Dodge Instrument Cluster 3500 2005, Instrument Cluster 2500 2005, Instrument Cluster 1500 2005 Service Manual

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Page 1

DR/DH INSTRUMENT CLUSTER 8J - 1

INSTRUMENT CLUSTER

TABLE OF CONTENTS

page page

INSTRUMENT CLUSTER - ELECTRICAL

DIAGNOSTICS ........................... 1

INSTRUMENT CLUSTER -SERVICE

INFORMATION.......................... 97

INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS

TABLE OF CONTENTS

page page

INSTRUMENT CLUSTER - ELECTRICAL

DIAGNOSTICS

DIAGNOSIS AND TESTING

ABS INDICATOR OUTPUT CIRCUIT OPEN

OR SHORT TO GROUND ................3

ABS INDICATOR OUTPUT CIRCUIT

OVERLOAD OR SHORT TO BATTERY.......4

AIRBAG INDICATOR OUTPUT CIRCUIT

OPEN OR SHORT TO GROUND ...........5

AIRBAG WARNING INDICATOR OUTPUT

CIRCUIT OVERLOAD OR SHORT TO

BATTERY.............................6

BRAKE INDICATOR OUTPUT CIRCUIT

OPEN OR SHORT TO GROUND ...........7

BRAKE INDICATOR OUTPUT CIRCUIT

OVERLOAD OR SHORT TO BATT ..........8

CARGO LAMP INDICATOR OUTPUT

CIRCUIT OPEN OR SHORT TO GROUND ....9

CARGO LAMP INDICATOR OUTPUT

CIRCUIT OVERLOAD SHORT TO BATT .....10

CHECK GAUGES INDICATOR OUTPUT

CIRCUIT OPEN OR SHORT TO GROUND . . . 11

CHECK GAUGES INDICATOR OUTPUT

CIRCUIT OVERLOAD OR SHORT BATT.....12

DOOR AJAR INDICATOR OUTPUT CIRCUIT

OPEN OR SHORT TO GROUND ..........13

DOOR AJAR INDICATOR OUTPUT CIRCUIT

OVERLOAD SHORT TO BATT ............14

ETC INDICATIOR OUTPUT CIRCUIT

OVERLOAD OR SHORT TO BATT .........15

ETC INDICATOR OUTPUT CIRCUIT OPEN

OR SHORT TO GROUND................16

FUEL INDICATOR CIRCUIT OPEN OR

SHORT TO GROUND...................17

FUEL INDICATOR CIRCUIT OVERLOAD

SHORT TO BATT ......................18

HIGH BEAM INDICATOR CIRCUIT OPEN

SHORT TO GROUND...................19

HIGH BEAM INDICATOR CIRCUIT

OVERLOAD OR SHORT TO BATT .........20

MIL INDICATOR OUTPUT CIRCUIT OPEN

OR SHORT TO GROUND................21

MIL INDICATOR OUTPUT CIRCUIT

OVERLOAD OR SHORT TO BATTERY......22

SEATBELT INDICATOR OUTPUT CIRCUIT

OVERLOAD SHORT TO BATT ............23

SEATBELT INDICATOR OUTPUT CIRCUIT

OPEN SHORT TO GROUND .............24

TRANS TEMP INDICATOR OUTPUT

CIRCUIT OPEN OR SHORT TO GROUND . . . 25

TRANS TEMP INDICATOR OUTPUT

CIRCUIT OVERLOAD OR SHORT TO BATT . . 26

WAIT TO START INDICATOR OUTPUT

CIRCUIT OPEN OR SHORT TO GROUND . . . 27

WAIT TO START INDICATOR OUTPUT

CIRCUIT OVERLOAD OR SHORT TO

BATTERY............................28

WATER IN FUEL INDICATOR OUTPUT

CIRCUIT OPEN OR SHORT TO GROUND . . . 29

WATER IN FUEL INDICATOR OUTPUT

CIRCUIT OVERLOAD OR SHORT TO BATT . . 30

ABS MESSAGES NOT RECEIVED .........31

ACM MESSAGES NOT RECEIVED ........32

FCM MESSAGES NOT RECEIVED ........33

SKIM MMESSAGES NOT RECEIVED ......34

TCCM MESSAGES NOT RECEIVED .......35

TCM MESSAGES NOT RECEIVED ........36

BATTERY VOLTAGE OPEN ..............37

BTSI OUTPUT CIRCUIT HIGH ............40

BTSI OUTPUT CIRCUIT SHORTED OR

OPEN ..............................43

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8J - 2 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

IGNITION RUN-START CIRCUIT

RATIONALITY CHECK ..................47

IGNITION UNLOCK CIRCUIT RATIONALITY

CHECK .............................48

INCORRECT ODOMETER VALUE FOUND . . . 49 INTERNAL MODULE BOOTLOADER

FAILURE ............................50

INTERNAL MODULE FLASH MEMORY

CHECKSUM FAILURE ..................51

PCI BUS INTERNAL FAILURE ............52

PCM MESSAGES NOT RECEIVED ........53

PRNDL SWITCH INPUT CIRCUIT OPEN

(DIESEL ONLY) .......................56

PRNDL SWITCH INPUT CIRCUIT SHORTED

(DIESEL ONLY) .......................59

VIN CHECKSUM ERROR ................62

VIN PREVIOUSLY STORED ..............63

*ALL GAUGES INOPERATIVE ............64

*ANY PCI INDICATOR INOPERATIVE ......69

*BRAKE WARNING INDICATOR ALWAYS ON . 71 *BRAKE WARNING INDICATOR

INOPERATIVE ........................75

*FUEL GAUGE INACCURATE ............80

*ONE GAUGE INOPERATIVE - GAS

ENGINES............................83

*PRNDL NOT DISPLAYING CORRECT

POSITION (EATX VEHICLES) ............84

*SEAT BELT WARNING INDICATOR ALWAYS

OFF................................85

*SEAT BELT WARNING INDICATOR ALWAYS

OFF - STANDARD CAB .................87

*SEAT BELT WARNING INDICATOR ALWAYS

ON.................................89

*SEAT BELT WARNING INDICATOR ALWAYS

ON - STANDARD CAB ..................92

SCHEMATICS AND DIAGRAMS ............96

INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS

DIAGNOSIS AND TESTING

Page 3

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 3

ABS INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 4

8J - 4 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

ABS INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATTERY

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 5

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 5

AIRBAG INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 6

8J - 6 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

AIRBAG WARNING INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATTERY

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 7

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 7

BRAKE INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 8

8J - 8 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

BRAKE INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 9

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 9

CARGO LAMP INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 10

8J - 10 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

CARGO LAMP INDICATOR OUTPUT CIRCUIT OVERLOAD SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 11

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 11

CHECK GAUGES INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 12

8J - 12 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

CHECK GAUGES INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 13

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 13

DOOR AJAR INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 14

8J - 14 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

DOOR AJAR INDICATOR OUTPUT CIRCUIT OVERLOAD SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 15

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 15

ETC INDICATIOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 16

8J - 16 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

ETC INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 17

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 17

FUEL INDICATOR CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 18

8J - 18 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

FUEL INDICATOR CIRCUIT OVERLOAD SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 19

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 19

HIGH BEAM INDICATOR CIRCUIT OPEN SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 20

8J - 20 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

HIGH BEAM INDICATOR CIRCUIT OVERLOAD OR SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 21

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 21

MIL INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 22

8J - 22 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

MIL INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATTERY

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 23

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 23

SEATBELT INDICATOR OUTPUT CIRCUIT OVERLOAD SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 24

8J - 24 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

SEATBELT INDICATOR OUTPUT CIRCUIT OPEN SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 25

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 25

TRANS TEMP INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 26

8J - 26 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

TRANS TEMP INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 27

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 27

WAIT TO START INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 28

8J - 28 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

WAIT TO START INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATTERY

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 29

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 29

WATER IN FUEL INDICATOR OUTPUT CIRCUIT OPEN OR SHORT TO GROUND

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 30

8J - 30 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

WATER IN FUEL INDICATOR OUTPUT CIRCUIT OVERLOAD OR SHORT TO BATT

For a complete wiring diagram Refer to Section 8W.

