| Diagnosis and Testing The Ford approved diagnostic tool Inspection and Verification - Verify the customer concern.
- Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart | Mechanical | Electrical | - Engine oil filter
- Engine oil level
- Engine coolant temperature (ECT) sensor
- Engine coolant level
- Thermostat
- Collapsed or damaged fuel tank
- Door adjustment
- Fuel level sensor - Vehicles with Liquified Petroleum Gas (LPG) fuel system
- Fuel level sensor gauge - Vehicles with LPG fuel system
| - Fuse(s)
- Wiring harness
- Electrical connector(s)
- Instrument cluster
- Light emitting diode(s) (LED)(s)
- Alternative fuel control module (AFCM) - Vehicles with LPG fuel system
- Powertrain control module (PCM)
| - If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
- If the cause is not visually evident, verify the symptom and enter the instrument cluster Self-Diagnostic Mode.
Self-Diagnostic Mode NOTE:The instrument cluster tripmeter reset button is located on the right-hand side of the instrument cluster lens. - To enter the instrument cluster Self-Diagnostic Mode simultaneously press and hold the tripmeter reset button and turn the ignition switch to position II. It will take between 5 and 8 seconds for the instrument cluster to enter the Self-Diagnostic Mode.
- The tripmeter reset button must be released within 3 seconds of tESt being displayed in the tripmeter LCD, or the Self-Diagnostic Mode will exit.
- The Self-Diagnostic Mode will enter the gauge sweep test.
- To navigate through or skip any of the instrument cluster Self-Diagnostic Mode tests press the tripmeter RESET button. If the reset button is pressed and held for more than 3 seconds between tests, the instrument cluster will exit the Self-Diagnostic Mode.
- The Self-Diagnostic Mode is deactivated when the ignition switch is turned to the OFF position.
- If the Self-Diagnostic Mode cannot be accessed, refer to the Symptom Chart or use the Ford approved diagnostic tool to diagnose the instrument cluster.
Self-Diagnostic Mode | Test | Odometer Display | Gauge/Indicator/Display Tested | Description | | 1. Gauge sweep | GAGE | Tachometer, speedometer, temperature and fuel | All gauges go through a full up and down pointer sweep smoothness check, which takes approximately 6 seconds. | | 2. Fill in all LCD | All segments illuminated | Odometer LCD and clock LCD | Fills in the LCDs of the odometer and clock. | | 3. Indicator LED(s) | lEdS | - Anti-lock brake system (ABS) warning indicator
- Parking brake/brake warning indicator
- Charging system warning indicator
- Glow plug indicator
- Low fuel level indicator
- Malfunction indicator Lamp (MIL)
| Illuminates all the LED warning indicators that are controlled by the instrument cluster. | | 4. ROM level | r XXX or FAIL | Instrument cluster read only memory (ROM) | Displays the instrument cluster ROM level and type. | | 5. Non-volatile memory level | EXXX or FAIL | Instrument cluster non-volatile memory | Displays the instrument cluster ROM level and type as stored in the non-volatile memory. | | 6. Diagnostic trouble code (DTC) | dtc then XXXX or nonE | DTCs | To list the DTCs stored, press the RESET button. REFER to the instrument cluster DTC index. A new DTC code will be displayed with each press of the reset button. | | 7. Vehicle speed m.p.h. | XXX.X | Speedometer | Displays the speed signal input in m.p.h. 000.0 will be displayed in odometer display if no signal received. | | 8. Vehicle speed km/h | XXX.X | Speedometer | Displays the speed signal input in km/h. 000.0 will be displayed in odometer display if no signal received. | | 9. Not required | XXX.0 | - | Not required. | | 10. Engine speed | XXXX | Tachometer | Displays the tachometer input signal (RPM). 0000 will be displayed in odometer display if no signal received. | | 11. Not required | XXX.t | - | Not required. | | 12. Fuel volume | FXXX | Fuel sender system | Displays the fuel volume signal input. 000 - 009 Short circuit. 010 - 254 Normal range. 