~Www2.justanswer.com/uploads/fordguy4u/2011-12-19_183312_a1.pdf · 12/19/2011 · Is the resistance greater than 10,000 ohms? YES REPAIR circuit 29 (Y/W). TEST the system for normal

DIAGNOSIS AND TESTING

Pinpoint Test

PINPOINT TEST A: FUEL LEVEL GAUGE READS INACCURATELY

Section 413-01: Instrument Cluster 1997 Explorer/Mountaineer Workshop Manual

Special Service Tool(s)

73 Digital Multimeter or equivalent 105-R0051

EEC-V 104-Pin Breakout Box or equivalent 014-00950

Instrument Gauge System Tester or equivalent 014-R1063

TEST CONDITIONS TEST DETAILS/RESULTS/ACTIONS

A1 CHECK THE POWER TO THE INSTRUMENT CLUSTER

Instrument Cluster C287

Measure the voltage between instrument cluster C287-8, circuit 640 (R/Y), and ground.

� Is the voltage greater than 10 volts?

YES GO to A2 .

NO REPAIR circuit 640 (R/Y). TEST the system for normal operation.

A2 CHECK THE GROUND TO THE INSTRUMENT CLUSTER

Measure the resistance between instrument cluster C287-2, circuit 570 (BK/W), and ground.

� Is the resistance less than 5 ohms?

YES GO to A3 .

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NO REPAIR circuit 570 (BK/W). TEST the system for normal operation.

A3 CHECK THE GROUND TO THE FUEL LEVEL SENSOR

Fuel Level Sensor and Pump C311

Measure the resistance between fuel level sensor and pump C311-8, circuit 651(BK/Y), and ground.


YES RECONNECT instrument cluster C287. GO to A4 .

NO REPAIR circuit 651 (BK/Y). TEST the system for normal operation.

A4 CHECK FUEL GAUGE (EMPTY)

Connect one lead of Instrument Gauge System Tester to the fuel level sensor and pump C311-5, circuit 29 (Y/W). Connect the other lead to ground.

Set the tester to 22 ohms.

Set the power switch on the tester to the ON position.

Wait one minute.

Read the fuel gauge (9280).

� Does the fuel gauge read E (empty)?

YES GO to A6 .

NO DISCONNECT Instrument Gauge System Tester. GO to A5 .

A5 CHECK CIRCUIT 29 (Y/W) FOR OPEN

Instrument Cluster

Measure the resistance of circuit 29 (Y/W) between the fuel level sensor and pump C311-5, and instrument cluster C287-12.



� Is the resistance greater than 10,000 ohms?

YES REPAIR circuit 29 (Y/W). TEST the system for normal operation.

NO GO to A8 .

A6 CHECK FUEL GAUGE (FULL)

Set the tester to 145 ohms.

Wait one minute.

Read the fuel gauge.

� Does the fuel gauge read F (FULL)?

YES REPLACE the fuel level sensor (9275). TEST the system for normal operation.

NO DISCONNECT Instrument Gauge System Tester. GO to A7 .

A7 CHECK CIRCUIT 29 (Y/W) FOR SHORT TO GROUND


Measure the resistance between instrument cluster C287-12, circuit 29 (Y/W), and ground.


YES REPAIR circuit 29 (Y/W). TEST the system for normal operation.

NO GO to A8 .

A8 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Instrument Cluster

Measure the resistance of the instrument cluster printed circuit (10K843) between the following:

� Fuel gauge SIG terminal and gauge amplifier.



PINPOINT TEST B: ENGINE COOLANT TEMPERATURE GAUGE READS INACCURATELY

� Fuel gauge terminals and instrument cluster printed circuit terminals C287-2 and C287-8.

� Fuel gauge ground terminal and gauge amplifier.

� Gauge amplifier and instrument cluster printed circuit terminals C287-2, C287-12, and C288-1.

� Are the resistances less than 5 ohms?

YES REPLACE the fuel gauge and instrument cluster gauge amplifier (10E849). TEST the system for normal operation.

NO REPLACE the instrument cluster printed circuit. TEST the system for normal operation.


B1 PERFORM COMPONENT TEST

Perform the Coolant Temperature Gauge Component Test in this section.

� Is the engine coolant temperature gauge OK?

YES REPLACE the water temperature indicator sender unit (10884). TEST the system for normal operation.

NO GO to B2 .