Possible Causes

INSTRUMENT CLUSTER

NOTE: Diagnose and repair any PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

The Instrument Cluster indicator LEDs are not replaceable, view repair.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 31

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 31

ABS MESSAGES NOT RECEIVED

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The Instrument Cluster does not receive any messages from the ABS (CAB) module for at least 5 seconds.

Possible Causes

BUS MESSAGE NOT RECEIVED DTC PRESENT INSTRUMENT CLUSTER

BUS MESSAGE NOT RECEIVED DTC PRESENT

With the DRBIIIT, attempt to communicate with the module that corresponds to the DTC that is set.

Was the DRBIIIT able to I/D or communicate with the Module in question?

Yes >> No >>

INSTRUMENT CLUSTER

NOTE: If this is an active DTC, answer yes to the question.

With the DRBIIIT, erase DTCs. Cycle the ignition, wait approximately 1 minute. With the DRBIIIT, read DTCs.

Did the DTC reset?

Yes >>

No >>

Go To 2 Refer to Communication category for the related symptom(s).

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

The condition is not present at this time. Monitor DRBIIIT parameters while wiggling the related wire harness. Refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 32

8J - 32 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

ACM MESSAGES NOT RECEIVED

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The Instrument Cluster does not receive any messages from the ACM for at least 5 seconds.

Possible Causes

BUS MESSAGE NOT RECEIVED DTC PRESENT INSTRUMENT CLUSTER

BUS MESSAGE NOT RECEIVED DTC PRESENT

With the DRBIIIT, attempt to communicate with the module that corresponds to the DTC that is set.

Was the DRBIIIT able to I/D or communicate with the Module in question?

Yes >> No >>

INSTRUMENT CLUSTER

NOTE: If this is an active DTC, answer yes to the question.

With the DRBIIIT, erase DTCs. Cycle the ignition, wait approximately 1 minute. With the DRBIIIT, read DTCs.

Did the DTC reset?

Yes >>

No >>

Go To 2 Refer to Communication category for the related symptom(s).

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 33

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 33

FCM MESSAGES NOT RECEIVED

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The Instrument Cluster does not receive any messages from the FCM for at least 5 seconds.

Possible Causes

BUS MESSAGE NOT RECEIVED DTC PRESENT INSTRUMENT CLUSTER

BUS MESSAGE NOT RECEIVED DTC PRESENT

With the DRBIIIT, attempt to communicate with the module that corresponds to the DTC that is set.

Was the DRBIIIT able to I/D or communicate with the Module in question?

Yes >> No >>

INSTRUMENT CLUSTER

NOTE: If this is an active DTC, answer yes to the question.

With the DRBIIIT, erase DTCs. Cycle the ignition, wait approximately 1 minute. With the DRBIIIT, read DTCs.

Did the DTC reset?

Yes >>

No >>

Go To 2 Refer to Communication category for the related symptom(s).

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 34

8J - 34 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

SKIM MMESSAGES NOT RECEIVED

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The Instrument Cluster does not receive any messages from the SKIM for at least 5 seconds.

Possible Causes

BUS MESSAGE NOT RECEIVED DTC PRESENT INSTRUMENT CLUSTER

BUS MESSAGE NOT RECEIVED DTC PRESENT

With the DRBIIIT, attempt to communicate with the module that corresponds to the DTC that is set.

Was the DRBIIIT able to I/D or communicate with the Module in question?

Yes >> No >>

INSTRUMENT CLUSTER

NOTE: If this is an active DTC, answer yes to the question.

With the DRBIIIT, erase DTCs. Cycle the ignition, wait approximately 1 minute. With the DRBIIIT, read DTCs.

Did the DTC reset?

Yes >>

No >>

Go To 2 Refer to Communication category for the related symptom(s).

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 35

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 35

TCCM MESSAGES NOT RECEIVED

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The Instrument Cluster does not receive any messages from the SKIM for at least 5 seconds.

Possible Causes

BUS MESSAGE NOT RECEIVED DTC PRESENT INSTRUMENT CLUSTER

BUS MESSAGE NOT RECEIVED DTC PRESENT

With the DRBIIIT, attempt to communicate with the module that corresponds to the DTC that is set.

Was the DRBIIIT able to I/D or communicate with the Module in question?

Yes >> No >>

INSTRUMENT CLUSTER

NOTE: If this is an active DTC, answer yes to the question.

With the DRBIIIT, erase DTCs. Cycle the ignition, wait approximately 1 minute. With the DRBIIIT, read DTCs.

Did the DTC reset?

Yes >>

No >>

Go To 2 Refer to Communication category for the related symptom(s).

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 36

8J - 36 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

TCM MESSAGES NOT RECEIVED

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The Instrument Cluster does not receive any messages from the SKIM for at least 5 seconds.

Possible Causes

BUS MESSAGE NOT RECEIVED DTC PRESENT INSTRUMENT CLUSTER

BUS MESSAGE NOT RECEIVED DTC PRESENT

With the DRBIIIT, attempt to communicate with the module that corresponds to the DTC that is set.

Was the DRBIIIT able to I/D or communicate with the Module in question?

Yes >> No >>

INSTRUMENT CLUSTER

NOTE: If this is an active DTC, answer yes to the question.

With the DRBIIIT, erase DTCs. Cycle the ignition, wait approximately 1 minute. With the DRBIIIT, read DTCs.

Did the DTC reset?

Yes >>

No >>

Go To 2 Refer to Communication category for the related symptom(s).

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 37

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 37

BATTERY VOLTAGE OPEN

Page 38

8J - 38 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

BATTERY VOLTAGE OPEN (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

Continuously.

• Set Condition:

If the Battery Voltage Feed indicates OFF for 1 second, then fault is written directly to EEPROM. If the battery voltage feed is restored in under 36 miles, then the EEPROM is cleared.

Possible Causes

IOD FUSE NOT INSTALLED IOD FUSE OPEN (A944) BATTERY VOLTAGE FEED OPEN INSTRUMENT CLUSTER

IOD FUSE NOT INSTALLED

Inspect the IOD Fuse.

Is the IOD fuse installed?

Yes >> No >>

IOD FUSE OPEN

Turn the ignition off. Inspect the IOD fuse in the PDC.

Is the IOD fuse open?

