tire pressure Washer fluid level Electrical Smart junction box (SJB) fuse(s): 8 (15A) 18 (10A) 24 (10A) Wiring, terminals or connectors Bulb(s) Message center switches Key-in-ignition warning switch (part of the ignition switch) 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. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. Check the scan tool connection to the VCM. Refer to Section , Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: Verify the ignition key is in the ON position. Verify the scan tool operation with a known good vehicle. Refer to Section to diagnose no response from the PCM. 7. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to Section If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster (IC), ABS module, restraints control module (RCM), SJB and PCM. 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Section If no DTCs related to the concern are retrieved, GO to Symptom Chart Instrument Cluster (IC), GO to Symptom Chart Information And Message Center or GO to Symptom Chart Warning Chimes. DTC Charts Instrument Cluster (IC) DTC Chart DTC Description Action B1203 Fuel Sender Circuit Short to Battery GO to Pinpoint Test B. B1204 Fuel Sender Circuit Short to Ground GO to Pinpoint Test B. B1213 Anti-Theft Number of Programmed Keys Is Below Minimum B1255 Air Temperature External Sensor Circuit Open B1257 Air Temperature External Sensor Circuit Short to Ground REFER to Section GO to Pinpoint Test AH. GO to Pinpoint Test AH. B1317 Battery Voltage High CLEAR the DTCs. REPEAT the self-test. If DTC B1317 is still present, REFER to Section B1318 Battery Voltage Low B1342 ECU is Faulted B1600 PATS Ignition Key Transponder Signal Is t Received B1601 PATS Received Incorrect Key-Code From Ignition Key Transponder B1602 PATS Received Invalid Format Of Key- Code From Ignition Key Transponder B1605 Lamp Anti-Theft Indicator Circuit Short To Battery B1681 PATS Transceiver Module Signal Is t Received B1868 Lamp Air Bag Warning Indicator Circuit Failure B1915 Air Bag Driver Circuit Failure B2097 Compass Module Failure GO to Pinpoint Test AB. CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is still present, REPROGRAM the instrument cluster (IC). REFER to Section If the DTC is still present after the reprogramming, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. REFER to Section REFER to Section REFER to Section REFER to Section REFER to Section CLEAR the DTCs. REPEAT the self-test. If DTC B1868 is still present, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. CLEAR the DTCs. REPEAT the self-test. If DTC B1915 is still present, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. GO to Pinpoint Test AE. B2103 Antenna t Connected REFER to Section B2141 NVM Configuration Failure REFER to Section B2143 NVM Memory Failure CLEAR the DTCs. REPEAT the self-test. If DTC B2143 is still present, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation.

7 Page 7 of 58 B2431 Transponder Programming Failed REFER to Section B2477 Module Configuration Failure U0140 Lost Communication With Body Control Module (GEM) U0159 Lost Communication With Parking Assist Control Module (PAM) U0208 Lost Communication With Seat Control Module (DSM) U0244 Lost Communication With Running Board Control Module (PRB) U1900 CAN Communication Bus Fault Receive Error U2013 Compass Module is t Responding U2023 Fault Received From External de U2050 Application Present U2051 One or More Calibration Files Missing/Corrupt CARRY OUT the instrument cluster (IC) programmable module installation (PMI). REFER to Section CLEAR the DTCs. REPEAT the self-test. If DTC B2477 is still present, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. GO to Pinpoint Test AC. CLEAR the DTCs. REPEAT the self-test. If DTC B1318 is present, GO to Pinpoint Test AB. If DTC U0159 is still present, REFER to Section to diagnose no communication with the driver seat module. CLEAR the DTCs. REPEAT the self-test. If DTC B1318 is present, GO to Pinpoint Test AB. If DTC U0208 is still present, REFER to Section to diagnose no communication with the driver seat module. CLEAR the DTCs. REPEAT the self-test. If DTC B1318 is present, GO to Pinpoint Test AB. If DTC U0244 is still present, REFER to Section to diagnose no communication with the power running board module. REPAIR all other DTCs first. CLEAR the DTCs. CYCLE the key off then on and wait 10 seconds. REPEAT the self-test. If DTC U1900 is still present, REFER to