ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
413-01 Instrument Cluster > < Instrument Cluster and Panel Illumination - Vehicles Built Up To: 05-1999

Mondeo 1997 (08.1996-09.2000)

Instrument Cluster and Panel Illumination - Instrument Cluster and Panel Illumination—Vehicles Built From: 05/1999 Mondeo 1997 (08/1996-09/2000)
Diagnosis and Testing

Refer to Wiring Diagrams Section 413-00, for schematic and connector information.

Inspection and Verification

  1. Verify the customer concern by operating the system.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Instrument cluster
  • Fluid levels
  • Engine/engine compartment or underbody components
  • Accessory installation
  • Fuse(s)
  • Loose or corroded connector(s)
  • Instrument cluster
  • Instrument cluster printed circuit
  • Wiring harness
  • Liquefied petroleum gas (LPG) tank gauge
  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 concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
The control illumination is inoperative
*
Fuse(s).
*
Bulb(s).
*
Circuit(s).
*
Dimmer switch.
*
Headlamp switch.
*
GO to Pinpoint Test ??. .
The instrument cluster illumination inoperative
*
Circuit(s).
*
Instrument cluster printed circuit.
*
GO to Pinpoint Test ??. .
The climate control illumination is inoperative
*
Bulb(s).
*
Circuit(s).
*
GO to Pinpoint Test ??. .
The audio system illumination is inoperative
*
Circuit(s).
*
Audio unit.
*
GO to Pinpoint Test ??. .
A single illumination source is inoperative
*
Bulb(s).
*
Circuit(s).
*
GO to Pinpoint Test ??. .

Pinpoint Tests

PINPOINT TEST A : THE CONTROL ILLUMINATION IS INOPERATIVE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE PARKING LAMP OPERATION
1
Ignition switch in position 0.
2
Turn the headlamp switch to the ON position.

Do the parking lamps and license lamps operate?
Yes
PLACE the headlamp switch in the OFF position. GO to A2. .
No
CHECK fuse 31 (7.5A). If the fuse is OK. REFER to Section  417-01 Exterior Lighting.
If the fuse has failed, INSTALL a new fuse. TEST the system for normal operation. If the fuse fails again, CHECK for a short to ground, REPAIR as necessary.
A2: CHECK THE VOLTAGE TO THE ILLUMINATION DIMMER
1
Disconnect Illumination Dimmer C846.
2
Place the headlamp switch in the ON position.

3
Measure the voltage between illumination dimmer C846 pin 2, circuit 29S-LK22 (OG/WH), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to A3. .
No
GO to A4. .
A3: CHECK CIRCUIT 64S-LK22 (BU/OG) FOR OPEN

1
Measure the resistance between illumination dimmer C846 pin 3, circuit 64S-LK22 (BU/OG), harness side and ground.

Is the resistance greater than 10,000 ohms?
Yes
REPAIR the circuit. TEST the system for normal operation.
No
INSTALL a new illumination dimmer. TEST the system for normal operation.
A4: CHECK CIRCUIT 29-LK22 (OG/WH) FOR OPEN

1
Measure the resistance between illumination dimmer switch C846 pin 2, circuit 29S-LK22 (OG/WH), harness side and the central junction box (CJB) C361 pin 1, circuit 29S-LK4 (OG/BU), harness side.

Is the resistance less than 5 ohms?
Yes
INSTALL a new CJB. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.

PINPOINT TEST B : THE INSTRUMENT CLUSTER ILLUMINATION INOPERATIVE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE ILLUMINATION
1
Ignition switch in position 0.
2
Turn the headlamp switch to the ON position.

Is only the instrument cluster illumination inoperative?
Yes
Place the headlamp switch in the OFF position.GO to B2. GO to Pinpoint Test B. .
No
If the exterior lighting is inoperative, REFER to Section  417-01 Exterior Lighting. If all illumination is inoperative GO to A1. .
B2: CHECK CIRCUIT 64S-LK29 (BU/RD) FOR VOLTAGE
1
Disconnect Instrument Cluster C808a.

2
Measure the voltage between instrument cluster C808a pin 16, circuit 64S-LK29 (BU/RD), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to B3. GO to Pinpoint Test B. .
No
REPAIR the circuit. TEST the system for normal operation.
B3: CHECK CIRCUIT 91-GG14 (BK/OG)/ 91-GA6 (BK/YE) FOR OPEN
1
Disconnect Instrument Cluster C808b.

2
Measure the resistance between instrument cluster C808a pin 13, circuit 91-GG14 (BK/OG), harness side and ground; and between the instrument cluster C808b pin 4, circuit 91-GA6 (BK/YE), harness side and ground.

Are the resistances less than 5 ohms?
Yes
INSTALL a new instrument cluster. REFER to Section  413-01 Instrument Cluster. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.

PINPOINT TEST C : THE CLIMATE CONTROL ILLUMINATION IS INOPERATIVE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK CIRCUIT 64S-LH27 (BU/YE) FOR VOLTAGE
1
Ignition switch in position 0.
2
Disconnect Heater Panel Illumination Lamp C406.
3
Place the headlamp switch in the ON position.