Yes >>

No >>

Go To 2 Install the IOD fuse.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Using the wiring diagram/schematic as a guide, inspect the wiring and connectors for a short to ground condition.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.) Go To 3

Page 39

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 39

BATTERY VOLTAGE OPEN (CONTINUED)

CHECK THE (A944) BATTERY VOLTAGE FEED FOR AN OPEN

Disconnect the Instrument Cluster C1 harness connector. Turn the ignition on. Measure the voltage of the (A944) Battery Voltage Feed circuit.

Is the voltage above 10 volts?

Yes >>

No >>

Replace the Instrument Cluster in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Using the wiring diagram/schematic as a guide, repair the (A944) Battery Voltage feed circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 40

8J - 40 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

BTSI OUTPUT CIRCUIT HIGH

Page 41

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 41

BTSI OUTPUT CIRCUIT HIGH (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition in the Unlock or Run position and the driver’s foot applied to the brake pedal.

• Set Condition:

The instrument cluster detects a high value on the BTSI Solenoid Control Circuit.

Possible Causes

(K32) BTSI CONTROL CIRCUIT OPEN (Z101) BTSI GROUND CIRCUIT OPEN BTSI SOLENOID INSTRUMENT CLUSTER

BTSI SOLENOID

Turn the ignition on. Disconnect the BTSI Solenoid. Using a 12-volt test light connected to ground, check for voltage on

the (K32) BTSI Solenoid control circuit. With the DRBIIIT, actuate the BTSI Solenoid.

Does the test light illuminate brightly?

Yes >> No >>

Go To 2 Go To 3

Page 42

8J - 42 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

BTSI OUTPUT CIRCUIT HIGH (CONTINUED)

CHECK THE (Z101) BTSI GROUND CIRCUIT FOR AN OPEN

Turn the ignition off. Connect a 12-volt test light between the (K32) BTSI Solenoid Control

circuit and the (Z101) BTSI Solenoid Ground circuit. Turn the ignition on. With the DRBIIIT, actuate the BTSI Solenoid.

Does the test light illuminate brightly?

Yes >>

No >>

CHECK THE (K32) BTSI CONTROL CIRCUIT FOR AN OPEN

Turn the ignition off. Disconnect the BTSI Solenoid harness connector. Disconnect the Instrument Cluster C1 harness connector. Measure the resistance of the (K32) BTSI Solenoid control circuit

between the BTSI Solenoid harness connector and the Instrument Cluster C1 harness connector.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Replace the BTSI Solenoid in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Repair the (Z101) BTSI Solenoid ground circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Repair the (K32) BTSI Solenoid control circuit for an open. Perform BODY VERIFICATION TEST - VER 1. (Refer to

BODY VERIFICATION TEST - VER 1.) Replace the Instrument Cluster in accordance with the ser-

vice information. Perform BODY VERIFICATION TEST - VER 1. (Refer to

BODY VERIFICATION TEST - VER 1.)

Page 43

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 43

BTSI OUTPUT CIRCUIT SHORTED OR OPEN

Page 44

8J - 44 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

BTSI OUTPUT CIRCUIT SHORTED OR OPEN (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition in the Unlock or On position and the operator’s foot applied to the brake pedal. (Customer Complaint: Vehicle can be shifted out of Park without pressing the brake pedal.)

• Set Condition:

The Instrument Cluster detects a 909 or low value on the input circuit for the BTSI when ON.

Possible Causes

(Z101) BTSI SOLENOID GROUND CIRCUIT OPEN (K32) BTSI SOLENOID CONTROL CIRCUIT SHORTED TO THE (Z101) BTSI SOLENOID GROUND CIRCUIT (K32) BTSI SOLENOID CONTROL CIRCUIT SHORT TO GROUND (K32) BTSI SOLENOID CONTROL CIRCUIT OPEN BTSI SOLENOID INSTRUMENT CLUSTER

Diagnostic Test

TCM DTC PRESENT

Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display any TCM DTCs?

Yes >>

No >>

CHECK THE (Z101) BTSI SOLENOID GROUND CIRCUIT FOR AN OPEN

Turn the ignition off. Disconnect the BTSI Solenoid harness connector. Measure the resistance between ground and the (Z101) BTSI Solenoid

Ground circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Refer to Transmission for the related symptom(s). Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 2

Repair the (Z101) BTSI Solenoid Ground circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 3

Page 45

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 45

BTSI OUTPUT CIRCUIT SHORTED OR OPEN (CONTINUED)

CHECK THE (K32) BTSI SOLENOID CONTROL CIRCUIT FOR A SHORT TO THE (Z101) BTSI SOLENOID

GROUND CIRCUIT

Disconnect the Instrument Cluster C1 harness connector. Measure the resistance between the (K32) BTSI Solenoid Control cir-

cuit and the (Z101) BTSI Solenoid Ground circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

CHECK THE (K32) BTSI SOLENOID CONTROL CIRCUIT FOR A SHORT TO GROUND

Measure the resistance between ground and the (K32) BTSI Solenoid Control circuit.

Is the resistance below 5.0 ohms?

Repair the (K32) BTSI Solenoid Control circuit for a short to the (Z101) BTSI Solenoid Ground circuit.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 4

Yes >>

No >>

Repair the (K32) BTSI Solenoid Control circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 5

Page 46

8J - 46 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

BTSI OUTPUT CIRCUIT SHORTED OR OPEN (CONTINUED)

CHECK THE (K32) BTSI SOLENOID CONTROL CIRCUIT FOR AN OPEN

Measure the resistance of the (K32) BTSI Solenoid Control circuit between the Solenoid connector and the Instrument Cluster C1 connector.

Is the resistance above 5.0 ohms?

Yes >>

No >>

BTSI SOLENOID

Reconnect the Instrument Cluster C1 harness connector. Turn the ignition on. With the DRBIIIT, actuate the BTSI Solenoid. Using a 12-volt test light connected to ground, check for voltage on

the (K32) BTSI Solenoid Control circuit.

Repair the (K32) BTSI Solenoid Control circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 6

Does the test light illuminate brightly?

Yes >>

No >>

Replace the BTSI Solenoid in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 47

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 47

IGNITION RUN-START CIRCUIT RATIONALITY CHECK

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

Continuously.

• Set Condition:

Ignition RUN/START Voltage below 5 volts while the RUN/ACC and UNLOCK voltage status is logic high.

Possible Causes

IGNITION RUN-START FUSE OPEN (F21) IGNITION RUN-START CIRCUIT OPEN INSTRUMENT CLUSTER

Diagnostic Test

IGNITION RUN-START FUSE OPEN

Turn the ignition off. Inspect the Ignition Run-Start fuse in the PDC.

Is the fuse open?

Yes >>

No >>

CHECK THE (F1) IGNITION RUN-START CIRCUIT FOR AN OPEN

Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage of the (F21) Ignition Run-Start circuit.

Is the voltage above 5.0 volts?

Yes >>

No >>

Using the wiring diagram/schematic as a guide, inspect the wiring and connectors for a short to ground condition.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.) Go To 2

Replace the Instrument Cluster in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Repair the (F21) Ignition Run-Start circuit for an open. Perform BODY VERIFICATION TEST - VER 1. (Refer to

BODY VERIFICATION TEST - VER 1.)

Page 48

8J - 48 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

IGNITION UNLOCK CIRCUIT RATIONALITY CHECK

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

Continuously.

• Set Condition:

One second of Run/Start above 5 Volts, Unlock Status Low, and Run/ACC Status High.