Section GO to Pinpoint Test AE. U2510 CAN - Invalid data for Vehicle Security REFER to Section U2511 CAN - Data Mis-Match (Receive data does not match expected) U2023 is set when a module receives invalid network data from another module with a faulted input. RETRIEVE and REPAIR all nonnetwork DTCs in the other modules on the network. REFER to Section for a list of all DTCs. REPROGRAM the instrument cluster (IC). REFER to Section If the DTC occurs after the reprogramming, REPROGRAM the instrument cluster (IC) again. If the DTC is present after each attempt to reprogram, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. CARRY OUT the programmable module installation (PMI) for the instrument cluster (IC). REFER to Section If the DTC is still present, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. REFER to Section Smart Junction Box (SJB) DTC Chart DTC Description Action C1769 Park Brake Apply Switch Circuit Short to Ground GO to Pinpoint Test I. All other DTCs REFER to Section PCM DTC Chart DTC Description Action P0457 Evaporative Emission System Leak Detected (fuel cap loose/off) GO to Pinpoint Test AA. 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. If sent here from the PC/ED manual, GO to Pinpoint Test B. All other DTCs REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. Instrument Cluster (IC) Dealer Test Mode To enter the instrument cluster (IC) dealer test mode with the engine off, press and hold the SELECT/RESET button (base cluster) or the message center RESET button (message center cluster). Turn the ignition switch to the ON position and hold the button for approximately 3 to 5 seconds. Release the button and press the reset button one time to display ENGINEERING TEST MODE. Press the reset button once to advance to each stage of the self-test. The information from this mode is displayed in the odometer display. All gauges and lamps will operate normally during this test mode unless otherwise noted. To exit the instrument cluster (IC) self-test mode, turn the ignition to the OFF position. Message Center Cluster Display ENGINEERING TEST MODE GAUGE TEST All pixels illuminated TELLTALE TEST PART NUMBER, XXXX - XX ROM LEVEL $XXXX NVM LEVEL $XX MANUFACTURE Description Initial entry display into the self-test mode. Carries out a gauge sweep of all the gauges, then displays the present gauge values. Carries out the prove-out of all dot matrix pixels in all characters. Illuminates all the micro-controlled lamps and LEDs. Return to normal operation of all micro controlled lamps/leds and displays the alpha-numeric prefix and suffix instrument cluster (IC) part number. Carries out checksum tests on ROM. Displays Hex and ROM level and type. Carries out checksum tests on NVM. Displays the final manufacturing test date.

8 Page 8 of 58 DATE $XXXX Auto configuration BYTE 1 $XX B&A CONFIG BYTE 1 $XX MANUF CONFIG BYTE 1 $XX CONTINUOUS DTC $XXXX VEHICLE SPD XXX.X MPH VEHICLE SPD XXX.X KMH TACHOMETER XXXX RPM FUEL LEVEL XXX INST FUEL LEVEL %, STATUS XXX INSTANT DTE XXX MILES FUEL ON/OFF Z XXX XXX XXX F#S ON/OFF Z XXX XXX XXX COOLANT TEMP XXX C ODOMETER XXX COUNTS Displays the Hex coding of first (1) byte of module configuration settings. Displays the Hex coding of second (2) byte of module configuration settings. Displays the Hex coding of the NVM module configuration settings. Displays a 16-bit DTC in hexadecimal format. DTCs displayed are those detected in continuous operation, not during the self-test. Displays the English speed value being input. The speedometer indicates the present speed. Displays the metric speed value being input. The speedometer indicates the present speed. Displays the tachometer value being input to the instrument cluster (IC). Tachometer indicates present rpm. Displays the present fuel level analog/digital ratio input in decimal. The instrument cluster (IC) indicates present fuel level. Displays the present fuel level percent status in decimal. Displays the instant calculated DTE. Displays the key-on, key-off and zero speed fuel level values. Displays the key-on, key-off and zero speed fuel number of samples. Displays the last temperature gauge input value from high speed controller area network (HS-CAN) in degrees C. The temperature gauge indicates present value. Displays the odometer input received from HS-CAN in decimal format. Value is a rolling count. TRIP ODO XXX.X MI Displays the trip odometer value stored in RAM in miles. BATTERY XX.X