255 open circuit. | | 13. Fuel volume | LXXX | Fuel sender system | Displays the fuel volume signal input as a percentage. | | 14. Not required | XXX.f | - | Not required. | | 15. Engine coolant temperature (ECT) | XXX C | ECT | Displays the last engine coolant temperature signal input in 1/10 degree C. | | 16. Not required | XXX.C | - | Not required. | | 17. Battery charging voltage | bXX.X | Vehicle charging system input | Displays the charging voltage input to battery. | | 18. Anti-lock brake system (ABS) failure | Ab-H or Ab-L | ABS status input | Displays H for ABS input open circuit or battery positive (LED ON), L for ABS input to ground (LED OFF). | | 19. Electronic brake distribution (EBD) failure | Eb-H or Eb-L | EBD status Input | Displays H for EBD input open circuit or battery positive (LED ON), L for EBD input to ground (LED OFF). | | 20. Cluster illumination | IL-H or IL-L | Cluster illumination input | Displays H for illumination input battery positive (illumination ON), L for illumination input open circuit (illumination OFF). | | 21. Crank sensing | Cr-X | Engine crank input | Displays H with ignition in position II and L with ignition in position III. | | 22. Not required | A-HH | - | Not required. | | 23. Not required | b-HH | - | Not required. | | 24. Not required | C-HH | - | Not required. | | 25. Not required | d-HH | - | Not required. | | 26. Battery voltage | 0XXX | Battery voltage | Displays battery voltage input. | | 27. Fuel sender | 1XXX | Fuel sender input | Displays the raw input from the fuel level sender unit. | | 28. Intermittent front wiper | 2L or 2H | Intermittent front wiper switch input | Displays L for intermittent front wiper switch not pressed and H for intermittent front wiper switch pressed. | | 29. Drivers door courtesy switch | 3H or 2L | Drivers door courtesy switch position input | Displays H for door closed and L for door open. | | 30. Passenger and rear door courtesy switch | 4H or 4L | Passenger and rear door courtesy switch position inputs | Displays H if both passenger and rear doors are closed and L if either passenger or rear door is open. | | 31. Sliding door courtesy switch | 5H or 5L | Sliding door courtesy switch position input | Displays H for door closed and L for door open. | | 32. Intermittent rear wiper | 6L or 6H | Intermittent rear wiper switch position input | Displays L for intermittent rear wiper switch not pressed or not installed and H for intermittent rear wiper switch pressed. | | 33. Windscreen washer switch | 7H or 7L | Windscreen washer switch position input | Displays H for windscreen washer switch not pressed and L for windscreen washer switch pressed. | | 34. Not required | P1XX | - | Not required. | | 35. Not required | P2XX | - | Not required. | | 36. Not required | P3XX | - | Not required. | | 37. Not required | P4XX | - | Not required. | NOTE:If the tripmeter reset button is pressed again, the self-diagnostic test will return to gauge sweep test and continue to repeat the Self Diagnostic routine. - If the concern is not evident refer to the Symptom Chart.
Symptom Chart | Symptom | Possible Sources | Action | | The fuel guage is inoperative or erratic. | * Fuel pump and sender unit/fuel level sensor. * Circuit * Instrument cluster | * | | The water-in-fuel indicator is inoperative/always on - diesel only. | * Water-in-fuel indicator bulb. * Circuit. * Water-in-fuel sensor. * Instrument cluster. * Fuse. * Fuel filter requires draining. | * | | Incorrect LPG fuel gauge indication - Vehicles with LPG fuel system. | * LPG fuel tank level float. * LPG fuel tank level indicator. * AFCM. * PCM. | * | | PINPOINT TEST A : THE FUEL GAUGE IS INOPERATIVE OR ERRATIC | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | A1: CHECK CIRCUITS 8-GA7 (WH/RD) AND 9-GA7 (BN/RD) FOR OPEN CIRCUIT | | | 1 Disconnect Instrument Cluster C809. | | | 2 Disconnect Fuel Level Sensor C732. | | | 3 Measure the resistance between the following instrument cluster connector pins, harness side and the fuel pump and sender unit/fuel level sensor connector pins, harness side: - C809 pin 8, circuit 8-GA7 (WH/RD) and C732 pin 2, circuit 8-GA7 (WH/RD).