Possible Causes

IGNITION UNLOCK-RUN-START FUSE OPEN (F21) IGNITION UNLOCK-RUN-START CIRCUIT OPEN INSTRUMENT CLUSTER

Diagnostic Test

IGNITION UNLOCK-RUN-START FUSE OPEN

Turn the ignition off. Inspect the Ignition Unlock-Run-Start fuse in the PDC.

Is the fuse open?

Yes >>

No >>

INSTRUMENT CLUSTER

Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage of the (F1) Ignition Unlock-Run-Start circuit.

Is the voltage above 10 volts?

Yes >>

No >>

Using the wiring diagram/schematic as a guide, inspect the wiring and connectors for a short to ground condition.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.) Go To 2

Replace the Instrument Cluster in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Repair the (F1) Ignition Unlock-Run-Start circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 49

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 49

INCORRECT ODOMETER VALUE FOUND

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

During power up.

• Set Condition:

If the Instrument Cluster detects the odometer value memory is corrupted, this code will set. When this code is set the VF Odometer displays[--].

Possible Causes

INSTRUMENT CLUSTER

Diagnostic Test

INSTRUMENT CLUSTER

CAUTION: Do not attempt to exchange or (swap( an Instrument Cluster from one vehicle to another. Module memory/configuration damage may occur. Refer to the Instrument Cluster Caution in the Service Information.

NOTE: When this code is set the VF Odometer will display dashes (- -). NOTE: If the PCM has been replaced, program the new module with the correct VIN.

Ensure that the Instrument Cluster has not been damaged or previously installed in a different vehicle. With the DRBIIIT, erase DTCs. Cycle the ignition. With the DRBIIIT, read DTCs.

Did this DTC reset?

Yes >>

No >>

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Test Complete.

Page 50

8J - 50 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

INTERNAL MODULE BOOTLOADER FAILURE

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

At power up for the module.

• Set Condition:

If the checksum value does not equate to the calculated value.

Possible Causes

INSTRUMENT CLUSTER

When this code is set, the Instrument Cluster must be replaced.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 51

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 51

INTERNAL MODULE FLASH MEMORY CHECKSUM FAILURE

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

At power up for the module.

• Set Condition:

If the checksum value does not equate to the calculated value. Indicates that the Instrument Cluster internal memory is corrupted.

Possible Causes

INSTRUMENT CLUSTER

When this code is set, the Instrument Cluster must be replaced.

Repair

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 52

8J - 52 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

PCI BUS INTERNAL FAILURE

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

Continuously.

• Set Condition:

The Instrument Cluster fails the loopback test on the PCI Bus.

Possible Causes

INSTRUMENT CLUSTER

Diagnostic Test

INSTRUMENT CLUSTER

NOTE: If this is an active DTC, answer yes to the question.

With the DRBIIIT, erase DTCs. Cycle the ignition and wait approximately 1 minute. With the DRBIIIT, read DTCs.

Did this DTC reset?

Yes >>

No >>

Replace the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Test Complete.

Page 53

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 53

PCM MESSAGES NOT RECEIVED

Page 54

8J - 54 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

PCM MESSAGES NOT RECEIVED (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The MIC does not receive any messages from the PCM for at least 5 seconds.

Possible Causes

(D25) PCI BUS CIRCUIT OPEN POWERTRAIN CONTROL MODULE

PCM MESSAGES NOT RECEIVED

Turn the ignition on.

NOTE: To proceed in this test, the DTC must be active.

With the DRB, enter SYSTEM MONITORS then J1850 MODULE SCAN.

Is the PCM active on the BUS?

Yes >>

No >>

ATTEMPT TO COMMUNICATE WITH THE PCM

Turn the ignition on. With the DRB, attempt to communicate with the PCM.

Was the DRB able to communicate with the PCM?

Yes >> No >>

Check the condition of the J1850 Bus circuit wiring. Erase DTC, if DTC resets replace the Instrument Cluster in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.) Go To 2

Go To 3 Refer to the communication category and perform the appropriate symptom.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 55

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 55

PCM MESSAGES NOT RECEIVED (CONTINUED)

CHECK THE (D25) PCI BUS CIRCUIT FOR AN OPEN

Turn the ignition off. Disconnect the PCM harness connector.

CAUTION: If NGC, DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.

Disconnect the DRBIIIT from the DLC. Measure the resistance of the (D25) PCI Bus circuit between the PCM

connector (from special tool #8815 if NGC) and the DLC.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Replace and program the Powertrain Control Module in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Repair the (D25) PCI Bus circuit for an open. Perform BODY VERIFICATION TEST - VER 1. (Refer to

BODY VERIFICATION TEST - VER 1.)

Page 56

8J - 56 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

PRNDL SWITCH INPUT CIRCUIT OPEN (DIESEL ONLY)

Page 57

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 57

PRNDL SWITCH INPUT CIRCUIT OPEN (DIESEL ONLY) (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The instrument Cluster detects that an open condition exists in the PRNDL circuit.

Possible Causes

(T917) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER MUX CIRCUIT OPEN (T117) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY CIRCUIT OPEN TRANSMISSION RANGE SENSOR INSTRUMENT CLUSTER

Diagnostic Test

TRANSMISSION RANGE SENSOR

NOTE: Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle.

Turn the ignition off. Disconnect the Transmission Range Sensor harness connector. Connect a jumper wire between cavity 2 and cavity 5. Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display PRNDL Switch Input Circuit Shorted?

Yes >>

No >>

Replace the Transmission Range Sensor in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 2

Page 58

8J - 58 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

PRNDL SWITCH INPUT CIRCUIT OPEN (DIESEL ONLY) (CONTINUED)

CHECK THE (T917) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER MUX CIRCUIT FOR AN

OPEN

Turn the ignition off. Disconnect the Transmission Range Sensor harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (T917) Transmission Range Sensor

Electronic Cluster MUX circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

CHECK THE (T117) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY CIRCUIT

FOR AN OPEN

Disconnect the Instrument Cluster C4 harness connector. Measure the resistance of the (T117) Transmission Range Sensor

Electronic Cluster 5 Volt Supply circuit.

Is the resistance above 5.0 ohms?

Repair the (T917) Transmission Range Sensor Electronic Cluster MUX circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 3

Yes >>

No >>

Repair the (T117) Transmission Range Sensor Electronic Cluster 5 Volt Supply circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 59

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 59

PRNDL SWITCH INPUT CIRCUIT SHORTED (DIESEL ONLY)

Page 60

8J - 60 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

PRNDL SWITCH INPUT CIRCUIT SHORTED (DIESEL ONLY) (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The instrument Cluster detects that a short condition exists in the PRNDL circuit.

Possible Causes

(T117) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY CIRCUIT SHORT TO THE (T917) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER MUX CIRCUIT

(T117) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY CIRCUIT SHORT TO GROUND

TRANSMISSION RANGE SENSOR INSTRUMENT CLUSTER

Diagnostic Test

TRANSMISSION RANGE SENSOR

NOTE: Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle.

Turn the ignition off. Disconnect the Transmission Range Sensor harness connector. Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display PRNDL Input Circuit Open?

