Ford Workshop Service and Repair Manuals

Principles of Operation

The instrument cluster is a mix of intelligent and hardwired electrical signals and has a built-in self-test feature. The instrument cluster is connected to the powertrain control module (PCM), anti-lock brake system (ABS), traction control (TC) (if equipped) and stability assist (if equipped) by a control area network (CAN) bus. This link allows the instrument cluster and the PCM to communicate with each other. The instrument cluster consists of gauges and warning indicators. On the high series instrument cluster a trip computer is fitted to the information and message center.

When the ignition switch is turned to position II from either position 0 or position I the instrument cluster carries out a display test to verify that the warning indicators or indicator bulbs and monitored systems are functioning correctly. The warning indicators or indicator bulbs which illuminate during this test are:

• ABS
• Air bag system
• Charging system (the indicator is functional but will illuminate with the during the test)
• Brake system
• Low fuel
• Low oil pressure
• Malfunction indicator lamp (MIL)
• TC (if equipped)
• Overdrive (displayed in a liquid crystal display (LCD)) (if equipped)
• Glow plugs - Vehicles with diesel engine
• Frost (orange)
• Ice (red)
• Safety belt
• Speed control (displayed in LCD)
• Door ajar

Instrument Cluster Gauges

Engine Temperature Gauge

The engine temperature gauge uses information supplied by the engine coolant temperature (ECT) or the cylinder head temperature (CHT) sensor, through the PCM on the CAN bus. If the temperature signal is missing or invalid, the instrument cluster will move the temperature gauge pointer to below the cold position.

Fuel Gauge

The instrument cluster receives the fuel level information from the fuel level sensor (part of the fuel pump and sender unit on vehicles with a petrol engine). This is a variable resistor in the fuel gauge ground circuit. If the fuel level signal is missing or invalid, the instrument cluster will move the fuel gauge pointer to below the empty position and the low fuel warning indicator will illuminate.

The fuel gauge signal is damped to prevent pointer surge as the fuel in the fuel tank moves while the vehicle is in motion. When the ignition switch is turned to position 0 the fuel gauge pointer is moved to below the empty position.

Speedometer

On vehicles built up to 06/2003 vehicle speed information is received by the PCM from the vehicle speed sensor (VSS). On vehicles built 05/2003 onwards vehicle speed information is received by the PCM from the ABS module which uses inputs from the ABS sensors. The PCM calculates the vehicle speed using various factors one of these being tire size. The vehicle speed information is sent to the instrument cluster through the CAN bus, the vehicle speed information is then indicated in MPH or km/h on the speedometer gauge. If this information is missing or invalid, the speedometer will default to zero.

If the tire size is changed from that originally fitted it may be necessary to change the PCM configuration. This can be done using WDS.

Odometer

Vehicle speed information is received by the PCM from the VSS. The PCM uses the configured tire size to calculate distance travelled and inputs this information to the instrument cluster through the CAN bus. The instrument cluster displays this information in an LCD. If this information is missing or invalid, the LCD will display dashes. Also incorporated in this LCD is a tripmeter.

Tachometer

Engine speed information is received by the PCM from the crankshaft position (CKP) and camshaft position (CMP) sensors. The engine speed information is sent to the instrument cluster through the CAN bus. If this information is missing or invalid, the tachometer will default to zero.

Warning Indicators

Air Bag Warning Indicator

The air bag warning indicator is controlled by the air bag module.
REFER to: Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and Testing).

Low Fuel Warning Indicator

The instrument cluster receives the fuel level information from the fuel level sensor (part of the fuel pump and sender unit on vehicles with a petrol engine). When the fuel level in the fuel tank drops below a predetermined limit the low fuel warning indicator receives a direct signal from the fuel level sensor and illuminates the low fuel warning indicator. This information is also based on calculations from the distance to empty display.

ABS Warning Indicator

The instrument cluster receives the ABS information from the ABS module. If the ABS module detects an open circuit, a short to battery, or an ABS failure the ABS warning indicator will illuminate.
REFER to: Anti-Lock Control (206-09A Anti-Lock Control, Diagnosis and Testing).
The ABS Warning indicator must be enabled when a new instrument cluster is installed. For additional information REFER to Programmable Module Installation Routine on WDS.