- C809 pin 15, circuit 9-GA7 (BN/RD), and C732 pin 4, circuit 9-GA7 (YE/VT).
| | | Are the resistances less than 1 ohm? Yes No REPAIR circuit 8-GA7 (WH/RD) or 9-GA7 (BN/RD) as necessary. TEST the system for normal operation. | | A2: CHECK THE OPERATION OF THE FUEL PUMP AND SENDER UNIT/FUEL LEVEL SENSOR | | | 1 Remove the fuel pump and sender unit/fuel level sensor.
REFER to: Fuel Level Sensor - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Pump - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Removal and Installation).
| | | 2 Measure the resistance between the fuel level sensor/fuel pump and sender unit pin 2, component side and the fuel level sensor/fuel pump and sender unit pin 4, component side while moving the float arm lever from the empty to the full positions. | | | Is the resistance approximately 300 ohms +/- 3.5 ohms at the empty position and approximately 10 ohms +/- 1 ohm at the full position? Yes REFER to the Ford approved diagnostic tool to diagnose the instrument cluster. No MOVE the rigid wire lever from empty to full a minimum of 10 times. CARRY OUT the resistance check again. If the concern persists, INSTALL a new fuel level sensor. TEST the system for normal operation. | | PINPOINT TEST B : THE WATER-IN-FUEL INDICATOR IS INOPERATIVE/ALWAYS ON - DIESEL ONLY | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | B1: CHECK THE WATER-IN-FUEL WARNING LAMP | | | 1 Ignition switch in position II. | | | Does the water-in-fuel lamp illuminate? Yes CONFIRM there is no water in the fuel filter. If no water is present INSTALL a new water-in-fuel sensor. No | | B2: CHECK CIRCUIT 15-PE23 (GN/RD) FOR POWER | | | 1 Ignition switch in position 0. | | | 2 Disconnect Water-in-Fuel Sensor C724. | | | 3 Ignition switch in position II. | | | 4 Measure the voltage between water-in-fuel sensor C724 pin 2, circuit 15-PE23 (GN/RD), harness side and ground. | | | Is the voltage greater than 10 volts? Yes No REPAIR the circuit. TEST the system for normal operation. | | B3: CHECK THE WATER-IN-FUEL SENSOR | | | 1 Ignition switch in position 0. | | | 2 Install a 10 amp fused jumper wire between water-in-fuel sensor C724 pin 3, circuit 15-PE23 (GN/RD), harness side and water-in-fuel sensor C724 pin 1, circuit 15S-PE23 (GN/RD), harness side. | | | 3 Ignition switch in position II. | | | Does the water-in-fuel lamp illuminate? Yes No | | B4: CHECK CIRCUITS 91-RN2 (BK/BU) AND 91-PE23 (BK/OG) FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Measure the resistance between water-in-fuel sensor C724 pin 3, circuit 91-PE23 (BK/OG), harness side and ground. | | | Is the resistance less than 5 ohms? Yes INSTALL a new water-in-fuel sensor. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. | | B5: CHECK CIRCUIT 15S-PE23 (GN/RD) FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Disconnect Instrument Cluster C809. | | | 3 Measure the resistance between water-in-fuel sensor C724 pin 1, circuit 15S-PE23 (GN/RD), harness side and instrument cluster C809 pin 17, circuit 15S-PE23 (GN/RD), harness side. | | | Is the resistance less than 5 ohms? Yes INSTALL a new instrument cluster.
REFER to: Instrument Cluster (413-01 Instrument Cluster, Removal and Installation).
TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. | | B6: CHECK CIRCUIT 91-PE23 (BK/OG) FOR POWER | | | 1 Ignition switch in position 0. | | | 2 Disconnect Water-in-Fuel Sensor C724. | | | 3 Ignition switch in position II. | | | 4 Measure the voltage between water-in-fuel sensor C724 pin 3, circuit 91-PE23 (BK/OG), harness side and ground. | | | Is the voltage greater than 10 volts? Yes No REPAIR the circuit. TEST the system for normal operation. | | B7: CHECK CIRCUITS 91-RN2 (BK/BU) AND 91-PE23 (BK/OG) FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Measure the resistance between water-in-fuel sensor C724 pin 2, circuit 91-PE23 (BK/OG), harness side and ground. | | | Is the resistance less than 5 ohms? Yes No REPAIR the circuit. TEST the system for normal operation. | | B8: CHECK THE WATER-IN-FUEL SENSOR | | | 1 Ignition switch in position 0. | | | 2 Install a jumper wire between water-in-fuel sensor C724 pin 2, circuit 91-PE23 (BK/OG), harness side and water-in-fuel sensor C724 pin 1, circuit 91S-PE23 (BK/OG), harness side. | | | 3 Ignition switch in position II. | | | Does the water-in-fuel lamp illuminate? Yes INSTALL a new water-in-fuel sensor. TEST the system for normal operation. No | | B9: CHECK CIRCUIT 91S-PE23 (BK/OG) FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Disconnect Instrument Cluster C813. | | | 3 Measure the resistance between water-in-fuel sensor C724 pin 1, circuit 91S-PE23 (BK/OG), harness side and instrument cluster C813 pin 4, circuit 91S-PE23 (BK/OG), harness side. | | | Is the resistance less than 5 ohms? Yes INSTALL a new instrument cluster.
REFER to: Instrument Cluster (413-01 Instrument Cluster, Removal and Installation).
TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. | | PINPOINT TEST C : INCORRECT LPG FUEL GAUGE INDICATION - VEHICLES WITH LPG FUEL SYSTEM | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | C1: CHECK THE LPG FUEL GAUGE FOR SWEEP | | | 1 Disconnect LPG Fuel Tank C907. | | | 2 Ignition switch in position II. | | | 3 Select LPG | | | Does the LPG fuel indicator in the instrument cluster sweep to full? Yes No | | C2: CHECK THE LPG FUEL GAUGE FOR RETURN | | | 1 Install a 10 amp fused jumper wire between the LPG fuel tank C907 pin 3, circuit 91-XL31 (BK/BU), harness side and the LPG fuel tank C907 pin 1, circuit 8-GA6 (WH), harness side. | | | Does the LPG fuel indicator in the instrument cluster return to empty? Yes No | | C3: CHECK CIRCUIT 8-GA6 FOR POWER | | | 1 Measure the voltage between the LPG fuel tank C907 pin 1, circuit 8-GA6 (WH), harness side and ground. | | | Is the voltage 5 volts? Yes No | | C4: CHECK CIRCUIT 91-XL31 (BK/BU) FOR OPEN | | | 1 Measure the resistance between the LPG fuel tank C907 pin 3, circuit 91-XL31 (BK/BU), harness side and ground. | | | Is the resistance less than 5 ohms? Yes No REPAIR the circuit. TEST the system for normal operation. | | C5: CHECK THE LPG FUEL TANK GAUGE CIRCUIT | | | 1 Measure the resistance between the LPG fuel tank C907 pin 3, circuit 91-XL31 (BK/BU), component side and the LPG fuel tank C907 pin 1, circuit 8-GA6 (WH), component side. | | | Is the resistance between 0-160 ohms? Yes No CHECK and REPAIR the circuit as necessary. TEST the system for normal operation. | | C6: CHECK THE FUEL LEVEL SENSOR GAUGE FOR CORRECT OPERATION | | | 1 Remove the LPG fuel level sensor gauge. | | | NOTE:Place the magnet underneath the fuel level sensor gauge. 2 Using a suitable magnet, check the fuel level sensor gauge for movement by twisting the magnet clockwise and counterclockwise. | | | Does the fuel level sensor gauge move freely? Yes INSTALL a new fuel level sensor.
REFER to: Fuel Level Sensor (310-01 Fuel Tank and Lines - Liquified Petroleum Gas (LPG), Removal and Installation).