Yes >>

No >>

Replace the Transmission Range Sensor in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 2

Page 61

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 61

PRNDL SWITCH INPUT CIRCUIT SHORTED (DIESEL ONLY) (CONTINUED)

(T117) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY CIRCUIT SHORT TO

THE (T917) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER MUX CIRCUIT

Turn the ignition off. Disconnect the Transmission Range Sensor harness connector. Disconnect the Instrument Cluster C3 and C4 harness connectors. Measure the resistance between the (T117) Transmission Range Sen-

sor Electronic Cluster 5 Volt Supply circuit and the (T917) Transmission Range Sensor Electronic Cluster MUX circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

(T117) TRANSMISSION RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY CIRCUIT SHORT TO

GROUND

Measure the resistance between ground and the (T117) Transmission Range Sensor Electronic Cluster 5 Volt Supply circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Repair the (T117) Transmission Range Sensor Electronic Cluster 5 Volt Supply circuit for a short to the (T917) Transmission Range Sensor Electronic Cluster MUX circuit.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 3

Repair the (T117) Transmission Range Sensor Electronic Cluster 5 Volt Supply circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 62

8J - 62 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

VIN CHECKSUM ERROR

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

Once the Instrument Cluster learns a valid VIN and another valid VIN is transmitted on the bus. The Instrument Cluster decodes the VIN that is transmitted on the bus by the PCM. If the VIN is valid the Instrument Cluster stores the information. If the VIN information does not equate to the encrypted value then the fault is set.

Possible Causes

POWERTRAIN CONTROL MODULE

NOTE: The V.I.N. is embedded into the Instrument Cluster memory during production and can not be modified. Do not attempt to (swap( a cluster from one vehicle to another. Refer to the Instrument Cluster Caution in the Service Information.

NOTE: This code will only be set if the PCM has been exchanged or (swapped( into this vehicle from another.

If any components have been exchanged or 9swapped9, reinstall the original parts. With the DRBIIIT, erase DTCs. Cycle the ignition. With the DRBIIIT, read DTCs.

If this code resets, view repair.

Repair

Replace and program the Powertrain Control Module in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 63

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 63

VIN PREVIOUSLY STORED

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

Once the Instrument Cluster learns a valid VIN and another VIN is transmitted on the bus. This code can only be set if a PCM or MIC has been exchanged or 9swapped9 from another vehicle. The VIN is embedded in both the cluster and the PCM and cannot be used in any other vehicle.

Possible Causes

POWERTRAIN CONTROL MODULE

Diagnostic Test

POWERTRAIN CONTROL MODULE

NOTE: This code will only be set if the PCM has been exchanged or (swapped( into this vehicle from another.

If any components have been exchanged or 9swapped9, reinstall the original parts. With the DRBIIIT, erase DTCs. Cycle the ignition. With the DRBIIIT, read DTCs.

If this code resets, view repair.

Repair

Replace and program the Powertrain Control Module in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 64

8J - 64 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*ALL GAUGES INOPERATIVE

Page 65

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 65

*ALL GAUGES INOPERATIVE (CONTINUED)

For a complete wiring diagram Refer to Section 8W.

Possible Causes

NO RESPONSE - PCI BUS NO RESPONSE - PCI BUS - POWERTRAIN CONTROL MODULE PCI BUS - INSTRUMENT CLUSTER (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT SHORT TO GROUND (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT SHORT TO GROUND (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT OPEN (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT OPEN (Z18) INSTRUMENT CLUSTER GROUND CIRCUIT FOR AN OPEN INSTRUMENT CLUSTER

Diagnostic Test

NO RESPONSE - PCI BUS

NOTE: NOTE: Diagnose and repair any MIC, PCM (ECM if diesel equipped), or Communication DTCs before proceeding with this test.

Turn the ignition on. With the DRBIIIT, select System Monitors, then J1850 Module Scan.

Does the DRBIIIT display MIC PRESENT on the BUS?

Yes >> No >>

NO RESPONSE - PCI BUS - POWERTRAIN CONTROL MODULE

Turn the ignition on. With the DRBIIIT, select Body, MIC, SYSTEM TESTS, PCM Monitor.

Does the DRBIIIT display PCM INACTIVE on the BUS?

Yes >>

No >>

PCI BUS - INSTRUMENT CLUSTER

Turn the ignition on. With the DRBIIIT, select Body, MIC, MODULE DISPLAY.

Does the DRBIIIT display NO RESPONSE from MIC?

Yes >>

No >>

Go To 2 Refer to the COMMUNICATION category and perform the appropriate symptom.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 3

Refer to the COMMUNICATION category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 4

Page 66

8J - 66 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*ALL GAUGES INOPERATIVE (CONTINUED)

CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR A SHORT TO

GROUND

Turn the ignition off. Inspect the #20 Fuse in the PDC. If the fuse is open, replace with proper rated fuse. Turn the ignition on for one minute. Turn the ignition off. Inspect the #20 Fuse in the PDC.

Is the fuse open?

Yes >>

No >>

CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR A SHORT TO

GROUND

Turn the ignition off. Remove and inspect the #29 Fuse in the PDC. If the fuse is open, replace with the proper rated fuse. Turn the ignition on for 1 minute. Turn the ignition off. Remove and inspect the #29 Fuse in the PDC.

Is the fuse open?

Yes >>

No >>

Repair the (F21) Fused Ignition Switch Output (Unlock/ Run) circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 5

Repair the (F1) Fused Ignition Switch Output (Run/Start) circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 6

Page 67

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 67

*ALL GAUGES INOPERATIVE (CONTINUED)

CHECK THE (F21) FUSED IGNITION SWITCH OUTPUT (RUN/START) CIRCUIT FOR AN OPEN

Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F21) Fused Ignition Switch Output

(Run/Start) circuit and ground.

Is the voltage below 10.5 volts?

Yes >>

No >>

CHECK THE (F1) FUSED IGNITION SWITCH OUTPUT (OFF/RUN/START) CIRCUIT FOR AN OPEN

Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Turn the ignition on. Measure the voltage between the (F1) Fused Ignition Switch Output

(Off/Run/Start) circuit and ground.

Is the voltage below 10.5 volts?

Yes >>

No >>

Repair the (F21) Fused Ignition Switch Output (Run/Start) circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 7

Repair the (F1) Fused Ignition Switch Output (Off/Run/ Start) circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 8

Page 68

8J - 68 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*ALL GAUGES INOPERATIVE (CONTINUED)

CHECK THE (Z18) INSTRUMENT CLUSTER GROUND CIRCUIT FOR AN OPEN

Turn the ignition off. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (Z18) Instrument

Cluster Ground circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Repair the (Z18) Instrument Cluster Ground circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 69

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 69

*ANY PCI INDICATOR INOPERATIVE

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

NO RESPONSE - PCI BUS NO RESPONSE - INSTRUMENT CLUSTER INDICATOR MESSAGE NOT RECEIVED INSTRUMENT CLUSTER

Diagnostic Test

NO RESPONSE - PCI BUS

Turn the ignition on. With the DRBIIIT, select System Monitors, then J1850 Module Scan.

Does the DRBIIIT display MIC PRESENT on the BUS?

Yes >> No >>

NO RESPONSE - INSTRUMENT CLUSTER

With the DRBIIIT, select MIC, then MODULE DISPLAY.

Does the DRBIIIT display NO RESPONSE from MIC?

Yes >>

No >>

NO RESPONSE - PCI BUS

With the DRBIIIT, select Body, MIC, MONITORS, PCI BUS MONITORS.