4
Measure the voltage between heater panel illumination lamp C406 pin 2, circuit 29S-LH26 (OG/BK), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to C2. GO to Pinpoint Test C. .
No
REPAIR the circuit. TEST the system for normal operation.
C2: CHECK CIRCUIT 31-LH26 (BK) FOR OPEN

1
Measure the resistance between heater panel illumination lamp C406 pin 1, circuit 31-LH26 (BK), harness side and ground,

Is the resistance less than 5 ohms?
Yes
INSTALL a new heater panel. REFER to Section  412-04 Control Components. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.

PINPOINT TEST D : THE AUDIO SYSTEM ILLUMINATION IS INOPERATIVE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK VOLTAGE TO THE AUDIO UNIT BULBS CIRCUIT 29S-LK34 (OG/BK)
1
Ignition switch in position 0.
2
Disconnect Audio Unit C443a.
3
Place the headlmap switch in the ON position.

4
Measure the voltage between audio unit C443a pin 4, circuit 29S-LK34 (OG/BK), harness side and ground.

Is the voltage greater than 10 volts?
Yes
INSTALL a new audio unit. REFER to Section  415-01 Audio Unit. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.

PINPOINT TEST E : A SINGLE ILLUMINATION SOURCE IS INOPERATIVE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK ILLUMINATION SOURCE
1
Ignition switch in position 0.
2
CHECK the inoperative bulb.

Is the bulb okay?
Yes
REINSTALL the bulb, if the inoperative bulb is in the instrument cluster, INSTALL a new instrument cluster. REFER to Section  413-01 Instrument Cluster. TEST the system for normal operation.
If the inopertative bulb is in the audio unit.GO to D1. GO to Pinpoint Test D. .
If the inoperative bulb is in the heater panel, INSTALL a new heater panel illumination. REFER to Section  412-04 Control Components.
If the inoperative bulb is in the gearshift lever, GO to E2. GO to Pinpoint Test E. .
If the inoperative bulb is in the cigar lighter, GO to E4. GO to Pinpoint Test E. .
If the inoperative bulb is in the rear window heater switch, GO to E6. GO to Pinpoint Test E. .
If the inoperative bulb is in the headlamp switch panel, GO to E7. GO to Pinpoint Test E. .
If the inoperative bulb is in the power window switch, GO to E9. GO to Pinpoint Test E. .
If the inoperative bulb is in the traction control switch, GO to E11. GO to Pinpoint Test E. .
If the inoperative bulb is in the liquefied petroleum gas (LPG) tank gauge, GO to E12. GO to Pinpoint Test E. .
No
INSTALL a new bulb. TEST the system for normal operation.
E2: CHECK CIRCUIT 64S-LK21 (BU/BK) FOR VOLTAGE
1
Disconnect Gearshift Lever C931.
2
Place the headlamp switch in the ON position.

3
Measure the voltage between gearshift lever C931 pin 5, circuit 64S-LK21 (BU/BK), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to E3. GO to Pinpoint Test E. .
No
REPAIR the circuit. TEST the system for normal operation.
E3: CHECK CIRCUIT 31-LK21 (BK) FOR OPEN

1
Measure the resistance between gearshift lever C931 pin 6, circuit 31-LK21 (BK), harness side and ground.

Is the resistance less than 5 ohms?
Yes
INSTALL a new gearshift illumination bulb. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
E4: CHECK CIRCUIT 64S-LK15 (BU/BK) FOR VOLTAGE
1
Disconnect Cigar Lighter C912b.

2
Measure the voltage between cigar lighter C912b pin 2, circuit 64S-LK15 (BU/WH), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to E5. GO to Pinpoint Test E. .
No
REPAIR the circuit. TEST the system for normal operation.
E5: CHECK CIRCUIT 31-HA6 (BK) FOR OPEN

1
Measure the resistance between cigar lighter C912b pin 1, circuit 31-HA6 (BK), harness side and ground.

Is the resistance less than 5 ohms?
Yes
INSTALL a new cigar lighter bulb. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
E6: CHECK CIRCUIT 31-LH37 (BK) FOR OPEN
1
Disconnect Rear Windshield Heater Switch C437.

2
Measure the resistance between rear windshield heater switch C437 pin 4, circuit 31-LH37 (BK), harness side and ground.

Is the resistance less than 5 ohms?
Yes
INSTALL a new rear windshield heater switch. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
E7: CHECK CIRCUIT 29S-LH26 (OG/BK) FOR VOLTAGE
1
Disconnect Headlamp Switch Illumination C406.

2
Measure the voltage between headlamp switch illumination C406 pin 2, circuit 29S-LH26 (OG/BK), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to E8. GO to Pinpoint Test E. .
No
REPAIR the circuit. TEST the system for normal operation.
E8: CHECK CIRCUIT 31-LH26 (BK) FOR OPEN

1
Measure the resistance between headlamp illumination switch C406 pin 1, circuit 31-LH26 (BK), harness side and ground.

Is the resistance less than 5 ohms?
Yes
INSTALL a new illumination bulb socket. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
E9: CHECK THE VOLTAGE TO THE INOPERATIVE WINDOW SWITCH BULB
1
Disconnect Inoperative Switch.