TEST the system for normal operation. No INSTALL an new fuel level sensor gauge. TEST the system for normal operation. | | C7: CHECK CIRCUIT 8-GA6 (WH) FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Disconnect AFCM C405. | | | 3 Measure the resistance between the AFCM C405 pin 51, circuit 8-GA6 (WH), harness side and the LPG fuel tank C907 pin 1, circuit 8-GA6 (WH), harness side. | | | Is the resistance less than 5 ohms? Yes No REPAIR the circuit. TEST the system for normal operation. | | C8: CHECK CIRCUIT 5-EG9C (BU/BK) AND CIRCUIT 5-EG8 (BU/WH) FOR OPEN | | | 1 Disconnect PCM C415. | | | 2 Disconnect Instrument Cluster C809. | | | 3 Measure the resistance between the PCM C415 pin 15, circuit 5-EG9C (BU/BK), harness side and the instrument cluster C809 pin 26, circuit 5-EG8 (BU/WH), harness side. | | | Is the resistance less than 5 ohms? Yes No REPAIR the circuit. TEST the system for normal operation. | | C9: CHECK CIRCUIT 4-EG9C (GY/OG) AND CIRCUIT 5-EG8 (GY/VT) FOR OPEN | | | 1 Measure the resistance between the PCM C415 pin 16, circuit 4-EG9C (GY/OG), harness side and the instrument cluster C809 pin 13, circuit 5-EG8 (GY/VT), harness side. | | | Is the resistance less than 5 ohms? Yes No REPAIR the circuit. TEST the system for normal operation. | | C10: CHECK THE PCM FOR CORRECT OPERATION | | | 1 Connect the Ford approved diagnostic tool to the vehicle and select the SCOPE function. | | | 2 Connect PCM C415. | | | 3 Connect Instrument Cluster C809. | | | Is a pulse width modulated (PWM) signal indicated? Yes No | | C11: CHECK THE CLUSTER FUNCTIONS | | | 1 Observe the cluster for correct functionality. | | | Does the instrument cluster work correctly? Yes INSTALL a new PCM.
REFER to: Powertrain Control Module (PCM) - 1.8L Duratec-DOHC (Zetec)/1.8L Duratorq-TDDi (Lynx) Diesel LHD (303-14 Electronic Engine Controls, Removal and Installation).
TEST the system for normal operation. No INSTALL a new instrument cluster.
REFER to: Instrument Cluster (413-01 Instrument Cluster, Removal and Installation).
TEST the system for normal operation. | | C12: CHECK THE CALIBRATION DATA OF THE AFCM | | | 1 Using the Ford approved diagnostic tool check the AFCM for the latest calibration information. | | | Is the latest calibration information installed? Yes INSTALL a new AFCM.
REFER to: Alternative Fuel Control Module (303-04 Fuel Charging and Controls - Liquified Petroleum Gas (LPG), Removal and Installation).
TEST the system for normal operation. No Reprogram the AFCM using the Ford approved diagnostic tool. TEST the system for normal operation. | | C13: CHECK CIRCUIT 30-XL35 (RD) AND CIRCUIT 30-XL35A (RD) FOR POWER | | | 1 Ignition switch in position 0. | | | 2 Disconnect AFCM C405. | | | 3 Measure the resistance between the AFCM C405 pin 1, circuit 30-XL35 (RD) harness side and ground and the AFCM C405 pin 17, circuit 30-XL35A (RD), harness side and ground. | | | Are both voltages greater than 10 volts? Yes No REPAIR the necessary circuit(s). TEST the system for normal operation. | | C14: CHECK CIRCUIT 15-LX35 (GN/WH) FOR SWITCHED POWER | | | 1 Ignition switch in position II. | | | 2 Measure the resistance between C405 pin 18, circuit 15-LX35 (GN/WH) harness side and ground. | | | Is the voltage greater than 10 volts? Yes No REPAIR the circuit. TEST the system for normal operation. | | C15: CHECK THE AFCM GROUND CIRCUIT FOR OPEN | | | 1 Ignition switch in position 0. | | | 2 Measure the resistance between the AFCM C406 pin 37, circuit 91-XL35 (BK), harness side and ground and the AFCM pin 38, circuit 91-XL35A (BK), harness side and ground and the AFCM pin 39, circuit 91-XL35B (BK), harness side and ground and the AFCM pin 40, circuit 91-XL35C (BK), harness side and ground and the AFCM pin 41, circuit 91-XL35D (BK), harness side and ground. | | | Are the resistances less than 5 ohms? Yes No REPAIR the necessary circuit(s). TEST the system for normal operation. | Configuration of Instrument Cluster The instrument cluster is a programmable module, which must be configured by selecting the Programmable Module Installation Routine on the Ford approved diagnostic tool. The following features will need to be configured when a new instrument cluster is installed: - Malfunction Indicator Lamp (MIL) (if equipped).
- Anti-lock Brake System (ABS) warning indicator.
- Electronic brake distribution (EBD) indicator.
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