B2 CHECK WIRE BETWEEN INSTRUMENT CLUSTER AND WATER TEMPERATURE INDICATOR SENDER UNIT

Water Temperature Indicator Sender Unit C163


Measure the resistance between instrument cluster C287-3, circuit 39 (R/W), and water temperature indicator sender unit C163, circuit 39 (R/W).

Measure the resistance between instrument cluster C287-3, circuit 39 (R/W), and ground.

� Is the resistance less than 5 ohms between instrument cluster C287 and water temperature indicator sender unit

C163; and greater than 10,000 ohms between instrument cluster C287 and ground?

YES GO to B3 .

NO REPAIR circuit 39 (R/W). TEST the system for normal operation.

B3 CHECK THE POWER TO THE INSTRUMENT CLUSTER




PINPOINT TEST C: OIL PRESSURE GAUGE READS INACCURATELY

Measure the voltage between instrument cluster C288-1, circuit 640 (R/Y), and ground.


YES GO to B4 .


B4 CHECK THE GROUND TO THE INSTRUMENT CLUSTER

Check the resistance between instrument cluster C287-2, circuit 570 (BK/W), and ground.


YES GO to B5 .


B5 CHECK INSTRUMENT CLUSTER TEMPERATURE GAUGE

Measure the resistance between the instrument cluster temperature gauge clip "B" and the instrument cluster temperature gauge clip "S."

Measure the resistance between the instrument cluster temperature gauge clip "S" and the instrument cluster temperature gauge clip "G."

� Is the resistance 235 +/- 21 ohms between the "B" clip and "S" clip; and 100 +/- 10 ohms between the "S" clip

and "G" clip?

YES REPLACE the instrument cluster printed circuit. TEST the system for normal operation.

NO REPLACE the engine coolant temperature gauge (10883). TEST the system for normal operation.


C1 CHECK THE OIL PRESSURE GAUGE (LOW)

NOTE: For proper operation of the oil pressure gauge, verify the engine oil is at the proper level and the connector is securely mated to the oil pressure switch. During hard braking, a momentary drop in oil pressure is normal.

Check the oil pressure gauge (9273).

� Does the gauge read L (low) or below?

YES GO to C4 .

NO GO to C2 .

C2 CHECK THE INPUT SIGNAL TO THE OIL PRESSURE GAUGE




Measure the resistance between instrument cluster C286-12, circuit 253 (DG/W), and ground.


YES GO to C3 .

NO REPLACE the oil pressure gauge. TEST the system for normal operation.

C3 CHECK CIRCUIT 253 (DG/W) FOR SHORT TO GROUND

Oil Pressure Switch

Measure the resistance between instrument cluster C286-12, circuit 253 (DG/W), and ground.


YES REPLACE the oil pressure switch. TEST the system for normal operation.

NO REPAIR circuit 253 (DG/W). TEST the system for normal operation.

C4 CHECK THE OIL PRESSURE GAUGE (NORMAL)

Oil Pressure Switch

Connect a jumper wire between the oil pressure switch C175, circuit 253 (DG/W), and ground.



PINPOINT TEST D: VOLTAGE INDICATOR GAUGE READS INACCURATELY

Check the oil pressure gauge.

� Does the gauge read in the normal range or in the upper half of the normal range?

YES REPLACE the oil pressure switch. TEST the system for normal operation.

NO GO to C5 .

C5 CHECK CIRCUIT 253 (DG/W) FOR OPEN


Measure the resistance between instrument cluster C286-12, circuit 253 (DG/W), and the oil pressure switch C175, circuit 253 (DG/W).


YES GO to C6 .

NO REPAIR circuit 253 (DG/W). TEST the system for normal operation.

C6 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Instrument Cluster

Measure the resistance between instrument cluster printed circuit terminal C286-12, and the oil pressure gauge.

� Is the resistance approximately 20 ohms?

YES REPLACE the oil pressure gauge. TEST the system for normal operation.


TEST CONDITIONS

TEST DETAILS/RESULTS/ACTIONS

D1 CHECK VOLTAGE INDICATOR GAUGE OPERATION

Check the voltage indicator gauge.

� Does the voltage indicator gauge (10A835) operate?

YES If the gauge needle is at mid-scale in the NORMAL band, the voltage indicator gauge is OK. If the gauge needle is below or above mid-scale, CHECK the charging system. REFER to Section 414-00 . If the battery and charging system are OK, REPLACE the voltage indicator gauge. TEST the system for normal operation.