2
Measure the voltage between the inoperative switch and ground, refer to the following:
  • Driver side C74b pin 2, circuit 15-AJ7A (GN/BU), harness side.
  • Passenger side C489 pin 2, circuit 15S-AJ2 (GN/BU), harness side.
  • Right-hand side rear C490 pin 2, circuit 15S-AJ2 (GN/BU), harness side.
  • Left-hand side rear C1854 pin 2, circuit 15S-AJ2 (GN/BU), harness side.

Is the voltage greater than 10 volts?
Yes
GO to E10. GO to Pinpoint Test E. .
No
REPAIR the circuit in question. TEST the system for normal operation.
E10: CHECK THE GROUND TO THE INOPERATIVE WINDOW SWITCH BULB

1
Measure the resistance between inoperative switch and ground, refer to the following:
  • Driver side C74b pin 3, circuit 31-AJ7 (BK), harness side.
  • Passenger side C489 pin 4, circuit 31-LH23 (BK), harness side.
  • Right-hand side rear C490 pin 4, circuit 31-LA1 (BK), harness side.
  • Left-hand side rear C1854 pin 4, circuit 31-LA1 (BK), harness side.

Is the resistance less than 5 ohms?
Yes
INSTALL a new switch. TEST the system for normal operation.
No
REPAIR the circuit is question. TEST the system for normal operation.
E11: THE TRACTION CONTROL ILLUMINATION BULB IS INOPERATIVE
1
Disconnect Traction Control Switch C717.

2
Measure the resistance between traction control switch C717 pin 7, circuit 31-LH45 (BK), harness side and ground.

Is the resistance greater than 10,000 ohms?
Yes
REPAIR circuit 31-LH45 (BK). TEST the system for normal operation.
No
INSTALL a new traction control switch. TEST the system for normal operation
E12: THE LIQUEFIED PETROLEUM GAS (LPG) FUEL TANK GAUGE BULB IS INOPERATIVE
1
Switch the lighting system ON.

Does the cigar lighter illumination operate correctly?
Yes
GO to E13. GO to Pinpoint Test E. .
No
GO to E4. GO to Pinpoint Test E. .
E13: CHECK CIRCUIT 8-LG11A (WH/VT) FOR VOLTAGE
1
Disconnect LPG Switch C3028.

2
Measure the voltage between the LPG switch C3028 pin 8, circuit 8-LG11A (WH/VT), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to E14. GO to Pinpoint Test E. .
No
GO to E15. GO to Pinpoint Test E. .
E14: CHECK THE GROUND CIRCUIT FOR OPEN

1
Measure the resistance between the LPG switch C3028 pin 4, (BK), harness side and ground.

Is the resistance less than 5 ohms?
Yes
INSTALL a new LPG switch. TEST the system for normal operation.
No
REPAIR the circuit (BK). TEST the system for normal operation.
E15: CHECK THE CIRCUIT 8-LG11A (WH/VT) FOR OPEN
1
Disconnect Cigar Lighter C912b.

2
Measure the resistance between the LPG switch C3028 pin 8, circuit 8-LG11A (WH/VT), harness side and cigar lighter C912b pin 2, circuit 8-LG11A (WH/VT), harness side.

Is the resistance less than 0.5 ohms?
Yes
GO to E16. GO to Pinpoint Test E. .
No
REPAIR the circuit. TEST the system for normal operation.
E16: CHECK CIRCUIT 8-LG11 (WH/VT) FOR VOLTAGE
1
Connect LPG Switch C3028.
2
Connect Cigar Lighter C912b.
3
Disconnect LPG Fuel Tank Gauge C3029.

4
Measure the voltage between the LPG fuel tank gauge C3029 pin 5, circuit 8-LG11 (WH/VT), harness side and ground.

Is the voltage greater than 10 volts?
Yes
GO to E17. GO to Pinpoint Test E. .
No
GO to E14. GO to Pinpoint Test E. .
E17: CHECK THE GROUND CIRCUIT FOR OPEN

1
Measure the resistance between the LPG fuel tank gauge C3029 pin 6, (BK), harness side and ground.

Is the resistance less than 5 ohms?
Yes
INSTALL a new LPG fuel tank gauge. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
E18: CHECK CIRCUIT 8-LG11 (WH/VT) FOR OPEN
1
Disconnect LPG Switch C3028.

2
Measure the resistance between the LPG fuel tank gauge C3029 pin 5, circuit 8-LG11 (WH/VT), harness side and the LPG switch C3028 pin 8, circuit 8-LG11 (WH/VT), harness side.

Is the resistance less than 0.5 ohms?
Yes
GO to E4. GO to Pinpoint Test E. .
No
REPAIR the circuit. TEST the system for normal operation.

413-01 Instrument Cluster > < Instrument Cluster and Panel Illumination - Vehicles Built Up To: 05-1999