Dodge Instrument Cluster Service Manual

DR INSTRUMENT CLUSTER 8J - 1

INSTRUMENT CLUSTER

TABLE OF CONTENTS

page page

INSTRUMENT CLUSTER

DESCRIPTION ..........................2

OPERATION ............................6

DIAGNOSIS AND TESTING - INSTRUMENT

CLUSTER ...........................10

REMOVAL .............................14

DISASSEMBLY .........................14

ASSEMBLY ............................15

INSTALLATION .........................16

ABS INDICATOR

DESCRIPTION .........................17

OPERATION ...........................17

AIRBAG INDICATOR

DESCRIPTION .........................18

OPERATION ...........................18

BRAKE/PARK BRAKE INDICATOR

DESCRIPTION .........................18

OPERATION ...........................19

DIAGNOSIS AND TESTING - BRAKE

INDICATOR ..........................19

CARGO LAMP INDICATOR

DESCRIPTION .........................20

OPERATION ...........................20

CHECK GAUGES INDICATOR

DESCRIPTION .........................21

OPERATION ...........................21

CRUISE INDICATOR

DESCRIPTION .........................22

OPERATION ...........................22

DOOR AJAR INDICATOR

DESCRIPTION .........................23

OPERATION ...........................23

ENGINE TEMPERATURE GAUGE

DESCRIPTION .........................23

OPERATION ...........................23

ETC INDICATOR

DESCRIPTION .........................24

OPERATION ...........................25

FUEL GAUGE

DESCRIPTION .........................25

OPERATION ...........................26

GEAR SELECTOR INDICATOR

DESCRIPTION .........................26

OPERATION ...........................27

HIGH BEAM INDICATOR

DESCRIPTION .........................27

OPERATION ...........................28

LAMP OUT INDICATOR

DESCRIPTION .........................28

OPERATION ...........................28

LOW FUEL INDICATOR

DESCRIPTION .........................29

OPERATION ...........................29

MALFUNCTION INDICATOR LAMP (MIL)

DESCRIPTION .........................30

OPERATION ...........................30

ODOMETER

DESCRIPTION .........................31

OPERATION ...........................31

OIL PRESSURE GAUGE

DESCRIPTION .........................32

OPERATION ...........................32

OVERDRIVE OFF INDICATOR

DESCRIPTION .........................33

OPERATION ...........................33

SEATBELT INDICATOR

DESCRIPTION .........................34

OPERATION ...........................34

SECURITY INDICATOR

DESCRIPTION .........................34

OPERATION ...........................35

SERVICE 4WD INDICATOR

DESCRIPTION .........................35

OPERATION ...........................36

SPEEDOMETER

DESCRIPTION .........................36

OPERATION ...........................36

TACHOMETER

DESCRIPTION .........................37

OPERATION ...........................37

TRANS TEMP INDICATOR

DESCRIPTION .........................38

OPERATION ...........................38

TURN SIGNAL INDICATOR

DESCRIPTION .........................39

OPERATION ...........................39

UPSHIFT INDICATOR

DESCRIPTION .........................40

OPERATION ...........................40

VOLTAGE GAUGE

DESCRIPTION .........................40

OPERATION ...........................41

WAIT-TO-START INDICATOR

DESCRIPTION .........................42

OPERATION ...........................42

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WASHER FLUID INDICATOR

DESCRIPTION .........................42

OPERATION ...........................42

INSTRUMENT CLUSTER

DESCRIPTION

Fig. 1 Instrument Cluster

1 - INSTRUMENT PANEL 2 - INSTRUMENT CLUSTER

The instrument cluster for this model is an ElectroMechanical Instrument Cluster (EMIC) that is located in the instrument panel above the steering column opening, directly in front of the driver (Fig.

1). The remainder of the EMIC, including the mounts and the electrical connections, are concealed within the instrument panel behind the cluster bezel. Besides analog gauges and indicators, the EMIC module incorporates two blue-green digital Vacuum Fluorescent Display (VFD) units for displaying odometer/trip odometer information, engine hours, automatic transmission gear selector position (PRNDL), several warning or reminder indications and certain diagnostic information. The instrument cluster for this model also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node or CCN.

The EMIC gauges and indicators are visible through a dedicated opening in the cluster bezel on the instrument panel and are protected by a clear plastic cluster lens (Fig. 2) that is integral to a cluster lens, hood and mask unit. Just behind the cluster lens is the cluster hood and an integral cluster mask, which are constructed of molded black plastic. The cluster hood serves as a visor and shields the face of the cluster from ambient light and reflections to reduce glare, while the cluster mask serves to separate and define the individual gauges and indicators of the EMIC. A black plastic odometer/trip odometer

WATER-IN-FUEL INDICATOR

DESCRIPTION .........................43

OPERATION ...........................43

Fig. 2 Instrument Cluster Components

1 - SCREW (9) 2 - REAR COVER 3 - CLUSTER HOUSING 4 - LENS, HOOD & MASK

switch button protrudes through dedicated holes in the cluster mask and the cluster lens, located near the lower edge of the cluster just to the left of the tachometer. The molded plastic EMIC lens, hood and mask unit has four integral mounting tabs, one each on the upper and lower outboard corners of the unit. These mounting tabs are used to secure the EMIC to the molded plastic instrument panel cluster carrier with four screws.

The rear of the cluster housing and the EMIC electronic circuitry are protected by a molded plastic rear cover, which is secured to the cluster housing with a single screw, while eight screws installed around the outside perimeter of the rear cover secure it to the cluster lens, hood and mask unit. The rear cover includes clearance holes for service access to each of the eleven incandescent bulb and bulb holder units installed on the cluster circuit board for general illumination lighting and for the cluster connector receptacles. The connector receptacles on the back of the cluster electronic circuit board connect the EMIC to the vehicle electrical system through three take outs with connectors from the instrument panel wire harness. The EMIC also has an integral interface connector on the back of the cluster circuit board that joins it to the optional external RKE receiver through a connector receptacle that is integral to that unit. The rear cover includes a molded receptacle and two latch features to secure the RKE receiver on vehicles that are so equipped.