PINPOINT TEST E: SPEEDOMETER/ODOMETER READS INACCURATELY

NO GO to D2 .

D2 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Instrument Cluster

Remove the instrument cluster.

NOTE: Design 2 voltage indicator gauges have calibrated 190 ohm resistor on the flex circuit between the battery input and the gauge.

Measure the resistance between the voltage indicator gauge and the instrument cluster printed circuit terminals C286-13 and C287-2.

� Are the resistances less than 5 ohms (Design 1); less than 5 ohms between instrument cluster printed circuit terminal C287-2 and voltage

indicator gauge, and between 180 ohms and 200 ohms between instrument cluster printed circuit terminal C286-13 and voltage indicator gauge (Design 2)?

YES REPLACE the voltage indicator gauge. TEST the system for normal operation.


TEST CONDITIONS

TEST DETAILS/RESULTS/ACTIONS

E1 CHECK VEHICLE SPEED SENSOR CONNECTION

Verify the connector is properly attached to the vehicle speed sensor.

� Is the connection OK?

YES GO to E2 .

NO REPAIR as necessary. TEST the system for normal operation.

E2 CHECK ODOMETER

Check the accuracy of the odometer (17A265) by performing the Odometer Accuracy Test . Refer to Component Tests in this section.

� Is the odometer accurate?

YES GO to E3 .

NO GO to E4 .

E3 CHECK SPEEDOMETER

Check the accuracy of the speedometer (17255) by performing the Speedometer Calibration Test . Refer to General Procedures in this section.

� Is the speedometer accurate?

YES Speedometer/odometer OK.

NO GO to E4 .

E4 CHECK DRIVEN GEAR

Check for proper driven gear. Refer to the Ford Speedometer Gear Supplement Charts in the Ford Master Parts Catalog for speedometer gear applications.

� Is the correct driven gear installed?

YES GO to E5 .

NO REPLACE the driven gear. REPEAT Step E3 .

E5 CHECK DRIVE GEAR, AXLE, TIRES AND RATIO ADAPTER

Check for proper drive gear, axle, tires and ratio adapter.

� Are drive gear, axle, tire and ratio adapter correct?

YES



PINPOINT TEST F: SPEEDOMETER/ODOMETER INOPERATIVE

REPLACE the speedometer. REPEAT Step E3

NO REPLACE the incorrect component. REPEAT Step E3 .


F1 CHECK THE POWER TO THE INSTRUMENT CLUSTER


Measure the voltage between instrument cluster C288-7, circuit 1001 (W/Y), and ground.


YES GO to F2 .

NO REPAIR circuit 1001 (W/Y). TEST the system for normal operation.

F2 CHECK CIRCUIT 679 (GY/BK) FOR OPEN

Vehicle Speed Sensor (VSS) C178

Measure the resistance between instrument cluster C287-1, circuit 679 (GY/BK), and VSS C178, circuit 679 (GY/BK).


YES GO to F3 .

NO REPAIR circuit 679 (GY/BK). TEST the system for normal operation.

F3 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Instrument Cluster


NOTE: Measurements must be made to the speedometer gauge pins that are inside the instrument cluster printed circuit clips.

Measure the resistance between the speedometer pins (which can be seen in the middle of the instrument cluster printed circuit clips) and the corresponding instrument cluster terminal. Refer to the table for the pin and terminal assignments.

Instrument Cluster Terminal Speedometer Gauge Pin

C286-4 I

C287-1 S

C287-2 G



PINPOINT TEST G: TACHOMETER INOPERATIVE

C288-7 B


YES GO to F4 .


F4 CHECK VEHICLE SPEED SENSOR (VSS)

Remove the VSS.

Measure the resistance between VSS C179 terminals.

� Is the resistance between 200 ohms and 300 ohms?

YES GO to F5 .

NO REPLACE the VSS. TEST the system for normal operation.

F5 CHECK VSS OPERATION

Measure the AC voltage between the terminals of the VSS as the shaft is spun.

� Does the voltage change?

YES GO to F6 .

NO REPLACE the VSS. TEST the system for normal operation.

F6 CHECK DRIVEN GEAR

Check the driven gear for damage or wear.

� Is the driven gear damaged or worn?

YES REPLACE the driven gear. TEST the system for normal operation.

NO REPLACE the speedometer. TEST the system for normal operation.