Does the DRBIIIT display PCM INACTIVE on the BUS?

Yes >>

No >>

Go To 2 Refer to the COMMUNICATION category and perform the appropriate symptom.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Refer to the symptom list for problems related to *NO RESPONSE FROM THE INSTRUMENT CLUSTER.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.) Go To 3

Refer to the symptom list for problems related to *NO RESPONSE FROM THE POWERTRAIN CONTROL MODULE.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.) Go To 4

Page 70

8J - 70 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*ANY PCI INDICATOR INOPERATIVE (CONTINUED)

INDICATOR MESSAGE NOT RECEIVED

NOTE: NOTE: Diagnose and repair any PCM or BCM DTCs before proceeding with this test.

Perform the Instrument Cluster Self Test. Depress and hold the Trip Odometer button while turning the ignition from the off to the on position. Observe the indicator in question.

Did the indicator illuminate?

Yes >>

No >>

Refer to the appropriate Service Information category to diagnose the related system. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 71

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 71

*BRAKE WARNING INDICATOR ALWAYS ON

Page 72

8J - 72 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*BRAKE WARNING INDICATOR ALWAYS ON (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

(B20) BRAKE FLUID LEVEL SENSOR SENSE CIRCUIT SHORT TO GROUND (B25) PARK BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND BRAKE FLUID LEVEL SENSOR PARK BRAKE SWITCH ANTI-LOCK BRAKES MODULE INSTRUMENT CLUSTER

Diagnostic Test

BRAKE FLUID LEVEL SENSOR

NOTE: Diagnose and repair any MIC, Brake, or Communication DTCs before proceeding with this test.

Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance of the Brake Fluid Level Sensor between pin 1

and pin 2.

Does the resistance measure less than 900 ohms?

Yes >>

No >>

Replace the Brake Fluid Level Sensor in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 2

Page 73

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 73

*BRAKE WARNING INDICATOR ALWAYS ON (CONTINUED)

(B20) BRAKE FLUID LEVEL SENSOR SENSE CIRCUIT SHORT TO GROUND

Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance between ground and the (B20) Brake Fluid

Level Sensor Sense circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

PARK BRAKE SWITCH

Turn the ignition off. Disconnect the Park Brake Switch harness connector. Turn the ignition on. Observe the Brake warning indicator.

Did the Brake warning indicator illuminate briefly and then turn off?

Repair the (B20) Brake Fluid Level Sensor Sense circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 3

Yes >>

No >>

Replace the Park Brake Switch in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 4

Page 74

8J - 74 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*BRAKE WARNING INDICATOR ALWAYS ON (CONTINUED)

(B25) PARK BRAKE SWITCH SENSE CIRCUIT SHORT TO GROUND

Turn the ignition off. Disconnect the Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (B25) Park Brake

Switch Sense circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

ANTI-LOCK BRAKES MODULE

Turn the ignition off. Reconnect any harness connector(s) that were previously disconnected. Turn the ignition on. With the DRBIIIT in Inputs/Outputs, read the Brake Fluid Level Sensor state.

Does the DRBIIIT display (Closed(?

Repair the (B25) Park Brake Switch Sense circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 5

Yes >>

No >>

Replace the Anti-lock Brakes Module in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 75

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 75

*BRAKE WARNING INDICATOR INOPERATIVE

Page 76

8J - 76 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*BRAKE WARNING INDICATOR INOPERATIVE (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

(Z420) BRAKE FLUID LEVEL SENSOR GROUND CIRCUIT OPEN (B25) PARK BRAKE SWITCH SENSE CIRCUIT OPEN (B20) BRAKE FLUID LEVEL SENSE CIRCUIT OPEN PARK BRAKE SWITCH BRAKE FLUID LEVEL SENSOR ANTI-LOCK BRAKES MODULE INSTRUMENT CLUSTER

Diagnostic Test

FAULT LOCATION

NOTE: Diagnose and repair any MIC, ABS, or Communication DTCs before proceeding with this test.

Is the Brake warning indicator only inoperative using the Park Brake?

Yes >> No >>

PARK BRAKE SWITCH

Disconnect the Park Brake Switch harness connector. Connect a jumper wire between the (B25) Park Brake Switch Sense

circuit and ground. Turn the ignition on. Observe the BRAKE indicator.

Did the BRAKE indicator illuminate?

Yes >>

No >>

Go To 2 Go To 4

Replace the Park Brake Switch in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 3

Page 77

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 77

*BRAKE WARNING INDICATOR INOPERATIVE (CONTINUED)

(B25) PARK BRAKE SWITCH SENSE CIRCUIT OPEN

Turn the ignition off. Disconnect the (B25) Park Brake Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (B25) Park Brake Switch Sense circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

BRAKE FLUID LEVEL SENSOR

Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on.

Repair the (B25) Park Brake Switch Sense circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Does the Brake warning indicator illuminate?

Yes >>

No >>

Replace the Brake Fluid Level Sensor in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 5

Page 78

8J - 78 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*BRAKE WARNING INDICATOR INOPERATIVE (CONTINUED)

(Z420) BRAKE FLUID LEVEL SENSOR GROUND CIRCUIT OPEN

Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Measure the resistance between ground and the (Z420) Brake Fluid

Level Sensor Ground circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

(B20) BRAKE FLUID LEVEL SENSE CIRCUIT OPEN

Turn the ignition off. Disconnect the Brake Fluid Level Sensor harness connector. Disconnect the Anti-lock Brakes Module harness connector. Measure the resistance of the (B20) Brake Fluid Level Sensor Sense

circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Repair the (Z420) Brake Fluid Level Sensor Ground circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 6

Repair the (B20) Brake Fluid Level Sensor Sense circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 7

Page 79

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 79

*BRAKE WARNING INDICATOR INOPERATIVE (CONTINUED)

INSTRUMENT CLUSTER

Turn the ignition off. Disconnect the Anti-lock Brakes Module harness connector. Connect a jumper wire between the (B25) Brake Fluid Level Sensor

Sense circuit and ground. With the DRBIIIT in Inputs/Outputs, read the Brake Fluid Level Sensor

state.

Does the DRBIIIT display (Closed(?

Yes >>

No >>

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Anti-lock Brakes Module in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 80

8J - 80 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*FUEL GAUGE INACCURATE

Page 81

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 81

*FUEL GAUGE INACCURATE (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

FUEL LEVEL SENSOR WIRING INSTRUMENT CLUSTER

Diagnostic Test

DTC PRESENT

NOTE: Diagnose and repair any PCI Bus problems before proceeding with this test.

Turn the ignition on. With the DRBIIIT, read the PCM DTCs.

Does the DRBIIIT display any Fuel Level Sensor related DTC?

Yes >>

No >>

INSTRUMENT CLUSTER

Perform the Instrument Cluster Self Test as follows: Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the Fuel Gauge during the Self Test. The Fuel Gauge pointer should pause at each of these following positions: E, 1/4, 1/2, 3/4, Full, and back to E.

Does the Fuel Gauge function as described above?

Yes >> No >>

Refer to the Powertrain Diagnostic Information for the related symptom(s). Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 5.