VOLTS KEY IN SW X DIMMING CMD XXX DIMMING STEP XX MC SWITCH XXX A/D CNTS LWF OPS OAT X X XXX COMPASS XXX LAST CHIME SOUNDED XX GAUGE TEST Displays the present VBAT analog/digital readings in volts, compensated to yield voltage at instrument cluster (IC) input pin. Displays the input status of key-in-ignition switch. Displays the smart junction box (SJB) dimming command in decimal. Displays the instrument cluster (IC) dimming step in decimal. Displays the present message center switch input analog/digital counts in decimal. Displays the present low washer fluid, oil pressure switch and outside air temperature input analog/digital counts in decimal. Displays the present input from sensor in decimal. Displays either the last chime sounded by the instrument cluster (IC) or the chime that is presently sounding, this excludes the trip reset button chime used to enter ETM or scroll through ETM. AB = air bag chime, BU = backup, BM = Belt-Minder, F1 = failsafe cooling 1, F2 = failsafe cooling 2, HL = headlamps on, KI = key in ignition, MB = message center button press, MW = message center warning, OS = overspeed, PB = park brake, SB = seatbelt, TS = turn signal, TR = turn signal reminder, TP = tire pressure low, TL = losing tire pressure, -- = none. Repeats the test display cycle. Symptom Charts communication with the instrument cluster (IC) The instrument cluster (IC) is inoperative Incorrect fuel gauge indication The temperature gauge is inoperative Incorrect temperature gauge indication The tachometer is inoperative Incorrect tachometer indication The speedometer/odometer is inoperative Incorrect speedometer indication Symptom Chart Instrument Cluster Condition Possible Sources Action Fuse Wiring, terminals or connectors Fuse Wiring, terminals or connectors Wiring, terminals or connectors Fuel level sensor Fuel pump module assembly Fuel tank PCM Engine coolant temperature (ECT) sensor (4.0L) Cylinder head temperature (CHT) sensor (4.6L) PCM concern PCM PCM PCM Tire size configuration Axle ratio configuration ABS concern REFER to Section GO to Pinpoint Test A. 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.

9 Page 9 of 58 The brake warning indicator is never on The brake warning indicator is always on The ABS warning indicator is never/always on The safety belt warning indicator is never/always on The LH/RH turn or high beam indicator is never/always on The low oil pressure warning indicator is never/always on The malfunction indicator lamp (MIL) indicator is never/always on The air bag warning indicator is never/always on The speed control indicator is never/always on The powertrain malfunction (wrench) warning indicator is never/always on (base instrument cluster [IC]) The door ajar indicator is never/always on The O/D OFF indicator is never/always on The tire pressure monitoring system (TPMS) warning indicator is never/always on The 4x4 high indicator is never/always on The 4x4 low indicator is never/always on The engine coolant over temperature warning indicator is never/always on (base instrument cluster [IC]) The traction control/stability assist indicator is never/always on PCM concern Wiring, terminals or connectors Parking brake switch Brake fluid level switch (part of the master cylinder) Smart junction box (SJB) ABS module Wiring, terminals or connectors Parking brake switch Brake fluid level switch (part of the master cylinder) SJB ABS module ABS module Restraints control module (RCM) Exterior lighting concern SJB Wiring, terminals or connectors Base engine concern Engine oil pressure switch PCM RCM Speed control system concern PCM Four-wheel drive (4WD) system concern SJB TCM (4.6L engine) PCM (4.0L engine) TPMS concern SJB 4WD system concern 4X4 control module 4WD system concern 4X4 control module PCM Traction control/stability assist system concern ABS module The charging system warning indicator is never/always on (base instrument cluster [IC]) Charging system concern PCM The check fuel cap indicator is never/always on (Sport Trac base cluster only) PCM Symptom Chart Information And Message Center Condition Possible Sources Action GO to Pinpoint Test I. GO to Pinpoint Test J. GO to Pinpoint Test K. GO to Pinpoint Test L. GO to Pinpoint Test M. 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. 