Brake System Warning Indicator

The brake system warning indicator has multiple functions. The warning indicator illuminates if the brake fluid level is low or if the parking brake is set or if the electronic brake force distribution (EBD) fail input is high.
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).

Charging System Warning Indicator

The PCM controls the charging system warning indicator through the CAN bus. The warning indicator is illuminated if the charging system is not operating correctly, or if the ignition switch is turned to position II but the engine is not running.
REFER to: Charging System (414-00 Charging System - General Information, Diagnosis and Testing).
This signal is sent to the generic electronic module (GEM) and fuel fired booster heater (if equipped). The signal is used by the GEM to control when the fuel fired booster heater can be activated.

Traction Control (TC) Warning Indicator (if equipped)

The TC indicator is controlled by the ABS/TC module. The TC indicator flashes to indicate when a concern is present.
REFER to: Anti-Lock Control - Traction Control (206-09B Anti-Lock Control - Traction Control, Diagnosis and Testing).
This information is provided to the instrument cluster through the CAN bus. The TC system can be disabled by pressing the TC OFF button which is located in the instrument panel center console.

If the TC indicator is required it must be enabled when a new instrument cluster is installed. For additional information REFER to Programmable Module Installation Routine on WDS.

Low Oil Pressure Warning Indicator

The low oil pressure warning indicator has a direct connection to the engine oil pressure switch through the instrument cluster. With the ignition switch in position II, the low oil pressure warning indicator illuminates. After the engine is started, the oil pressure switch opens at a predetermined pressure, breaking the ground circuit continuity which extinguishes the oil pressure warning indicator.

Door Ajar Warning Indicator

The door ajar indicator is controlled by the GEM. The system operates by supplying a ground when the GEM detects a door(s) or liftgate/luggage compartment lid which is opened or not fully closed, which will illuminate the indicator. The GEM has a direct connection to the door ajar indicator through the instrument cluster.

Frost Warning Indicator or Ice Warning Indicator

The ambient temperature is provided by the ambient temperature sensor to the PCM. The PCM provides this signal to the instrument cluster through the CAN bus. When the ambient temperature falls to 4°C (40°F) there is an audible chime from the GEM and the amber frost warning indicator illuminates. When the ambient temperature falls to 0°C (32°F) or below, the red ice warning indicator illuminates and the amber frost warning indicator is extinguished. This is to alert the driver to the possibility of icy roads.

On vehicles built up to 03/2003 the ice warning and frost warning indicators are separate LEDs

On vehicles built 03/2003 onwards the ice warning and frost warning indicator is a combined LED, that will change from amber to red depending on the conditions of the ambient temperature.

For additional information.
REFER to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation).

Glow Plug Warning Indicator - Vehicles with Diesel Engine

The glow plug warning indicator will illuminate when the ignition is in the ON position with the engine OFF while the glow plugs are heating. The glow plug warning indicator is controlled by the PCM through the CAN bus. The glow plug warning indicator will also flash to indicate the presence of a hard DTC.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel, Diagnosis and Testing) /
Fuel Charging and Controls (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).

High Beam Indicator

The high beam indicator has a direct connection to the steering column multifunction switch through the instrument cluster.

When high beam is selected on the steering column multifunction switch power is sent by a direct connection to the high beam indicator in the instrument cluster. The high beam indicator has a permanent ground and therefore when the power is supplied the indicator illuminates.

Left and Right Turn Signal Indicators

The left and right turn signal indicators have a direct connection to the GEM. The GEM provides a permanent ground to the turn signal indicators.

When the left or right turn signals are selected on the steering column multifunction switch power is sent through the GEM and instrument cluster to illuminate the left and right turn signal indicators.

Malfunction Indicator Lamp (MIL)

The MIL illuminates where the exhaust emissions are affected and an appropriate diagnostic trouble code (DTC) is registered in the PCM.

When an emission related DTC is registered in the PCM, the PCM will send a signal through the CAN bus to the instrument cluster to illuminate the MIL. The DTC and associated concern must be rectified and cleared from the PCM memory for the MIL to extinguish.

Liftgate/Luggage Compartment Release Inhibit

The GEM uses a direct connection to the instrument cluster to ascertain the current vehicle speed. If the vehicle speed is above 3 MPH (5 km/h) the GEM will inhibit the liftgate/luggage compartment lid from being opened using the remote luggage compartment release.

Ambient Temperature

The ambient temperature is provided by the ambient temperature sensor to the PCM. The PCM provides this signal to the instrument cluster through the CAN bus. The ambient temperature is displayed in the left-hand LCD in the instrument cluster. To change the ambient temperature from °C to °F press the left-hand reset button.

Warning Chimes

All warning chimes are generated by the GEM. The following warning chimes can be requested by the instrument cluster through the GEM to function on the vehicle:

• Reverse gear selected (if equipped)
• Low fuel
• Distance to fuel tank empty
• Frost/ice warning
• Overspeed chime (configurable if equipped)
• Trip computer mode select

Low Washer Fluid Warning Indicator

The low washer fluid warning indicator is controlled by the washer fluid level sensor installed into the windshield washer reservoir.

Information and Message Center Indicators and Warning Indicators

The information and message center is located in the left-hand LCD of a high series instrument cluster. The information and message center can supply the driver with the following information.

All the functions within the information and message center can be selected by pressing the INFO button on the directional indicator switch.

• Average speed
• Distance to empty
• Average fuel economy
• Outside air temperature

Average Speed

This function indicates the average vehicle speed calculated during the last 500 miles (804 km), or since the last reset. Press the left-hand reset button in the instrument cluster for 3 seconds at any time to reset the average speed calculated.

Distance to Empty

This function indicates the approximate distance the vehicle will travel using the remaining fuel in the fuel tank. Changes in driving pattern may cause this figure to vary. A short audible chime will be emitted when the remaining distance is 80 km (50 miles), 40 km (25 miles) and 20 km (10 miles).

Average Fuel Economy

This function indicates the average fuel consumption of the vehicle since the function was last reset. Press the left-hand reset button in the instrument cluster for 3 seconds at any time to reset the average fuel economy.

Gear Selection Display - Vehicles with 5-speed Automatic Transaxle

This function indicates what mode and gear the vehicle is in. If the transaxle is in automatic mode the display will show 'AUTO' and the selector lever indicator will display the gear selected. If the transaxle is in manual mode the display will show 'MAN' and the selector lever indicator will display the gear selected. The gear selection display is located in the information and message center which is located in the left-hand LCD of the instrument cluster

Control Area Network (CAN)

The CAN is an electronic link enabling the instrument cluster to communicate with the PCM, ABS/TC module and stability assist module. This creates a pathway through the data link connector (DLC) for WDS, although WDS uses the ISO link to access the instrument cluster control systems. This increases the WDS diagnostic capabilities. If DTC U1262 is retrieved from the vehicle this indicates that a breakdown in communication within the CAN has occurred at some point. This does not directly indicate a module failure and the system should be diagnosed accordingly.
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

Configuration of the Instrument Cluster

The instrument cluster is a programmable module, which must be configured by selecting the Programmable Module Installation Routine on the WDS.

The following features will need to be configured when a new instrument cluster is installed:

• Overspeed chime (if equipped)
• Speed control (if equipped)
• TC indicator (if equipped)
• Reverse warning chime (if equipped)

Inspection and Verification

Visual Inspection Chart

Self-Diagnostic Mode

NOTE:Additional tests are available after the following but are not applicable for this diagnostic.

Self-Diagnostic Mode

Instrument Cluster DTC Index Chart

Symptom Chart

Symptom	Possible Sources	Action
The information and message center selector lever indicator displays two dashes	* Transmission range (TR) sensor.	* CHECK the TR sensor. REFER to: Diagnostic Strategy (307-01A Automatic Transmission/Transaxle - Vehicles With: 4-Speed Automatic Transmission (CD4E), Diagnosis and Testing) / Diagnostic Strategy (307-01B Automatic Transmission/Transaxle - Vehicles With: 5-Speed Automatic Transmission (5F31J), Diagnosis and Testing).
	* Circuit.	* CARRY out wiring checks between the TR sensor and the instrument cluster. REFER to the wiring diagrams.
	* Instrument cluster.	* REFER to the WDS.
The fuel level gauge pointer does not move down at a constant rate (Full to 3/4 and 1/4 to empty periods vary)	* The fuel gauge considers unindicated full and empty reserve as part of the indicated volume. The pointer catches up with the real volume outside of these areas.	* No action required. Do not install a new component.
The low fuel warning indicator illuminates too early	* This is dependant on the drive style. The on-board computer calculates the average consumption and illuminates the low fuel warning indicator when there is 80 Km (50 miles) of fuel left in the fuel tank. The on-board computer does not consider a more economical drive style after a higher fuel consumption, but keeps the Distance To Empty (DTE) constant until the fuel level has caught up with the remaining DTE.	* No action required. Do not install a new component.
Indicated fuel level does not match the amount of fuel expected to be in the fuel tank	* A certain amount of fuel is not indicated or not useable respectively and is needed to avoid unintended engine hesitations at low fuel levels. This amount is carline and engine type dependent.	* No action required. Do not install a new component.
Information and message center inconsistent with the fuel gauge	* The fuel gauge considers unindicated full and empty reserve as part of the indicated volume. The pointer catches up with the real volume outside of these areas. * A certain amount of fuel is not indicated or not useable respectively and is needed to avoid unintended engine hesitations at low fuel levels. This amount is carline and engine type dependent.	* No action required. Do not install a new component.
The fuel gauge pointer moves too quickly off the full position or needs too long to move off the full position after refuelling	* A certain amount of unindicated fuel is normal and is dependent on fuel tank geometry and the fuel station filler nozzle shutoff behaviour	* No action required. Do not install a new component.
The fuel gauge reads zero even when the fuel tank is refilled	* Short circuit * Open circuit * Float arm obstructed or collision between the fuel fired booster heater pipe (if equipped) and the float arm. * Instrument cluster * Intermittent contact on the fuel level resistor card	* GO to Pinpoint Test A.
Fuel gauge shows 1/4, ½ or is stuck at a specific position	* Float arm obstructed or collision between the fuel fired booster heater pipe (if equipped) and the float arm. * Instrument cluster	* GO to Pinpoint Test B.
Fuel gauge pointer delayed in moving up when the fuel tank is refilled	* Fuel tank refilled with the ignition ON	* Refilling with the ignition OFF next time will cure the concern. Do not install a new component.
	* Float arm obstructed or collision between the fuel fired booster heater pipe (if equipped) and the float arm. * Instrument cluster	* GO to Pinpoint Test C.
Fuel gauge pointer fluctuates up and down while driving on straight/flat roads	* Float arm obstructed or collision between the fuel fired booster heater pipe (if equipped) and the float arm. * Excessive wear in the fuel level resistor card ink (more robust ink was introduced 10/2003). * Fuel level resistor card * Instrument cluster	* GO to Pinpoint Test D.
Fuel gauge shows less than full (even when refilled/trickle filled)	* Recirculation hose incorrectly routed * Float arm obstructed or collision between the fuel fired booster heater pipe (if equipped) and the float arm. * Float arm incorrectly installed * Fuel level resistor card * Instrument cluster	* GO to Pinpoint Test E.
	* Float arm too long - vehicles built (or repaired) between 08/2003 and 01/2004	* GO to Pinpoint Test F.
Vehicle runs out of fuel but the fuel gauge indicates a quantity of fuel left in the fuel tank	* Float arm obstructed or collision between the fuel fired booster heater pipe (if equipped) and the float arm. * Float arm incorrectly installed * Fuel level resistor card * Instrument cluster	* GO to Pinpoint Test G.

Pinpoint Tests

NOTE:Use a digital multimeter for all electrical measurements.