Go To 2

Go To 3 Replace the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 82

8J - 82 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*FUEL GAUGE INACCURATE (CONTINUED)

FUEL LEVEL SENSOR WIRING

Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Disconnect the PCM C2 and C3 harness connectors. Measure the resistance of the (N4) Fuel Level Sensor Signal circuit

between the Fuel Pump Module harness connector and the PCM harness connector.

Measure the resistance of the (K900) Sensor Ground circuit between the Fuel Pump Module harness connector and the PCM harness connector.

Is the resistance below 5.0 ohms on both circuits.

Yes >>

No >>

Replace the Fuel Level Sensor in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Repair the circuits with a resistance above 5.0 ohms for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 83

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 83

*ONE GAUGE INOPERATIVE - GAS ENGINES

For a complete wiring diagram Refer to Section 8W.

Possible Causes

POWERTRAIN CONTROL MODULE INSTRUMENT CLUSTER

Diagnostic Test

POWERTRAIN CONTROL MODULE

Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display any PCM DTCs?

Yes >>

No >>

INSTRUMENT CLUSTER

Turn the ignition off. Perform the Instrument Cluster Self Test.

NOTE: NOTE: The Self Test can be initiated manually by depressing and holding the Trip Reset button while turning the ignition on, or by using the DRBIIIT.

Observe the gauge in question while the Instrument Cluster performs the Self Test. The gauges should position at the following calibrations points: Speedometer MPH: 0, 20, 60, 90 Tachometer Gas: 0, 1000, 3000, 6000 Fuel: E, 1/4, 1/2, 3/4, F Coolant: Cold, 1/4, 1/2, 3/4, HI Volts: 6, 9, 12, 15, 17

Did the gauge in question operate properly?

Yes >>

No >>

Refer to the DRIVEABILITY category and perform the appropriate symptom. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 2

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.) Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 84

8J - 84 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES)

For a complete wiring diagram Refer to Section 8W.

Possible Causes

DTC PRESENT INSTRUMENT CLUSTER

Diagnostic Test

DTC PRESENT

NOTE: Ensure that the correct Instrument Cluster is installed and is correctly configured for the vehicle. NOTE: Ensure that there is communication between the Cluster and PCM before proceeding with this test. NOTE: Diagnose and repair any DTCs before proceeding with this test. NOTE: Ensure that the PCM passes the Shift Lever Test with the DRBIIIT before proceeding with this test.

Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display any MIC or PCM DTCs?

Yes >>

No >>

INSTRUMENT CLUSTER

Perform the Instrument Cluster Self Test. Turn the ignition off. Press and hold the Trip/Reset button. Turn the ignition on. Observe the PRNDL display during the Self Test.

Did any part of the VF display fail to illuminate?

Yes >>

No >>

Refer to the correct symptom list for problems related to DTCs. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 2

Replace and program the Instrument Cluster in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

The condition is not present at this time. Monitor DRBIIIT parameters while wiggling the related wiring harness. refer to any Technical Service Bulletins (TSB) that may apply. Visually inspect the related wiring harness and connector terminals.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 85

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 85

*SEAT BELT WARNING INDICATOR ALWAYS OFF

Page 86

8J - 86 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*SEAT BELT WARNING INDICATOR ALWAYS OFF (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

(G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND INSTRUMENT CLUSTER

Diagnostic Art

CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR A SHORT TO GROUND

Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt

Switch Sense circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Repair the (G10) Seat Belt Switch Sense circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 87

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 87

*SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB

Page 88

8J - 88 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

(G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND INSTRUMENT CLUSTER

Diagnostic Test

(G10) SEAT BELT SWITCH SENSE CIRCUIT SHORT TO GROUND

Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Disconnect the Instrument Cluster C3 harness connector. Measure the resistance between ground and the (G10) Seat Belt

Switch Sense circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Repair the (G10) Seat Belt Switch Sense circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 89

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 89

*SEAT BELT WARNING INDICATOR ALWAYS ON

Page 90

8J - 90 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*SEAT BELT WARNING INDICATOR ALWAYS ON (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

(Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN (G10) SEAT BELT SWITCH SENSE CIRCUIT OPEN SEAT BELT SWITCH INSTRUMENT CLUSTER

Diagnostic Test

CHECK THE OPERATION OF THE SEAT BELT SWITCH

Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator.

Did the Seat Belt Warning Indicator illuminate for approximately 4 seconds and then turn off?

Yes >>

No >>

CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN

Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Measure the resistance between ground and the (Z951) Seat Belt

Switch Ground circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Replace the Seat Belt Switch in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 2

Repair the (Z951) Seat Belt Switch Ground circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 3

Page 91

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 91

*SEAT BELT WARNING INDICATOR ALWAYS ON (CONTINUED)

CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN

Measure the resistance of the (G10) Seat Belt Switch Sense circuit between the Seat Belt Switch connector and the Instrument Cluster C3 connector.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Repair the (G10) Seat Belt Switch Sense circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Page 92

8J - 92 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB

Page 93

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 93

*SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB (CONTINUED)

For the Instrument Cluster circuit diagram (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

Possible Causes

(F983) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) CIRCUIT OPEN (Z951) SEAT BELT SWITCH GROUND CIRCUIT OPEN (G10) SEAT BELT SWITCH SENSE CIRCUIT OPEN SEAT BELT TENSIONER REDUCER SEAT BELT SWITCH INSTRUMENT CLUSTER

(F983) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) CIRCUIT OPEN

Turn the ignition off. Disconnect the Seat Belt Tensioner Reducer harness connector. Turn the ignition on. Measure the voltage between the (F983) Fused Ignition Switch Output

(Run-Acc) circuit and ground in the Tensioner Reducer harness connector.

Is the voltage above 10.5 volts?

Yes >> No >>

Go To 2 Repair the (F983) Fused Ignition Switch Output (Run-Acc)

circuit for an open. Perform BODY VERIFICATION TEST - VER 1. (Refer to

BODY VERIFICATION TEST - VER 1.)

Page 94

8J - 94 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS DR/DH

*SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB (CONTINUED)

SEAT BELT TENSIONER REDUCER

Ensure that the Seat Belt Tensioner Reducer harness connector is connected.

Measure the voltage between the (G10) Seat Belt Switch Sense circuit and ground in the Seat Belt Tensioner Reducer harness connector (cavity 2).

Is there any voltage present?

Yes >> No >>

SEAT BELT SWITCH

Turn the ignition off. Disconnect the Seat Belt Switch harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. Observe the Seat Belt Warning Indicator.

Did the Seat Belt Warning Indicator illuminate?

Yes >>

No >>

Go To 3 Replace the Seat Belt Tensioner Reducer in accordance

with the Service Information. Perform BODY VERIFICATION TEST - VER 1. (Refer to

BODY VERIFICATION TEST - VER 1.)

Replace the Seat Belt Switch in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Go To 4

Page 95

DR/DH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 95

*SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB (CONTINUED)

CHECK THE (Z951) SEAT BELT SWITCH GROUND CIRCUIT FOR AN OPEN

Turn the ignition off. Measure the resistance between ground and the (Z951) Seat Belt

Switch circuit.

Is the resistance below 5.0 ohms?

Yes >> No >>

CHECK THE (G10) SEAT BELT SWITCH SENSE CIRCUIT FOR AN OPEN

Disconnect the Instrument Cluster C3 harness connector. Measure the resistance of the (G10) Seat Belt Switch Sense circuit

between the Seat Belt Switch connector and the Instrument Cluster C3 connector.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Go To 5 Repair the (Z951) Seat Belt Switch Ground circuit for an

open. Perform BODY VERIFICATION TEST - VER 1. (Refer to

BODY VERIFICATION TEST - VER 1.)