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. The message center display is blank INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. t all segments of the display illuminate INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. The message center is not operating correctly (base instrument cluster [IC]) The message center is not operating correctly (high series instrument cluster [IC]) The compass is inoperative Message center switch concern Fuse Wiring, terminals or connectors Compass sensor module OBSERVE the operation of the message center when pressing the SELECT/RESET button. Does the message center display change when the SELECT/RESET button is pressed? If the message center display changes, the system is operating normally at this time. If the message center display does not change, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. GO to Pinpoint Test AD. GO to Pinpoint Test AE.

10 Page 10 of 58 The compass is inaccurate Zone setting Calibration Compass sensor module GO to Pinpoint Test AF. The message center display is blank CARRY OUT the instrument cluster (IC) self-diagnostic test mode to illuminate all segments of the message center display. REFER to the Instrument Cluster Dealer Test Mode in this section. If the message center display is illuminated, the system is working correctly at this time. If the message center display is inoperative, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. The message center switch does not operate correctly (base instrument cluster [IC]) The message center switch does not operate correctly (high series instrument cluster [IC]) The outside air temperature display does not operate correctly The WASHER FLUID LOW LEVEL message is inoperative The DOOR/LIFTGATE/LIFTGATE GLASS AJAR warning is inoperative The CLEAR OBJECTS BY PASS SEAT warning is inoperative The CHECK CHARGING SYSTEM message is inoperative The FUEL LEVEL LOW warning is inoperative The PARK BRAKE ENGAGED warning is inoperative The CHECK BRAKE SYSTEM warning is inoperative Wiring, terminals or connectors Message center switch INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. GO to Pinpoint Test AG. Wiring, terminals or GO to Pinpoint Test AH. connectors Ambient air temperature sensor Wiring, terminals or connectors Washer fluid level switch (part of the windshield washer reservoir) Door ajar warning indication system RCM Charging system Fuel gauge indication Brake warning indication system Brake warning indication system The BRAKE FLUID LEVEL LOW warning is inoperative Brake warning indication system Base brake system The CHECK PARK AID message is inoperative (if equipped) The LOW TIRE PRESSURE, TIRE MONITOR FAULT, or TIRE SENSOR FAULT warning is inoperative The CHECK HEADLAMP, CHECK HIGHBEAM, or CHECK TURN LAMP message is inoperative The 4X4 LOW STOP VEHICLE, 4X4 LOW SHIFT TO N, TO EXIT 4X4 LOW STOP VEHICLE or TO EXIT 4X4 LOW SHIFT TO N message is inoperative Parking aid system Tire pressure monitoring system (TPMS) warning indication system Exterior lighting SJB 4WD system GO to Pinpoint Test AI. OBSERVE the operation of the door ajar warning indicator. If the door ajar warning indicator does not operate correctly, GO to Pinpoint Test S. If the door ajar warning indicator operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. OBSERVE the operation of the air bag warning indicator. If the air bag warning indicator does not operate correctly, GO to Pinpoint Test P. If the air bag warning indicator operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. GO to Pinpoint Test AJ. OBSERVE the operation of the fuel gauge. If the fuel gauge does not operate correctly, GO to Pinpoint Test B. If the fuel gauge operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. OBSERVE the BRAKE warning indicator. If the BRAKE warning indicator does not operate correctly, GO to Pinpoint Test I. If the BRAKE warning indicator operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. OBSERVE the BRAKE warning indicator. If the BRAKE warning indicator does not operate correctly, GO to Pinpoint Test I. If the BRAKE warning indicator operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. OBSERVE the BRAKE warning indicator. If the BRAKE warning indicator does not operate correctly, GO to Pinpoint Test I. If the BRAKE warning indicator operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. OPERATE the parking aid system. If the parking aid system does not operate correctly, REFER to Section If the parking aid system operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. OBSERVE the operation of the TPMS warning indicator. If the TPMS warning indicator does not operate correctly, GO to Pinpoint Test U. If the TPMS warning indicator operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. OBSERVE the exterior lighting system for correct operation. If the exterior lighting does not operate correctly, REFER to Section If the exterior lighting operates correctly, INSTALL a new smart junction box (SJB). REFER to Section TEST the system for normal operation. VERIFY that the 4X4 high and 4X4 low indicators operate correctly. If the 4X4 high and 4X4 low indicators do not operate correctly, GO to Pinpoint Test V (4x4 high) or GO to Pinpoint Test W (4x4 low). If the 4X4 high and 4X4 low indicators operate correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this

11 Page 11 of 58 Symptom Chart Warning Chimes section. TEST the system for normal operation. Condition Possible Sources Action communication with the instrument cluster (IC) The key-in-ignition warning chime is inoperative The headlamps on warning chime is inoperative Fuse(s) Wiring, terminals or connectors REFER to Section Wiring, terminals or GO to Pinpoint Test AK. connectors Key-in-ignition warning switch (part of the ignition switch) GO to Pinpoint Test AL. All the chimes are inoperative INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. The turn signal on warning chime is inoperative The door ajar warning chime is inoperative The chime sounds when the driver door is ajar (no key in ignition and headlamps off) The safety belt warning chime does not operate correctly The Belt-Minder feature does not operate correctly The parking brake warning chime is inoperative The air bag secondary warning chime is inoperative The message center warning chime is inoperative Turn signal indication concern Odometer rolling count input GO to Pinpoint Test AM. Wiring, terminals or GO to Pinpoint Test AN. connectors Key-in-ignition warning switch (part of the ignition switch) RCM Belt-Minder deactivated RCM Brake warning indication Vehicle speed input VERIFY the door ajar warning indicator operates correctly. If the door ajar warning indicator does not operate correctly, GO to Pinpoint Test S If the door ajar warning indicator operates correctly, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. GO to Pinpoint Test AO. GO to Pinpoint Test AP. GO to Pinpoint Test AQ. RETRIEVE the recorded instrument cluster (IC) DTCs from the continuous and on-demand self-tests. If the instrument cluster (IC) DTC B1868 or B1915 is not present, the system is operating correctly. The air bag secondary warning chime sounds only when a fault in the air bag warning indicator is present and DTC B1868 or B1915 is recorded. If the instrument cluster (IC) DTC B1868 or B1915 is present, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. NOTE: The message center warning chime only sounds to alert the driver of concerns with the TPMS, door ajar or low fuel. VERIFY that the door ajar chime sounds when the door is first opened and that as new warning messages display, the warning chime sounds. If the door ajar chime sounds when the door is first opened or when new warning messages display, the system is operating correctly at this time. The message center warning chime only sounds when the message center detects new warning messages. If the door ajar chime does not sound when the door is first opened and when new warning messages display, INSTALL a new instrument cluster (IC). REFER to Instrument Cluster (IC) in this section. TEST the system for normal operation. Pinpoint Tests Pinpoint Test A: The Instrument Cluster (IC) Is Inoperative Refer to Wiring Diagrams Cell 60, Instrument Cluster for schematic and connector information. rmal Operation With the ignition switch in the START or RUN position, the instrument cluster (IC) receives voltage from the ignition switch through circuit CDC34 (WH/OG). With the ignition switch in the OFF position, the instrument cluster (IC) receives its keep-alive voltage from the smart junction box (SJB) through circuit SBP24 (VT/RD). The instrument cluster (IC) grounding is through circuits GD145 (BK/BU) and RMC32 (GN/BU). Fuse Wiring, terminals or connectors PINPOINT TEST A : THE INSTRUMENT CLUSTER (IC) IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. A1 CHECK CIRCUIT SBP24 (VT/RD) FOR VOLTAGE Disconnect: Instrument Cluster (IC) C220. Measure the voltage between the instrument cluster (IC) C220-1, circuit SBP24 (VT/RD), harness side and ground.

12 Page 12 of 58 Is the voltage greater than 10 volts? GO to A2. VERIFY the SJB fuse 24 (10A) is OK. If OK, REPAIR the circuit. TEST the system for normal operation. A2 CHECK CIRCUIT CDC34 (WH/OG) FOR VOLTAGE Measure the voltage between the instrument cluster (IC) C220-2, circuit CDC34 (WH/OG), harness side and ground. Is the voltage greater than 10 volts? GO to A3. REPAIR the circuit. TEST the system for normal operation. A3 CHECK CIRCUIT GD145 (BK/BU) FOR AN OPEN Measure the resistance between the instrument cluster (IC) C220-13, circuit GD145 (BK/BU), harness side and ground. Is the resistance less than 5 ohms? GO to A4. REPAIR the circuit. TEST the system for normal operation. A4 CHECK FOR CORRECT INSTRUMENT CLUSTER (IC) OPERATION Pinpoint Test B: Incorrect Fuel Gauge Indication Refer to Wiring Diagrams Cell 60, Instrument Cluster for schematic and connector information. rmal Operation The fuel pump module is hardwired to the instrument cluster (IC) through the input circuit VMC11 (YE/VT) and return circuit RMC32 (GN/BU). The fuel level sensor (part of the pump module) is a variable resistor actuated by a float with resistance ranging between 180 ohms ± 4 ohms at empty (E) to 10 ohms ± 2 ohms at full (F). The instrument cluster (IC) provides a reference voltage to the fuel pump module on the input circuit. As the fuel level changes, the fuel level sensor float moves up or down according to the fuel level altering the fuel level signal voltage through the resistor. The instrument cluster (IC) interprets this signal and commands the fuel gauge pointer to sweep to the correct level.

13 Page 13 of 58 The instrument cluster (IC) 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 (IC) 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 (IC) 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 circuits. Recovery mode (empty [E] to full [F] approximately 20 minutes) is initiated when the following 2 conditions are met: The instrument cluster (IC) 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. Instrument Cluster (IC) DTCs DTC Description DTC B1203 Fuel Sender Circuit Short to Battery DTC B1204 Fuel Sender Circuit Short to Ground Fault Trigger Condition A continuous and on-demand DTC that sets if the instrument cluster (IC) detects an open or short to voltage on the input circuit VMC11 (YE/VT) for more than 33 seconds. A continuous and on-demand DTC that sets if the instrument cluster (IC) detects a short to ground on the input circuit VMC11 (YE/VT) or a short together between the input circuit VMC11 (YE/VT) and the return circuit RMC32 (BN/BU) for more than 33 seconds. PCM DTCs DTC Description P0460 Fuel Level Sensor A Circuit P0461 Fuel Level Sensor A Circuit Range/Performance Fault Trigger Condition Sets when the PCM determines the value of the fuel pump module signal is stuck, that the fuel level input signal does not change or does not correspond with the calculated fuel usage. Sets when the PCM determines the fuel pump module signal repeatedly moves in and out of range, exceeding the minimum or maximum allowable calibrated parameters for a specified fuel fill percentage in the fuel tank. P0462 Fuel Level Sensor A Circuit Low Sets in the PCM when the PCM detects a short to ground on the fuel pump module signal circuit based on the messaged input received from the instrument cluster (IC). P0463 Fuel Level Sensor A Circuit High Sets in the PCM when the PCM detects an open or a short to voltage on the fuel pump module signal circuit based on the messaged input received from the instrument cluster (IC). Wiring, terminals or connectors Fuel level sensor (float and card) Fuel pump module assembly Fuel tank PINPOINT TEST B : INCORRECT FUEL GAUGE INDICATION NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: The fuel pump module may also be called the fuel sender or fuel tank unit. B1 RETRIEVE THE RECORDED DTCs FROM BOTH THE CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER (IC) SELF-TESTS Check for recorded instrument cluster (IC) DTCs from the continuous and on-demand self-tests. Are any instrument cluster (IC) DTCs recorded? For DTC B1203, GO to B3. For DTC B1204, GO to B7. For all other DTCs, REFER to DTC Charts in this section. GO to B2.

14 Page 14 of 58 B2 CARRY OUT THE INSTRUMENT CLUSTER (IC) FUEL GAUGE ACTIVE COMMAND USING THE SCAN TOOL Enter the following diagnostic mode on the scan tool: Instrument Cluster (IC) DataLogger. Select the instrument cluster (IC) fuel gauge (FUEL) active command. Command and scroll the fuel gauge level at 0%, 20%, 80% and 100%. Does the fuel gauge display empty (E) with 0%, approximately 1/4 tank with 20%, 3/4 tank with 80% and full (F) with 100%? GO to B10. GO to B13. B3 CHECK THE FUEL PUMP MODULE FOR AN OPEN Disconnect: Fuel Pump Module In-Line C495. Connect a fused (5A) jumper wire between the fuel pump module in-line C495-8, circuit VMC11 (YE/VT), harness side and the fuel pump module in-line C495-5, circuit RMC32 (GN/BU), harness side. Wait one minute. Enter the following diagnostic mode on the scan tool: Instrument Cluster (IC) Self-Test. NOTE: It may be normal for DTC B1203 to be present when carrying out this test step and should be ignored. Clear the instrument cluster (IC) DTCs. Repeat the instrument cluster (IC) self-test. Is DTC B1204 retrieved? REMOVE the jumper wire. GO to B12. REMOVE the jumper wire. GO to B4. B4 CHECK CIRCUITS VMC11 (YE/VT) AND RMC32 (GN/BU) FOR A SHORT TO VOLTAGE Disconnect: Instrument Cluster (IC) C220. Measure the voltage between the instrument cluster (IC) C220-16, circuit VMC11 (YE/VT), harness side and ground and between the instrument cluster (IC) C220-17, circuit RMC32 (GN/BU), harness side and ground. Is any voltage present? REPAIR the circuit in question. REPEAT the self-test. CLEAR the DTCs. GO to B5. B5 CHECK CIRCUIT VMC11 (YE/VT) FOR AN OPEN Measure the resistance between the instrument cluster (IC) C220-16, circuit VMC11 (YE/VT), harness side and the fuel pump module in-line C495-8, circuit VMC11 (YE/VT), harness side. Is the resistance less than 5 ohms? GO to B6. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B6 CHECK CIRCUIT RMC32 (GN/BU) FOR AN OPEN

15 Page 15 of 58 harness side. Is the resistance less than 5 ohms? GO to B13. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B7 CHECK THE FUEL PUMP MODULE FOR A SHORT TO GROUND Disconnect: Fuel Pump Module In-Line C495. Wait one minute. Enter the following diagnostic mode on the scan tool: Instrument Cluster (IC) Self-Test. NOTE: It may be normal for DTC B1204 to be present when carrying out this test step and should be ignored. Clear the instrument cluster (IC) DTCs. Repeat the instrument cluster (IC) self-test. Is DTC B1203 retrieved? GO to B12. GO to B8. B8 CHECK CIRCUIT VMC11 (YE/VT) FOR A SHORT TO GROUND Disconnect: Instrument Cluster (IC) C220. Measure the resistance between the instrument cluster (IC) C220-16, circuit VMC11 (YE/VT), harness side and ground. Is the resistance greater than 10,000 ohms? GO to B9. REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B9 CHECK CIRCUITS VMC11 (YE/VT) AND RMC32 (GN/BU) FOR A SHORT TOGETHER Measure the resistance between the instrument cluster (IC) C220-16, circuit VMC11 (YE/VT), harness side and the instrument cluster (IC) C220-17, circuit RMC32 (GN/BU), harness side. Is the resistance greater than 10,000 ohms? REPAIR the circuit in question. REPEAT the self-test. CLEAR the DTCs. GO to B13. B10 CHECK THE FUEL INPUT TO THE INSTRUMENT CLUSTER (IC) NOTE: Since the instrument cluster (IC) may be in anti-slosh fuel indication mode, the PID values may not match the fuel gauge readings. The actual gauge indication should be disregarded during this test step. Disconnect: Fuel Pump Module In-Line C495. Connect one lead of the instrument gauge tester to the fuel pump module C495-8, circuit VMC11 (YE/VT), harness side and the other lead of the instrument gauge tester to the fuel pump module C495-5, circuit RMC32 (BK/OG), harness side.

16 Page 16 of 58 Enter the instrument cluster dealer test mode. Refer to the Instrument Cluster Dealer Test Mode in this section. NOTE: The XXX represents a numeric value that displays the current analog/digital (A/D) ratio fuel level input in decimal format. Press and release the SELECT/RESET button (base cluster) or RESET button (message center cluster) to advance to FUEL LEVEL XXX INST. NOTE: It is extremely important to confirm the gauge tester settings with an ohmmeter to ensure that the gauge tester is in the correct position. Failure to follow this check may result in inaccurate test results. Monitor the fuel level fuel level input displayed with the gauge tester set at 180 ohms, 90 ohms, 55 ohms, 30 ohms then 10 ohms. Does the fuel level input display approximately 3, change to 70, 127, 185 then 251? DISCONNECT the instrument gauge tester. GO to B11. DISCONNECT the instrument gauge tester. GO to B13. B11 CHECK THE FUEL TANK Check the fuel tank for any damage or deformation. Is the fuel tank OK? GO to B12. VERIFY the fuel level sensor and the fuel pump module are OK. INSTALL a new fuel tank. REFER to Section CLEAR the DTCs. REPEAT the self-test. B12 CHECK THE FUEL LEVEL SENSOR NOTE: The fuel level sensor resistance measures between 10 ohms ± 2 ohms at the upper stop position and 180 ohms ± 4 ohms at the lower stop position. Remove the fuel pump module. Refer to Section NOTE: Disconnect the fuel level sensor input wire from the fuel level sensor for this measurement. Measure the resistance between the fuel level sensor input wire and the fuel level sensor ground while slowly moving the float arm between the upper stop to the lower stop position. Does the resistance slowly increase from approximately 10 ohms at the upper stop to 180 ohms at the lower stop? INSTALL a new fuel pump module. REFER to Section CLEAR the DTCs. REPEAT the self-test. INSTALL a new fuel level sensor. REFER to Section CLEAR the DTCs. REPEAT the self-test. B13 CHECK FOR CORRECT INSTRUMENT CLUSTER (IC) OPERATION CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. Pinpoint Test C: The Temperature Gauge Is Inoperative rmal Operation The PCM receives the engine coolant temperature status through hardwired circuitry to the engine coolant temperature (ECT) sensor (4.0L engine), or from the cylinder head temperature (CHT) sensor (4.6L engine). The instrument cluster (IC) receives the engine coolant temperature data from the PCM over the high speed controller area network (HS- CAN). The instrument cluster (IC) monitors the engine coolant temperature data received from the PCM and commands the temperature gauge indication with a corresponding movement of the pointer.