Ford Workshop Service and Repair Manuals

Principles of Operation

The instrument cluster carries out a display prove-out to verify that all warning/indicator lamps and monitored systems are operating correctly. When the ignition switch is turned to the ON position with the engine OFF, the following indicators will illuminate:

• Oil service lamp
• Charge system warning indicator.
• Anti-lock brake system (ABS) warning indicator.
• Air bag indicator.
• Glow plug indicator/engine check lamp (diesel only).

Gauge Indication Systems

The gauge indication systems use magnetic gauges mounted in the instrument cluster. No adjustment, calibration, or maintenance is required for any gauges.

Fuel Sending Unit

The fuel sending unit is a variable resistor controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high.

Water Temperature Indicator Sender Unit

When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and resulting in a corresponding movement of the pointer. For vehicles with diesel engines the temperature gauge receives a pulse width modulation (PWM) signal from the powertrain control module (PCM).

Oil Pressure Indicator Sender Unit

The oil pressure indicator sender unit consists of a diaphragm and contact points. The contact points are open with oil pressure causing the oil pressure indicator to extinguish. With no oil pressure, the contacts close and the low oil pressure indicator illuminates.

Charge System Warning Indicator

A red charge indicator is located in the instrument cluster. This indicator illuminates when there is low or no generator output. When the ignition switch contacts are closed, battery current flows through the charge indicator and the parallel resistor (390 ohms) to the voltage indicator, and the indicator comes on. When the generator builds up enough voltage to energize a circuit in the voltage regulator, the indicator turns off.

Speedometer

On vehicles equipped with tachograph, the speedometer receives the vehicle speed output (VSO) signal from a speed sensor in the transmission. On vehicles without a tachograph, the speedometer receives the vehicle speed signal directly from the PCM.

Odometer

A million-mile tamper-resistant odometer is standard. The odometer can be reset when installing a new speedometer.

Trip Odometer

The trip odometer indicates how many miles the vehicle has been driven since the last reset.

Tachometer

All vehicles can be equipped with a tachometer as an option. Diesel vehicles are equipped with a 4500–rpm tachometer. The tachometer receives a signal from the PCM.

Warning Indicators

Brake System

All vehicles use a brake system warning indicator in the instrument cluster to warn of system malfunctions. The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction. The brake fluid level switch is located in the brake fluid reservoir.

The yellow brake warning indicator is used to indicate a malfunction or deactivation of the anti-lock brake system (ABS). It illuminates when triggered by the ABS control module and stays illuminated as long as the malfunction remains in the system.

Service Indicator Lamp

The service indicator lamp will illuminate when a service is required. To extinguish the service indicator lamp following a service, turn the ignition switch to position II, press the brake and accelerator pedals together for 15 seconds. The service indicator lamp will flash to confirm the lamp has been reset. Release the pedals and turn the ignition switch to OFF.

Low Fuel

When the fuel level drops to a predetermined level, approximately four to eight liters (one to two gallons), the low fuel warning indicator will illuminate.

High Beam

This indicator is illuminated when the high beams are ON.

Water-in-Fuel (Diesel Only)

The WATER-IN-FUEL indicator will illuminate when 100cc (0.2 pints) of water has accumulated in the fuel filter/water separator. The WATER-IN-FUEL indicator will prove out when the ignition switch is in the START position.

Glow Plug Indicator/Engine Check Lamp (Diesel Only)

The glow plug indicator will illuminate when the ignition switch is in the ON position with the engine OFF while the glow plugs are heating. The indicator also acts as an engine check lamp which will flash continuously when a hard diagnostic trouble code (DTC) is detected by the powertrain control module (PCM).

CHECK ENGINE Warning Indicator (Petrol Only)

The CHECK ENGINE warning indicator is illuminated when a DTC is sensed in the closed loop by the PCM.

Inspection and Verification

Visual Inspection Chart

• Charging.
• Fuel delivery.
• Cooling.
• Turn signals.
• Headlamps.

If a particular system(s) is not working correctly, refer to the appropriate section of the workshop manual.

Symptom Chart

Symptom Chart

Pinpoint Tests

NOTE:Use a digital multimeter for all electrical measurements.