Sandwiched between the rear cover and the lens, hood and mask unit is the cluster housing. The

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INSTRUMENT CLUSTER (Continued)

molded plastic cluster housing serves as the carrier for the cluster circuit board and circuitry, the cluster connector receptacles, the RKE interface connector, the gauges, a Light Emitting Diode (LED) for each cluster indicator, two VFD units, an audible tone generator, the cluster overlay, the gauge pointers, the odometer/trip odometer switch and the switch button. The cluster overlay is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with all of the gauge dial faces and graduations, but this layer is also translucent. The darkness of this outer layer prevents the cluster from appearing cluttered or busy by concealing the cluster indicators that are not illuminated, while the translucence of this layer allows those indicators and icons that are illuminated to be readily visible. The underlying layer of the overlay is opaque and allows light from the LED for each of the various indicators and the incandescent illumination lamps behind it to be visible through the outer layer of the overlay only through predetermined stencil-like cutouts. A rectangular opening in the overlay at the base of both the speedometer and tachometer dial faces has a smoked clear lens through which the illuminated VFD units can be viewed.

Several versions of the EMIC module are offered on this model. These versions accommodate all of the variations of optional equipment and regulatory requirements for the various markets in which the vehicle will be offered. The microprocessor-based EMIC utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with several hard wired analog and multiplexed inputs to monitor sensors and switches throughout the vehicle. In response to those inputs, the internal circuitry and programming of the EMIC allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/COMMUNICATION - DESCRIPTION PCI BUS).

Besides typical instrument cluster gauge and indicator support, the electronic functions and features that the EMIC supports or controls include the following:

• Audible Warnings - The EMIC electronic cir- cuit board is equipped with an audible tone generator and programming that allows it to provide various audible alerts to the vehicle operator, including chime tones and beep tones. An electromechanical relay is also soldered onto the circuit board to produce audible clicks that emulate the sound of a conventional turn signal or hazard warning flasher.

(Refer to 8 - ELECTRICAL/CHIME/BUZZER DESCRIPTION).

• Brake Lamp Control - The EMIC provides electronic brake lamp request messages to the Front Control Module (FCM) located on the Integrated Power Module (IPM) for brake lamp control, excluding control of the Center High Mounted Stop Lamp (CHMSL), which remains controlled by a direct hard wired output of the brake lamp switch.

• Brake Transmission Shift Interlock Control

- The EMIC monitors inputs from the brake lamp switch, ignition switch, and the Transmission Range Sensor (TRS), then controls a high-side driver output to operate the Brake Transmission Shift Interlock (BTSI) solenoid that locks and unlocks the automatic transmission gearshift selector lever on the steering column.

• Cargo Lamp Control - The EMIC provides direct control of cargo lamp operation with a load shedding (battery saver) feature which will automatically turn off the cargo lamp if it remains on after a timed interval.

• Central Locking - The EMIC provides support for the central locking feature of the power lock system. This feature will lock or unlock all doors based upon the input from the door cylinder lock switch. Door cylinder lock switches are used only on models equipped with the optional Vehicle Theft Security System (VTSS).

• Door Lock Inhibit - The EMIC inhibits locking of the doors with the power lock switch when the key is in the ignition switch and the driver side front door is ajar. However, operation of the door locks is not inhibited under the same conditions when the Lock button of the optional RKE transmitter is depressed.

• Enhanced Accident Response - The EMIC monitors an input from the Airbag Control Module (ACM) and, following an airbag deployment, will immediately disable the power lock output, unlock all doors by activating the power unlock output, then enables the power lock output if the power lock switch input remains inactive for two seconds. This feature, like all other enhanced accident response features, is dependent upon a functional vehicle electrical system following the vehicle impact event.

• Exterior Lighting Control - The EMIC pro- vides electronic head lamp and/or park lamp request messages to the Front Control Module (FCM) located on the Integrated Power Module (IPM) for the appropriate exterior lamp control of standard head and park lamps, as well as optional front fog lamps. This includes support for headlamp beam selection and the optical horn feature, also known as flash-to-pass.

• Exterior Lighting Fail-safe - In the absence of a headlamp switch input, the EMIC will turn on the

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cluster illumination lamps and provide electronic headlamp low beam and park lamp request messages to the Front Control Module (FCM) located on the Integrated Power Module (IPM) for default exterior lamp operation. The FCM will also provide default park lamp and headlamp low beam operation and the EMIC will turn on the cluster illumination lamps if there is a failure of the electronic data bus communication between the EMIC and the FCM.

• Heated Seat Control - The EMIC monitors inputs from the ignition switch and electronic engine speed messages from the Powertrain Control Module (PCM) to control a high side driver output to the heated seat switch Light Emitting Diode (LED) indicators. This input allows the heated seat switches to wake up the heated seat module if the switch is actuated. The EMIC will de-energize the heated seat switch LED indicators, which deactivates the heated seat system, if the ignition switch is turned to any position except On or Start, or if the engine speed message indicates zero. (Refer to 8 - ELECTRICAL/ HEATED SEATS - DESCRIPTION).

• Interior Lamp Load Shedding - The EMIC provides a battery saver feature which will automatically turn off all interior lamps that remain on after a timed interval of about fifteen minutes.

• Interior Lamps - Enhanced Accident Response - The EMIC monitors inputs from the Air-

bag Control Module (ACM) and the Powertrain Control Module (PCM) to automatically turn on the interior lighting after an airbag deployment event ten seconds after the vehicle speed is zero. The interior lighting remains illuminated until the ignition switch is turned to the Off position, at which time the interior lighting returns to normal operation and control. This feature, like all other enhanced accident response features, is dependent upon a functional vehicle electrical system following the vehicle impact event.

• Interior Lighting Control - The EMIC moni- tors inputs from the interior lighting switch, the door ajar switches, the cargo lamp switch, the reading lamp switches, and the Remote Keyless Entry (RKE) module to provide courtesy lamp control. This includes support for timed illuminated entry with theater-style fade-to-off and courtesy illumination defeat features.

• Lamp Out Indicator Control - The EMIC monitors electronic lamp outage messages from the Front Control Module (FCM) located on the Integrated Power Module (IPM) in order to provide lamp out indicator control for the headlamps (low and high beams), turn signal lamps, and the brake lamps (excluding CHMSL).

• Panel Lamps Dimming Control - The EMIC provides a hard wired 12-volt Pulse-Width Modulated

(PWM) output that synchronizes the dimming level of all panel lamps dimmer controlled lamps with that of the cluster illumination lamps.

• Parade Mode - The EMIC provides a parade mode (also known as funeral mode) that allows all Vacuum-Fluorescent Display (VFD) units in the vehicle to be illuminated at full (daytime) intensity while driving during daylight hours with the exterior lamps turned on.

• Power Locks - The EMIC monitors inputs from the power lock switches and the Remote Keyless Entry (RKE) receiver module (optional) to provide control of the power lock motors through high side driver outputs to the power lock motors. This includes support for rolling door locks (also known as automatic door locks), automatic door unlock, a door lock inhibit mode, and central locking (with the optional Vehicle Theft Security System only). (Refer to 8 - ELECTRICAL/POWER LOCKS - DESCRIPTION).

• Remote Keyless Entry - The EMIC supports the optional Remote Keyless Entry (RKE) system features, including support for the RKE Lock, Unlock (with optional driver-door-only unlock, and unlockall-doors), Panic, audible chirp, optical chirp, illuminated entry modes, an RKE programming mode, as well as optional Vehicle Theft Security System (VTSS) arming (when the proper VTSS arming conditions are met) and disarming.

• Remote Radio Switch Interface - The EMIC monitors inputs from the optional remote radio switches and then provides the appropriate electronic data bus messages to the radio to select the radio operating mode, volume control, preset station scan and station seek features.

• Rolling Door Locks - The EMIC provides sup- port for the power lock system rolling door locks feature (also known as automatic door locks). This feature will automatically lock all unlocked doors each time the vehicle speed reaches twenty-four kilometers-per-hour (fifteen miles-per-hour) and, following an automatic lock event, will automatically unlock all doors once the ignition is turned to the Off position and the driver side front door is opened.

• Turn Signal & Hazard Warning Lamp Control - The EMIC provides electronic turn and hazard

lamp request messages to the Front Control Module (FCM) located on the Integrated Power Module (IPM) for turn and hazard lamp control. The EMIC also provides an audible click at one of two rates to emulate normal and bulb out turn or hazard flasher operation based upon electronic lamp outage messages from the FCM, and provides an audible turn signal on chime warning if a turn is signalled continuously for more than about 1.6 kilometers (one mile) and

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the vehicle speed remains greater than about twentyfour kilometers-per-hour (fifteen miles-per-hour).

• Vacuum Fluorescent Display Synchroniza-

tion - The EMIC transmits electronic panel lamp

dimming level messages which allows all other electronic modules on the PCI data bus with Vacuum Fluorescent Display (VFD) units to coordinate their illumination intensity with that of the EMIC VFD units.

• Vehicle Theft Security System - The EMIC monitors inputs from the door cylinder lock switch(es), the door ajar switches, the ignition switch, and the Remote Keyless Entry (RKE) receiver module, then provides electronic horn and lighting request messages to the Front Control Module (FCM) located on the Integrated Power Module (IPM) for the appropriate VTSS alarm output features.

• Wiper/Washer System Control - The EMIC provides electronic wiper and/or washer request messages to the Front Control Module (FCM) located on the Integrated Power Module (IPM) for the appropriate wiper and washer system features. (Refer to 8 ELECTRICAL/WIPERS/WASHERS - DESCRIPTION).

The EMIC houses six analog gauges and has provisions for up to twenty-three indicators (Fig. 3) or (Fig. 4). The EMIC includes the following analog gauges:

• Coolant Temperature Gauge

• Fuel Gauge

• Oil Pressure Gauge

• Speedometer

• Tachometer

• Voltage Gauge

Some of the EMIC indicators are automatically configured when the EMIC is connected to the vehicle electrical system for compatibility with certain optional equipment or equipment required for regulatory purposes in certain markets. While each EMIC may have provisions for indicators to support every available option, the configurable indicators will not be functional in a vehicle that does not have the equipment that an indicator supports. The EMIC includes provisions for the following indicators (Fig.

3) or (Fig. 4):

• Airbag Indicator (with Airbag System only)

• Antilock Brake System (ABS) Indicator

(with ABS or Rear Wheel Anti-Lock [RWAL] brakes only)

• Brake Indicator

• Cargo Lamp Indicator

• Check Gauges Indicator

• Cruise Indicator (with Speed Control only)

• Door Ajar Indicator

• Electronic Throttle Control (ETC) Indicator

(with 5.7L Gasoline Engine only)

• Gear Selector Indicator (with Automatic

Transmission only)

• High Beam Indicator

• Lamp Out Indicator

• Low Fuel Indicator

• Malfunction Indicator Lamp (MIL)

• Overdrive-Off Indicator (with Automatic

Transmission only)

• Seatbelt Indicator

• Security Indicator (with Sentry Key Immo-

bilizer & Vehicle Theft Security Systems only)

• Service Four-Wheel Drive Indicator (with

Four-Wheel Drive only)

• Transmission Overtemp Indicator (with

Automatic Transmission only)

• Turn Signal (Right and Left) Indicators

• Upshift Indicator (with Manual Transmis-

sion only)

• Washer Fluid Indicator

• Wait-To-Start Indicator (with Diesel Engine

only)

• Water-In-Fuel Indicator (with Diesel Engine

only)

Each indicator in the EMIC, except those located within one of the VFD units, is illuminated by a dedicated LED that is soldered onto the EMIC electronic circuit board. The LED units are not available for service replacement and, if damaged or faulty, the entire EMIC must be replaced. Cluster illumination is accomplished by dimmable incandescent back lighting, which illuminates the gauges for visibility when the exterior lighting is turned on. Each of the incandescent bulbs is secured by an integral bulb holder to the electronic circuit board from the back of the cluster housing.

Hard wired circuitry connects the EMIC to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the EMIC through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds.

The EMIC modules for this model are serviced only as complete units. The EMIC module cannot be adjusted or repaired. If a gauge, an LED indicator, a VFD unit, the electronic circuit board, the circuit board hardware, the cluster overlay, or the EMIC housing are damaged or faulty, the entire EMIC mod-

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Fig. 3 Gauges & Indicators - Gasoline Engine

1 - MALFUNCTION INDICATOR LAMP 13 - ELECTRONIC THROTTLE CONTROL (ETC) INDICATOR 2 - VOLTAGE GAUGE 14 - ENGINE TEMPERATURE GAUGE 3 - LEFT TURN INDICATOR 15 - SECURITY INDICATOR 4 - TACHOMETER 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES

5 - AIRBAG INDICATOR 17 - CHECK GAUGES INDICATOR 6 - HIGH BEAM INDICATOR 18 - BRAKE INDICATOR 7 - SEATBELT INDICATOR 19 - ABS INDICATOR 8 - SPEEDOMETER 20 - ODOMETER/TRIP ODOMETER DISPLAY (INCLUDES

9 - RIGHT TURN INDICATOR 21 - ODOMETER/TRIP ODOMETER SWITCH BUTTON 10 - OIL PRESSURE GAUGE 22 - FUEL GAUGE 11 - CARGO LAMP INDICATOR 23 - LOW FUEL INDICATOR 12 - DOOR AJAR INDICATOR 24 - TRANSMISSION OVERTEMP INDICATOR

ule must be replaced. The cluster lens, hood and mask unit and the individual incandescent lamp bulbs with holders are available for individual service replacement.

CRUISE & UPSHIFT INDICATORS)

ENGINE HOURS, WASHER FLUID, LAMP OUTAGE, OVERDRIVE-OFF & SERVICE 4x4 INDICATORS)

The EMIC is designed to allow the vehicle operator to monitor the conditions of many of the vehicle components and operating systems. The gauges and indicators in the EMIC provide valuable information about the various standard and optional powertrains,

OPERATION

The ElectroMechanical Instrument Cluster (EMIC) in this model also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node or CCN. The following information deals primarily with the instrument cluster functions of this unit. Additional details of the electronic body control functions of this unit may be found within the service information for the system or component that the EMIC controls. For example: Additional details of the audible warning functions of the EMIC are found within the Chime/Buzzer service information.

fuel and emissions systems, cooling systems, lighting systems, safety systems and many other convenience items. The EMIC is installed in the instrument panel so that all of these monitors can be easily viewed by the vehicle operator when driving, while still allowing relative ease of access for service. The microprocessor-based EMIC hardware and software uses various inputs to control the gauges and indicators visible on the face of the cluster. Some of these inputs are hard wired, but most are in the form of electronic messages that are transmitted by other electronic modules over the Programmable Communications Interface (PCI) data bus network. (Refer to 8

- ELECTRICAL/ELECTRONIC CONTROL MODULES/COMMUNICATION - OPERATION).

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Fig. 4 Gauges & Indicators - Diesel Engine

1 - MALFUNCTION INDICATOR LAMP 14 - ENGINE TEMPERATURE GAUGE 2 - VOLTAGE GAUGE 15 - SECURITY INDICATOR 3 - LEFT TURN INDICATOR 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES

4 - TACHOMETER 17 - WATER-IN-FUEL INDICATOR 5 - AIRBAG INDICATOR 18 - BRAKE INDICATOR 6 - HIGH BEAM INDICATOR 19 - WAIT-TO-START INDICATOR 7 - SEATBELT INDICATOR 20 - ODOMETER/TRIP ODOMETER DISPLAY (INCLUDES

8 - SPEEDOMETER 21 - ODOMETER/TRIP ODOMETER SWITCH BUTTON 9 - RIGHT TURN INDICATOR 22 - FUEL GAUGE 10 - OIL PRESSURE GAUGE 23 - LOW FUEL INDICATOR 11 - CARGO LAMP INDICATOR 24 - TRANSMISSION OVERTEMP INDICATOR 12 - DOOR AJAR INDICATOR 25 - CHECK GAUGES INDICATOR 13 - ABS INDICATOR

The EMIC microprocessor smooths the input data using algorithms to provide gauge readings that are accurate, stable and responsive to operating conditions. These algorithms are designed to provide gauge readings during normal operation that are consistent with customer expectations. However, when abnormal conditions exist such as high coolant temperature, the algorithm can drive the gauge pointer to an extreme position and the microprocessor can sound a chime through the on-board audible tone generator to provide distinct visual and audible indications of a problem to the vehicle operator. The instrument cluster circuitry may also produce audible warnings for other electronic modules in the vehicle based upon electronic tone request messages received over the PCI data bus. Each audible warning is intended to provide the vehicle operator with an audible alert to supplement a visual indication.

CRUISE & UPSHIFT INDICATORS)

ENGINE HOURS, WASHER FLUID, LAMP OUTAGE, OVERDRIVE-OFF & SERVICE 4x4 INDICATORS)

The EMIC circuitry operates on battery current received through a fused B(+) fuse in the Integrated Power Module (IPM) on a non-switched fused B(+) circuit, and on battery current received through a fused ignition switch output (run-start) fuse in the IPM on a fused ignition switch output (run-start) circuit. This arrangement allows the EMIC to provide some features regardless of the ignition switch position, while other features will operate only with the ignition switch in the On or Start positions. The EMIC circuitry is grounded through a ground circuit and take out of the instrument panel wire harness with an eyelet terminal connector that is secured by a ground screw to a ground location near the center of the instrument panel structural support.

The EMIC also has a self-diagnostic actuator test capability, which will test each of the PCI bus message-controlled functions of the cluster by lighting the appropriate indicators, positioning the gauge nee-

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dles at several predetermined calibration points across the gauge faces, and illuminating all segments of the odometer/trip odometer and gear selector indicator Vacuum-Fluorescent Display (VFD) units. (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). See the owner’s manual in the vehicle glove box for more information on the features, use and operation of the EMIC.

GAUGES

All gauges receive battery current through the EMIC circuitry only when the ignition switch is in the On or Start positions. With the ignition switch in the Off position battery current is not supplied to any gauges, and the EMIC circuitry is programmed to move all of the gauge needles back to the low end of their respective scales. Therefore, the gauges do not accurately indicate any vehicle condition unless the ignition switch is in the On or Start positions.

All of the EMIC gauges are air core magnetic units. Two fixed electromagnetic coils are located within each gauge. These coils are wrapped at right angles to each other around a movable permanent magnet. The movable magnet is suspended within the coils on one end of a pivot shaft, while the gauge needle is attached to the other end of the shaft. One of the coils has a fixed current flowing through it to maintain a constant magnetic field strength. Current flow through the second coil changes, which causes changes in its magnetic field strength. The current flowing through the second coil is changed by the EMIC circuitry in response to messages received over the PCI data bus. The gauge needle moves as the movable permanent magnet aligns itself to the changing magnetic fields created around it by the electromagnets.

The gauges are diagnosed using the EMIC self-diagnostic actuator test. (Refer to 8 - ELECTRICAL/ INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). Proper testing of the PCI data bus and the electronic data bus message inputs to the EMIC that control each gauge require the use of a DRBIIIt scan tool. Refer to the appropriate diagnostic information. Specific operation details for each gauge may be found elsewhere in this service information.

VACUUM-FLUORESCENT DISPLAYS

The Vacuum-Fluorescent Display (VFD) units are soldered to the EMIC electronic circuit board. With the ignition switch in the Off or Accessory positions, the odometer display is activated when the driver door is opened (Rental Car mode) and is deactivated when the driver door is closed. Otherwise, both display units are active when the ignition switch is in the On or Start positions, and inactive when the ignition switch is in the Off or Accessory positions.

The illumination intensity of the VFD units is controlled by the EMIC circuitry based upon an input from the headlamp switch and a dimming level input received from the headlamp dimmer switch. The EMIC synchronizes the illumination intensity of other VFD units with that of the units in the EMIC by sending electronic dimming level messages to other electronic modules in the vehicle over the PCI data bus.

The EMIC VFD units have several display capabilities including odometer, trip odometer, engine hours, gear selector indication (PRNDL) for models with an automatic transmission, several warning or reminder indications, and various diagnostic information when certain fault conditions exist. An odometer/trip odometer switch on the EMIC circuit board is used to control some of the display modes. This switch is actuated manually by depressing the odometer/trip odometer switch button that extends through the lower edge of the cluster lens, just left of the tachometer. Actuating this switch momentarily with the ignition switch in the On position will toggle the VFD between the odometer and trip odometer modes. Depressing the switch button for about two seconds while the VFD is in the trip odometer mode will reset the trip odometer value to zero. While in the odometer mode with the ignition switch in the On position and the engine not running, depressing this switch for about six seconds will display the engine hours information. Holding this switch depressed while turning the ignition switch from the Off position to the On position will initiate the EMIC self-diagnostic actuator test. Refer to the appropriate diagnostic information for additional details on this VFD function. The EMIC microprocessor remembers which display mode is active when the ignition switch is turned to the Off position, and returns the VFD display to that mode when the ignition switch is turned On again.

The VFD units are diagnosed using the EMIC selfdiagnostic actuator test. (Refer to 8 - ELECTRICAL/ INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). Proper testing of the PCI data bus and the electronic data bus message inputs to the EMIC that control some of the VFD functions requires the use of a DRBIIIt scan tool. Refer to the appropriate diagnostic information. Specific operation details for the odometer, the trip odometer, the gear selector indicator and the various warning and reminder indicator functions of the VFD may be found elsewhere in this service information.

INDICATORS

Indicators are located in various positions within the EMIC and are all connected to the EMIC electronic circuit board. The cargo lamp indicator, door

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ajar indicator, high beam indicator, and turn signal indicators operate based upon hard wired inputs to the EMIC. The brake indicator is controlled by PCI data bus messages from the Controller Antilock Brake (CAB) as well as by hard wired park brake switch inputs to the EMIC. The seatbelt indicator is controlled by the EMIC programming, PCI data bus messages from the Airbag Control Module (ACM), and a hard wired seat belt switch input to the EMIC. The Malfunction Indicator Lamp (MIL) is normally controlled by PCI data bus messages from the Powertrain Control Module (PCM); however, if the EMIC loses PCI data bus communication, the EMIC circuitry will automatically turn the MIL on until PCI data bus communication is restored. The EMIC uses PCI data bus messages from the Front Control Module (FCM), the PCM, the diesel engine only Engine Control Module (ECM), the ACM, the CAB, and the Sentry Key Immobilizer Module (SKIM) to control all of the remaining indicators.

The various EMIC indicators are controlled by different strategies; some receive fused ignition switch output from the EMIC circuitry and have a switched ground, while others are grounded through the EMIC circuitry and have a switched battery feed. However, all indicators are completely controlled by the EMIC microprocessor based upon various hard wired and electronic message inputs. All indicators are illuminated at a fixed intensity, which is not affected by the selected illumination intensity of the EMIC general illumination lamps.

In addition, certain indicators in this instrument cluster are automatically configured or self-configured. This feature allows the configurable indicators to be enabled by the EMIC circuitry for compatibility with certain optional equipment. The EMIC defaults for the ABS indicator and airbag indicator are enabled, and these configuration settings must be programmatically disabled in the EMIC using a DRBIIIt scan tool for vehicles that do not have this equipment. The automatically configured or self-configured indicators remain latent in each EMIC at all times and will be active only when the EMIC receives the appropriate PCI message inputs for that optional system or equipment.

The hard wired indicator inputs may be diagnosed using conventional diagnostic methods. However, the EMIC circuitry and PCI bus message controlled indicators are diagnosed using the EMIC self-diagnostic actuator test. (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). Proper testing of the PCI data bus and the electronic message inputs to the EMIC that control an indicator requires the use of a DRBIIIt scan tool. Refer to the appropriate diagnostic information. Specific details of

the operation for each indicator may be found elsewhere in this service information.

CLUSTER ILLUMINATION

The EMIC has several illumination lamps that are illuminated when the exterior lighting is turned on with the headlamp switch. The illumination intensity of these lamps is adjusted when the interior lighting thumbwheel on the headlamp switch is rotated (down to dim, up to brighten) to one of six available minor detent positions. The EMIC monitors a resistor multiplexed input from the headlamp switch on a dimmer input circuit. In response to that input, the EMIC electronic circuitry converts a 12-volt input it receives from a fuse in the Integrated Power Module (IPM) on a hard wired panel lamps dimmer switch signal circuit into a 12-volt Pulse Width Modulated (PWM) output. The EMIC uses this PWM output to power the cluster illumination lamps and the VFD units on the EMIC circuit board, then provides a synchronized PWM output on the various hard wired fused panel lamps dimmer switch signal circuits to control and synchronize the illumination intensity of other incandescent illumination lamps in the vehicle. The cluster illumination lamps are grounded at all times.

The EMIC also sends electronic dimming level messages over the PCI data bus to other electronic modules in the vehicle to control and synchronize the illumination intensity of their VFD units to that of the EMIC VFD units. In addition, the thumbwheel on the headlamp switch has a Parade Mode position to provide a parade mode. The EMIC monitors the request for this mode from the headlamp switch, then sends an electronic dimming level message over the PCI data bus to illuminate all VFD units in the vehicle at full (daytime) intensity for easier visibility when driving in daylight with the exterior lighting turned on.

The hard wired headlamp switch and EMIC panel lamps dimmer inputs and outputs may be diagnosed using conventional diagnostic methods. However, proper testing of the PWM output of the EMIC and the electronic dimming level messages sent by the EMIC over the PCI data bus requires the use of a DRBIIIt scan tool. Refer to the appropriate diagnostic information.

INPUT AND OUTPUT CIRCUITS

HARD WIRED INPUTS

The hard wired inputs to the EMIC include the following:

• Brake Lamp Switch Output

• Driver Cylinder Lock Switch Sense

• Driver Door Ajar Switch Sense

8J - 10 INSTRUMENT CLUSTER DR

INSTRUMENT CLUSTER (Continued)

• Driver Door Lock Switch MUX - with

Power Locks

• Fused B(+) - Ignition-Off Draw

• Fused B(+) - Power Lock Feed - with Power

Locks

• Fused Ignition Switch Output (Accessory-

Run)

• Fused Ignition Switch Output (Off-Run-

Start)

• Fused Ignition Switch Output (Run-Start)

• Headlamp Dimmer Switch MUX

• Headlamp Switch MUX

• Horn Relay Control

• Key-In Ignition Switch Sense

• Left Rear Door Ajar Switch Sense

• Panel Lamps Dimmer Switch Signal

• Park Brake Switch Sense

• Passenger Door Ajar Switch Sense

• Passenger Door Lock Switch MUX - with

Power Locks

• Radio Control MUX

• Right Rear Door Ajar Switch Sense

• RKE Supply - with RKE

• Seat Belt Switch Sense

• Transmission Range Sensor MUX - with

Auto Trans

• Turn/Hazard Switch MUX

• Washer/Beam Select Switch MUX

• Wiper Switch MUX

Refer to the appropriate wiring information for

additional details.

• Radio Illumination Driver

• Right Door Lock Driver - with Power Locks

• Right Door Unlock Driver - with Power

Locks

• Transfer Case Switch Illumination Driver -

with Four-Wheel Drive

Refer to the appropriate wiring information for additional details.

GROUNDS

The EMIC receives and supplies a ground path to several switches and sensors through the following hard wired circuits:

• Ground - Illumination (2 Circuits)

• Ground - Power Lock - with Power Locks

• Ground - Signal

• Headlamp Switch Return

• Multi-Function Switch Return

• Transmission Range Sensor Return - with

Auto Trans

Refer to the appropriate wiring information for additional details.

COMMUNICATION

The EMIC has provisions for the following communication circuits:

• PCI Data Bus

• RKE Program Serial Data - with RKE

• RKE Transmit Serial Data - with RKE

Refer to the appropriate wiring information for additional details.

HARD WIRED OUTPUTS

The hard wired outputs of the EMIC include the

following:

• Accessory Switch Bank Illumination Driver

• BTSI Driver - with Auto Trans

• Cargo Lamp Driver

• Dome/Overhead Lamp Driver

• Driver Door Unlock Driver - with Power

Locks

• Headlamp Switch Illumination Driver

• Heated Seat Switch Indicator Driver - with

Heated Seats

• Heater-A/C Control Illumination Driver

• Left Door Lock Driver - with Power Locks

• Left Rear Door Unlock Driver - with Power

Locks

• Map/Glove Box Lamp Driver

DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER

If all of the instrument cluster gauges and/or indicators are inoperative, refer to PRELIMINARY DIAGNOSIS. If an individual gauge or Programmable Communications Interface (PCI) data bus message-controlled indicator is inoperative, refer to ACTUATOR TEST. If an individual hard wired indicator is inoperative, refer to the diagnosis and testing information for that specific indicator.

Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds.

DR INSTRUMENT CLUSTER 8J - 11

INSTRUMENT CLUSTER (Continued)

CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation into electronic memory. This embedded information is learned through electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded into cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed.

NOTE: Certain indicators in this instrument cluster are automatically configured. This feature allows those indicators to be activated or deactivated for compatibility with certain optional equipment. If the problem being diagnosed involves improper illumination of the cruise indicator, the electronic throttle control indicator, the overdrive-off indicator, the service four-wheel drive indicator, the transmission overtemp indicator, the upshift indicator, the security indicator or the gear selector indicator, disconnect and isolate the battery negative cable. After about five minutes, reconnect the battery negative cable and turn the ignition switch to the On position. The instrument cluster should automatically relearn the equipment in the vehicle and properly configure the configurable indicators accordingly.

PRELIMINARY DIAGNOSIS

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

(1) Check the fused B(+) fuse (Fuse 28 - 10 ampere) in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.

(2) Check for battery voltage at the fused B(+) fuse (Fuse 28 - 10 ampere) in the IPM. If OK, go to Step

3. If not OK, repair the open fused B(+) circuit between the IPM and the battery as required.

(3) Disconnect and isolate the battery negative cable. Remove the instrument cluster. Reconnect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the instrument panel wire harness connector (Connector C1) for the instrument cluster. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit between the instrument cluster and the IPM as required.

(4) Check for continuity between the signal ground circuit cavity of the instrument panel wire harness connector (Connector C1) for the instrument cluster and a good ground. There should be continuity. If OK, refer to ACTUATOR TEST. If not OK, repair the open ground circuit to ground (G202) as required.

8J - 12 INSTRUMENT CLUSTER DR

INSTRUMENT CLUSTER (Continued)

ACTUATOR TEST

The instrument cluster actuator test will put the instrument cluster into its self-diagnostic mode. In this mode the instrument cluster can perform a selfdiagnostic test that will confirm that the instrument cluster circuitry, the gauges, and the indicators are capable of operating as designed. During the actuator test the instrument cluster circuitry will position each of the gauge needles at various calibration points, illuminate all of the segments in the Vacuum Fluorescent Display (VFD) units, turn all of the indicators on and off again, display any Diagnostic Trouble Code (DTC) information, and display the number of ignition key cycles that have occurred since the DTC was detected. It is suggested that a note pad and pencil be used to write down any fault information that is displayed during the test for reference.

Successful completion of the actuator test will confirm that the instrument cluster is operational. However, there may still be a problem with the PCI data bus, the Powertrain Control Module (PCM), the Engine Control Module (ECM), the Front Control Module (FCM), the Transmission Control Module (TCM), the Transfer Case Control Module (TCCM), the Airbag Control Module (ACM), the Controller Anti-lock Brake (CAB), or the inputs to one of these electronic control modules. Use a DRBIIIt scan tool

to diagnose these components. Refer to the appropriate diagnostic information.

(1) Begin the test with the ignition switch in the

Off position.

(2) Depress the odometer/trip odometer switch but-

ton.

(3) While still holding the odometer/trip odometer switch button depressed, turn the ignition switch to the On position, but do not start the engine.

(4) Release the odometer/trip odometer switch button.

(5) The instrument cluster will simultaneously illuminate all of the operational segments in both VFD units, perform a bulb check of each operational LED indicator. The VFD segments and LED indicators remain illuminated as each gauge needle is swept to several calibration points and back. If a VFD segment or an LED indicator fails to illuminate, or if a gauge needle fails to sweep through the calibration points and back during this test, the instrument cluster must be replaced. Following these tests, the actuator test will proceed as described in Step 6.

(6) The text “C Code” is displayed in the odometer VFD for about three seconds. If there is no stored fault information, the display will show two pairs of zeroes in the format “00” “00”, which indicate that the display of fault information is done. If there is stored fault information, two sets of two-digit alpha and alpha-numeric fault codes will appear in the odometer display for a three second interval. The first pair of digits represents a Diagnostic Trouble Code (DTC), or fault code for the instrument cluster. The second pair of digits is a counter for the number of ignition key cycles that have occurred since the displayed DTC was set. The instrument cluster will continue to display additional sets of two pairs of digits at three second intervals until all of the stored codes have been displayed, which is again signaled by a code of “00” “00”. Refer to the Instrument Cluster Failure Message table for a description of each fault code that the instrument cluster displays. If an instrument cluster fault is displayed, use a DRBIIIt scan tool to diagnose the problem. Refer to the appropriate diagnostic information.

INSTRUMENT CLUSTER FAILURE MESSAGE

Fault Code Description Correction

01 Airbag warning indicator output circuit shorted. Refer to the appropriate diagnostic information. 02 Airbag warning indicator output circuit open. Refer to the appropriate diagnostic information. 03 ABS indicator output circuit shorted. Refer to the appropriate diagnostic information. 04 ABS indicator output circuit open. Refer to the appropriate diagnostic information. 05 MIL indicator output circuit shorted. Refer to the appropriate diagnostic information. 06 MIL indicator output circuit open. Refer to the appropriate diagnostic information.

DR INSTRUMENT CLUSTER 8J - 13

INSTRUMENT CLUSTER (Continued)

INSTRUMENT CLUSTER FAILURE MESSAGE

Fault Code Description Correction

07 Wait to start indicator circuit shorted. Refer to the appropriate diagnostic information. 08 Wait to start indicator circuit open. Refer to the appropriate diagnostic information. 0B BTSI output circuit shorted or open. Refer to the appropriate diagnostic information. 22 Headlamp switch input circuit shorted. Refer to the appropriate diagnostic information. 23 Headlamp switch input circuit open. Refer to the appropriate diagnostic information. 24 Turn hazard switch input circuit shorted. Refer to the appropriate diagnostic information. 25 Turn hazard swiitch inpot circuit open. Refer to the appropriate diagnostic information. 27 Courtesy/dome output circuit shorted or open. Refer to the appropriate diagnostic information. 28 Glovebox/map lamp output circuit shorted or

open. 29 Cargo lamp output circuit shorted or open. Refer to the appropriate diagnostic information. 40 Wiper switch input circuit shorted. Refer to the appropriate diagnostic information. 41 Wiper switch input circuit open. Refer to the appropriate diagnostic information. 42 Wash/beam input circuit shorted. Refer to the appropriate diagnostic information. 60 Passenger door lock switch input circuit shorted. Refer to the appropriate diagnostic information. 61 Passenger door lock switch input circuit open. Refer to the appropriate diagnostic information. 62 Passenger door lock switch input circuit stuck. Refer to the appropriate diagnostic information. 63 Driver door lock switch input circuit shorted. Refer to the appropriate diagnostic information. 64 Driver door lock switch input circuit open. Refer to the appropriate diagnostic information. 65 Driver door lock switch input circuit stuck. Refer to the appropriate diagnostic information. 66 All door lock output circuit shorted to ground or

voltage. 67 All door unlock output circuit shorted to ground

or voltage. 68 Driver door unlock output circuit shorted to

ground or voltage.

6C Driver cylinder lock switch input circuit shorted. Refer to the appropriate diagnostic information. 6E Driver cylinder lock switch input circuit stuck. Refer to the appropriate diagnostic information.

80 Incorrect odometer value found. Refer to the appropriate diagnostic information. 81 Remote radio switch input circuit high. Refer to the appropriate diagnostic information. 82 Remote radio switch stuck. Refer to the appropriate diagnostic information.

A0 Internal module FLASH memory checksum

failure.

A1 Internal module bootloader failure. Refer to the appropriate diagnostic information. A3 Battery voltage open. Refer to the appropriate diagnostic information. A5 TCCM messages not received. Refer to the appropriate diagnostic information. A7 VIN checksum error. Refer to the appropriate diagnostic information. A8 VIN previously stored. Refer to the appropriate diagnostic information. A9 PCI bus internal failure. Refer to the appropriate diagnostic information. AA PCM messages not received. Refer to the appropriate diagnostic information. AB TCM messages not received. Refer to the appropriate diagnostic information. AC ABS messages not received. Refer to the appropriate diagnostic information.

Refer to the appropriate diagnostic information.

8J - 14 INSTRUMENT CLUSTER DR

INSTRUMENT CLUSTER (Continued)

INSTRUMENT CLUSTER FAILURE MESSAGE

Fault Code Description Correction

AD FCM messages not received. Refer to the appropriate diagnostic information. AE ACM messages not received. Refer to the appropriate diagnostic information. AF SKIM messages not received. Refer to the appropriate diagnostic information. B0 RKE fob batteries low. Refer to the appropriate diagnostic information. B1 RKE module communication link. Refer to the appropriate diagnostic information.

00 Done All Diagnostic Trouble Codes (DTC) have been

displayed.

(7) The actuator test is now completed. The instrument cluster will automatically exit the self-diagnostic mode and return to normal operation at the completion of the test, if the ignition switch is turned to the Off position during the test, or if a vehicle speed message indicating that the vehicle is moving is received from the PCM over the PCI data bus during the test.

(8)

Go back to Step 1 to repeat the test, if necessary.

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Remove the cluster bezel from the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ CLUSTER BEZEL - REMOVAL).

(3) Remove the four screws that secure the instrument cluster to the instrument panel structural support (Fig. 5).

Fig. 5 Instrument Cluster Remove/Install

1 - WIRE HARNESS CONNECTOR (3) 2 - INSTRUMENT CLUSTER 3 - SCREW (4) 4 - INSTRUMENT PANEL STRUCTURAL SUPPORT

(4) Pull the instrument cluster rearward far enough to access and disconnect the instrument panel wire harness connectors for the cluster from the connector receptacles on the back of the cluster housing.

(5) Remove the instrument cluster from the instrument panel.

DISASSEMBLY

Some of the components for the instrument cluster used in this vehicle are serviced individually. The serviced components include the incandescent instrument cluster illumination lamp bulbs (including the integral bulb holders), and the cluster lens, hood and mask unit. Following are the procedures for disassembling these components from the instrument cluster unit.

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