Repair the (G10) Seat Belt Switch Sense circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace and configure the Instrument Cluster in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

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SCHEMATICS AND DIAGRAMS

INSTRUMENT CLUSTER SYSTEM SCHEMATIC

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INSTRUMENT CLUSTER -SERVICE INFORMATION

TABLE OF CONTENTS

page page

INSTRUMENT CLUSTER -SERVICE

INFORMATION

DESCRIPTION .........................98

OPERATION ..........................104

DIAGNOSIS AND TESTING

INSTRUMENT CLUSTER ...............108

REMOVAL ............................113

DISASSEMBLY ........................113

ASSEMBLY ...........................114

INSTALLATION ........................116

ABS INDICATOR

DESCRIPTION ........................116

OPERATION ..........................117

AIRBAG INDICATOR

DESCRIPTION ........................117

OPERATION ..........................118

BRAKE/PARK BRAKE INDICATOR

DESCRIPTION ........................118

OPERATION ..........................118

DIAGNOSIS AND TESTING

BRAKE INDICATOR ...................119

CARGO LAMP INDICATOR

DESCRIPTION ........................120

OPERATION ..........................120

CHECK GAUGES INDICATOR

DESCRIPTION ........................120

OPERATION ..........................121

CRUISE INDICATOR

DESCRIPTION ........................122

OPERATION ..........................122

DOOR AJAR INDICATOR

DESCRIPTION ........................123

OPERATION ..........................123

ENGINE TEMPERATURE GAUGE

DESCRIPTION ........................123

OPERATION ..........................124

ETC INDICATOR

DESCRIPTION ........................125

OPERATION ..........................125

FUEL GAUGE

DESCRIPTION ........................126

OPERATION ..........................126

GEAR SELECTOR INDICATOR

DESCRIPTION ........................127

OPERATION ..........................127

HIGH BEAM INDICATOR

DESCRIPTION ........................128

OPERATION ..........................128

LAMP OUT INDICATOR

DESCRIPTION ........................129

OPERATION ..........................129

LOW FUEL INDICATOR

DESCRIPTION ........................130

OPERATION ..........................130

MALFUNCTION INDICATOR LAMP (MIL)

DESCRIPTION ........................131

OPERATION ..........................131

ODOMETER

DESCRIPTION ........................132

OPERATION ..........................133

OIL PRESSURE GAUGE

DESCRIPTION ........................133

OPERATION ..........................134

GAUGE-ENGINE OIL TEMPERATURE

DESCRIPTION ........................135

OPERATION ..........................136

DIAGNOSIS AND TESTING

OIL TEMPERATURE GAUGE ............137

OIL TEMPERATURE SENSOR ...........138

REMOVAL ............................138

INSTALLATION ........................139

SEATBELT INDICATOR

DESCRIPTION ........................140

OPERATION ..........................140

STANDARD PROCEDURE

ENHANCED SEATBELT REMINDER

PROGRAMMING .....................141

SECURITY INDICATOR

DESCRIPTION ........................141

OPERATION ..........................141

SERVICE 4WD INDICATOR

DESCRIPTION ........................142

OPERATION ..........................143

SPEEDOMETER

DESCRIPTION ........................143

OPERATION ..........................144

TACHOMETER

DESCRIPTION ........................144

OPERATION ..........................145

TOW/HAUL INDICATOR

DESCRIPTION ........................145

OPERATION ..........................146

TRANS TEMP INDICATOR

DESCRIPTION ........................146

OPERATION ..........................146

TURN SIGNAL INDICATOR

DESCRIPTION ........................147

OPERATION ..........................147

UPSHIFT INDICATOR

DESCRIPTION ........................148

OPERATION ..........................149

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VOLTAGE GAUGE

DESCRIPTION ........................149

OPERATION ..........................150

WAIT-TO-START INDICATOR

DESCRIPTION ........................151

OPERATION ..........................151

WASHER FLUID INDICATOR

DESCRIPTION ........................151

OPERATION ..........................152

WATER-IN-FUEL INDICATOR

DESCRIPTION ........................152

OPERATION ..........................152

INSTRUMENT CLUSTER -SERVICE INFORMATION

DESCRIPTION

The instrument cluster (2) for this model is an ElectroMechanical Instrument Cluster (EMIC) that is located in the instrument panel (1) above the steering column opening, directly in front of the driver. 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 that is integral to a cluster lens, hood and mask unit (4). 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 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 (2), which is secured to the cluster housing with a single screw (1), 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

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back of the cluster circuit board that joins it to the optional external Remote Keyless Entry (RKE) module 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 module on vehicles that are so equipped.

Sandwiched between the rear cover and the lens, hood and mask unit is the cluster housing (3). The 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 transducer, 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 stencillike cutouts. A rectangular opening in the overlay at the base of both the speedometer and the 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 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 circuit board is equipped with an audible tone transducer and pro- gramming 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).

• Audio System Cabin Equalization - The EMIC stores the cabin equalization curves for various optional speaker system architectures for use by the radio. The EMIC provides this information when requested by the radio over the PCI data bus. Changing the cabin equalization settings of the EMIC requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.

• Brake Lamp Control - The EMIC provides electronic brake lamp request messages to the Front Control Mod- ule (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 - On vehicles with an optional automatic transmission 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 on the driver side front door. A door cylinder lock switch is used only on models equipped with the optional Vehicle Theft Security System (VTSS).

• 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. The EMIC also monitors an input from 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 inte-

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rior lighting returns to normal operation and control. These Enhanced Accident Response System (EARS) features are each dependent upon a functional vehicle electrical system following the vehicle impact event.

• Exterior Lighting Control - The EMIC provides 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 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 at full intensity 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 mes- sages 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).

• Horn Control - The EMIC monitors an input from the horn switch and provides electronic horn request mes- sages to the Front Control Module (FCM) located on the Integrated Power Module (IPM) for horn relay control. The EMIC also controls horn relay operation in this manner to provide the horn features of the optional Remote Keyless Entry (RKE) or Vehicle Theft Security System (VTSS).

• Interior Lamp Load Shedding - The EMIC provides a battery saver feature which will automatically turn off all interior lamps and the cargo lamps if they remain on after a timed interval of about five minutes.

• Interior Lighting Control - The EMIC monitors 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 monitors hard wired multiplexed inputs from the headlamp switch on the instrument panel, then 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.

• Power Locks - The EMIC monitors inputs from the power lock switches and the Remote Keyless Entry (RKE) module (optional) to provide control of the power lock motors through high side driver outputs to the 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 unlock-all-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.

• Turn Signal & Hazard Warning Lamp Control - The EMIC monitors hard wired multiplexed inputs from the multi-function switch on the steering column, then 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 the vehicle speed remains greater than about twenty-four kilometers-per-hour (fifteen miles-per-hour).

• Vacuum Fluorescent Display Synchronization - The EMIC monitors hard wired multiplexed inputs from the headlamp switch on the instrument panel, then 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 coor-

Dodge Instrument Cluster 3500 2005, Instrument Cluster 2500 2005, Instrument Cluster 1500 2005 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual