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Diagnosis and Testing|Removal and Installation > < Instrument Cluster - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)

Transit 2000.5 (01.2000-05.2006)

Instrument Cluster - Instrument Cluster—Vehicles Built From: 07/2003, Vehicles With: Central Junction Box (CJB) Transit 2000.5 (01/2000-05/2006)
Diagnosis and Testing

Refer to Wiring Diagrams Section 413-01, for schematic and connector information.

General Equipment
Worldwide Diagnostic System (WDS)

Inspection and Verification

  1. Verify the customer concern.
  1. 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
  • Fuse(s)
  • Wiring harness
  • Electrical connector(s)
  • Instrument cluster
  • Light emitting diode(s) (LED)(s)
  • Alternitive fuel control module
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and enter the instrument cluster Self-Diagnostic Mode.

Self-Diagnostic Mode

NOTE:
NOTE:The instrument cluster tripmeter reset button is located on the right-hand side of the instrument cluster lens.
  1. 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.
  1. 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.
  1. The Self-Diagnostic Mode will enter the gauge sweep test.
  1. To navigate through or skip any of the instrument cluster Self-Diagnostic Mode tests press the tripmeter reset button.
  1. Record any DTCs displayed.
  1. If the reset button is pressed and held for more than 3 seconds between tests, the instrument cluster will exit the Self-Diagnostic Mode.
  1. The Self-Diagnostic Mode is deactivated when the ignition switch is turned to the OFF position.
  1. If the Self-Diagnostic Mode cannot be accessed, use the WDS 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) bulb
  • Alternative fuel indicator
  • Glow plug indicator
  • Low fuel level indicator
  • Malfunction indicator Lamp (MIL)
  • Service indicator
Illuminates all the LED warning indicators that are controlled by the instrument cluster.
4. ROM level r XXX FAIL - Displays the instrument cluster ROM level and type. Alternatly flashes FAIL and ROM level when a failure is present, INSTALL a new Instrument Cluster. TEST the system for normal operation.
5. Non Volatile Memory (NVM) ROM level nrXXX - Displays the instrument cluster Hex NVM ROM level and type.
6. Hex EE level EE01 FAIL - Displays the instrument cluster Hex EE level. Alternatly flashes FAIL and EE01 level when a failure is present, INSTALL a new Instrument Cluster. TEST the system for normal operation.
7. Manufacturing date dtXXXX Manufacturing date Displays the final manufacturing hexadecimal test date.
8. Cluster configuration Cc XX Configuration Displays the instrument cluster configuration. Cc08 No alternative fuel (A.F.)/Diesel/KMH. Cc09 No A.F./Diesel/MPH. Cc0A No A.F./Petrol/KMH. Cc0B No A.F./Petrol/MPH. Cc0E A.F./Petrol/KMH. Cc0F A.F./Petrol/MPH.
9. Cluster configuration CF1 XX Configuration Displays the 1st byte of module configuration. CF100 No tachograph fitted, speedo accuracy down shift not applied. CF102 Tachograph fitted, speedo accuracy down shift not applied. CF103 Tachograph fitted, speedo accuracy down shift applied.
10. Cluster configuration CF2 XX Configuration Displays the 2nd byte of module configuration.
11. Cluster configuration CF3 XX Configuration Displays the 3rd byte of module configuration.
12. Cluster configuration CF4 XX Configuration Displays the 4th byte of module configuration.
13. Diagnostic trouble code (DTC) dtc then XXXX 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. Alternatly flashes dtc and nonE when no DTCs are present.
14. Vehicle speed m.p.h. E XXXX Speedometer Displays the speed signal input in m.p.h. ---- will be displayed in the odometer display if no signal received.
15. Vehicle speed km/h XXXX Speedometer Displays the speed signal input in km/h. ---- will be displayed in the odometer display if no signal received.
16. Tachograph speed tsXXXX Tachograph Displays the speed signal input from the tachograph in km/h. nc will be displayed in the odometer display if the feature is not configured.
17. Tachograph frequency trXXXX Tachograph Displays the input frequency from the tachograph in Hz. nc will be displayed in the odometer display if the feature is not configured.
18. Speedometer display SGXXXX Speedometer Displays the speedometer driver gauge signal as a decimal value.
19. Tachometer value tXXXX Tachometer Displays the tachometer speed value in RPM. ---- will be displayed in the odometer display if no signal received.
20. Tachometer display tGXXXX Tachometer Displays the tachometer driver gauge signal as a decimal value.
21. Fuel volume FXXX Fuel sender system Displays the fuel volume signal input. 000-009 Short circuit. 010 - 254 Normal range. 255 Open circuit.
22. Fuel volume FPXXX Fuel sender system Displays the fuel volume signal input as a percentage.
23. Alternative fuel volume AFXXX Alternative fuel volume Displays the alternative fuel volume signal input. 000 - 254 Normal range. 255 Open/short circuit. nc will be displayed if the feature is not configured.
24. Alternative fuel volume AFPXXX Alternative fuel volume Displays the alternative fuel volume signal input as a percentage. nc will be displayed if the feature is not configured.
25. Fuel gauge FGXXXX Fuel gauge Displays the fuel driver gauge signal as a decimal value.
26. Engine coolant temperature (ECT) XXXC ECT Displays the last engine coolant temperature signal input in 1/10 degree C. ---- will be displayed in odometer display if no signal received.
27. Temperature gauge CGXXX Temperature gauge Displays the temperature driver gauge signal as a decimal value.
28. Odmeter odoXXX Odometer Displays the odometer signal input as a decimal value. ---- will be displayed in the odometer display if no signal received.
29. Battery voltage bAtXXX Vehicle charging system input Displays the battery voltage signal input in tenths of volts.
30. Side light switch IL -X Side light switch input Displays 'b' for side lights on and 'o' for side lights off.
31. LCD illumination LCXXX LCD illumination Displays the LCD illumination duty cycle as a percentage.
32. Crank sensing Cr-X Engine crank input Displays 'b' for signal high (B+) and 'o' for signal low (open).
33. Not required P6XX - Not required.
34. Not required AN0XX - Not required.
35. Not required AN1XX - Not required.
36. Not required AN2XX - Not required.
37. Not required AN3XX Trip and clock switch test Displays the switch signal input. 150 Trip switch pressed. 126 Trip and clock switch pressed. 255 No switch pressed.
NOTE:
NOTE:If the tripmeter reset button is pressed again, the Self-Diagnostic mode will return to the gauge sweep test and continue to repeat the Self-Diagnostic routine.
  1. REFER to the WDS to continue diagnostics.

Make a test lamp - Vehicles built from 01/10/2003 to 30/01/2004 with Liquified Petroleum Gas (LPG)

If the LPG warning lamp is illuminating, the probable cause is a fault within in the LPG system. Access to the alternative fuel control module DTCs is not possible without the use of a test lamp.

NOTE:
NOTE:For this procedure, it will be necessary to make a test lamp using locally procured parts.
  1. Using the following locally procured parts, make a test lamp.
    1. Male connector - to be connected to the alternative fuel control module wiring harness.
    1. Bulb holder and bulb.
    1. Terminal - to be connected to the battery positive terminal.
    • Wire.

Installing the alternative fuel control module wiring harness

  1. Disconnect the battery ground cable.
    REFER to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Detach the alternative fuel control module bracket from the steering column.

  1. Disconnect the alternative fuel control module electrical connector (white).

  1. Remove the alternative fuel control module electrical connector protection sleeve.
    • Press the locking tangs.

  1. Open the alternative fuel control module electrical connector body.

  1. Install the alternative fuel control module wiring harness terminal into pin 29.
  1. Connect the alternative fuel control module electrical connector.
    • Close the alternative fuel control module electrical connector body.
    • Install the alternative fuel control module electrical connector protection sleeve.
    • Connect the electrical connector.
  1. Install all components in reverse order.

Retrieving LPG DTCs

  1. Connect the test lamp to the alternative fuel control module wiring harness.
  1. Connect the other end of the test lamp to the battery positive terminal.
  1. Connect the battery ground cable.
    REFER to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. NOTE:
    NOTE:To identify the codes, the flashes will have a 0.5 second break in between to identify the 'tens'. After a 2 second break, the next flashes will also have a 0.5 second break in between to identify the units. Following this, there will be a 4 second break between each code.
    Read out any DTCs stored in the LPG module using the diagnosis and testing procedure.
    REFER to: Fuel Charging and Controls (303-04E Fuel Charging and Controls - Liquified Petroleum Gas (LPG), Diagnosis and Testing).
  1. Secure the alternative fuel control module wiring harness to the alternative fuel control module bracket using insulation tape or tie straps.

Instrument Cluster Configuration

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

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

  • Tachograph

Diagnosis and Testing|Removal and Installation > < Instrument Cluster - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)