G1 CHECK THE GROUND TO THE TACHOMETER

Instrument Cluster

Measure the resistance between instrument cluster C288-8, circuit 398 (BK/Y) (4.0L SOHC), and ground.


YES GO to G2 .

NO REPAIR circuit 397 (BK/W) or circuit 398 (BK/Y). TEST the system for normal operation.

G2 CHECK CIRCUIT 11 (T/Y) FOR OPEN

Battery Negative Cable

104-Pin Breakout Box

Measure the resistance between instrument cluster C286-15, circuit 11 (T/Y), and breakout box pin 48, circuit 11 (T/Y).


YES RECONNECT PCM and battery negative cable. GO to G3 .

NO REPAIR circuit 11 (T/Y). TEST the system for normal operation.

G3 CHECK SIGNAL TO TACHOMETER

Measure the voltage between instrument cluster C286-15, circuit 11 (T/Y), and ground.

� Is the voltage between 5 and 8 volts?

YES GO to G4 .

NO REPLACE PCM. TEST the system for normal operation.

G4 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Measure the resistance between the tachometer and instrument cluster printed circuit terminals C286-13, C286-15, C286-16, C288-8 (4.0L SOHC only) and C287-2.


YES



PINPOINT TEST H: TACHOMETER NOT REFLECTING CORRECT ENGINE SPEED

PINPOINT TEST J: CHARGING SYSTEM WARNING INDICATOR INOPERATIVE

REPLACE the tachometer (17360). TEST the system for normal operation.



H1 CHECK THE GROUND TO THE TACHOMETER


Measure the resistance between instrument cluster C286-16, circuit 397 (BK/W), and ground.


YES GO to H2 .


H2 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Instrument Cluster


Measure the resistance between the tachometer and instrument cluster printed circuit terminals C286-13, C286-15, C286-16 and C287-2.


YES REPLACE the tachometer. TEST the system for normal operation.



J1 CHECK THE FUSE

Fuse 15 (7.5A)

� Is the fuse OK?

YES GO to J2 .

NO REPLACE the fuse. If the fuse fails again, CHECK circuit 584 (Y) for a short to ground. REPAIR as necessary. TEST the system for normal operation.

J2 CHECK THE CHARGING SYSTEM WARNING INDICATOR CONTROL CIRCUIT



Generator C121

Connect a jumper wire between generator C121-I, circuit 904 (LG/R), and ground.

� Does the charging system warning indicator illuminate?

YES REFER to Section 414-00 .

NO GO to J3 .

J3 CHECK THE POWER TO THE INSTRUMENT CLUSTER


Measure the voltage between instrument cluster C288-2, circuit 584 (Y), and ground.


YES GO to J4 .

NO REPAIR circuit 584 (Y). TEST the system for normal operation.

J4 CHECK CIRCUIT 904 (LG/R) FOR OPEN

Measure the resistance between instrument cluster C288-3, circuit 904 (LG/R), and generator C121-I.


YES GO to J5 .



PINPOINT TEST K: ANTI-LOCK BRAKE WARNING INDICATOR INOPERATIVE

NO REPAIR circuit 904 (LG/R). TEST the system for normal operation.

J5 CHECK THE CHARGING SYSTEM WARNING INDICATOR BULB

Measure for continuity between the terminals of the charging system warning indicator bulb.

� Does continuity exist?


NO REPLACE the bulb. TEST the system for normal operation.


K1 CHECK THE ANTI-LOCK BRAKE WARNING INDICATOR CONTROL CIRCUIT

Anti-Lock Electronic Control Module C186

Connect a jumper wire between anti-lock electronic control module C186-18, circuit 603 (DG), and ground.

� Does the anti-lock brake warning indicator illuminate?


NO GO to K2 .

K2 CHECK THE ANTI-LOCK BRAKE WARNING INDICATOR BULB

Measure for continuity between the terminals of the anti-lock brake warning indicator bulb.


YES GO to K3 .


K3 CHECK CIRCUIT 603(DG) FOR OPEN



PINPOINT TEST L: ANTI-THEFT ALARM INDICATOR INOPERATIVE

Measure the resistance between instrument cluster C288-6, circuit 603 (DG), and anti-lock electronic control module C186-18, circuit 603 (DG).



NO REPAIR circuit 603 (DG). TEST the system for normal operation.


L1 CHECK THE POWER TO THE INSTRUMENT CLUSTER


Open any door. Press the power door lock switch (14028) to lock the doors. This will set the RAP module into prearm.

Measure the voltage between instrument cluster C286-6, circuit 343 (DB/LG), and ground.


YES GO to L4 .

NO GO to L2 .

L2 CHECK CIRCUIT 343 (DB/LG) FOR OPEN

RAP Module C338

Measure the resistance between RAP module C338-16, circuit 343 (DB/LG), and instrument cluster C286-6, circuit 343 (DB/LG).


YES GO to L3 .

NO REPAIR circuit 343 (DB/LG). TEST the system for normal operation.



PINPOINT TEST M: FUEL RESET INDICATOR INOPERATIVE

L3 CHECK CIRCUIT 343 (DB/LG) FOR SHORT TO GROUND

Measure the resistance between instrument cluster C286-6, circuit 343 (DB/LG), and ground.



NO REPAIR circuit 343 (DB/LG). TEST the system for normal operation.

L4 CHECK THE GROUND TO THE INSTRUMENT CLUSTER

Measure the resistance between instrument cluster C286-7, circuit 57 (BK), and ground.


YES GO to L5 .

NO REPAIR circuit 57 (BK). TEST the system for normal operation.

L5 CHECK THE ANTI-THEFT ALARM INDICATOR LED

NOTE: Do not apply battery voltage to the anti-theft alarm indicator LED. Battery voltage will burn out the anti-theft indicator LED.

Remove and check the anti-theft alarm indicator LED.

� Is the LED OK?


NO REPLACE the LED. TEST the system for normal operation.


M1 CHECK THE FUEL RESET INDICATOR CONTROL CIRCUIT

Inertia Fuel Shutoff Switch

Connect a jumper wire between inertia fuel shutoff switch C203-1, circuit 921 (GY/O), and ground.



PINPOINT TEST N: HIGH BEAM INDICATOR INOPERATIVE

� Does the fuel reset indicator illuminate?

YES Refer to Powertrain Control/Emissions Diagnosis Manual.

NO GO to M2 .

M2 CHECK THE FUEL RESET INDICATOR BULB

Remove and check the fuel reset indicator bulb.


YES GO to M3 .


M3 CHECK CIRCUIT 921 (GY/O) FOR OPEN


Measure the resistance between instrument cluster C286-11, circuit 921 (GY/O), and inertia fuel shutoff switch C203-1, circuit 921 (GY/O).



NO REPAIR circuit 921 (GY/O). TEST the system for normal operation.


N1 CHECK THE POWER TO THE INSTRUMENT CLUSTER


Turn the headlamp switch (11654) to the ON position.

Set the multi-function switch (13K359) to the high beam position.

Measure the voltage between instrument cluster C287-6, circuit 932 (GY/W), and ground.




YES GO to N2 .

NO If equipped with daytime running lamps (DRL), GO to N4 . REPAIR circuit 932 (GY/W) and/or circuit 12 (LG/BK). TEST the system for normal operation.

N2 CHECK THE GROUND TO THE INSTRUMENT CLUSTER

Measure the resistance between instrument cluster C287-7, circuit 57 (BK), and ground.


YES GO to N3 .


N3 CHECK THE HIGH BEAM INDICATOR BULB

Measure for continuity between the terminals of the high beam indicator bulb.




N4 CHECK THE POWER TO THE DAYTIME RUNNING LAMP (DRL) MODULE

DRL Module C134

Verify the headlamp switch is in the ON position.

Verify the multi-function switch is in the high beam position.

Measure the voltage between DRL module C134-8, circuit 12 (LG/BK), and ground.



PINPOINT TEST P: CHECK ENGINE WARNING INDICATOR INOPERATIVE


YES GO to N5 .

NO REPAIR circuit 12 (LG/BK). TEST the system for normal operation.

N5 CHECK CIRCUIT 932 (GY/W) FOR OPEN

Measure the resistance between DRL module C134-1, circuit 932 (GY/W), and instrument cluster C287-6, circuit 932 (GY/W).


YES REPLACE the DRL module. TEST the system for normal operation.

NO REPAIR circuit 932 (GY/W). TEST the system for normal operation.


P1 CHECK THE ENGINE WARNING INDICATOR CONTROL CIRCUIT


Connect a jumper wire between breakout box pin 2 and pin 24.

� Does the check engine warning indicator illuminate?

YES Refer to Powertrain Control/Emissions Diagnosis Manual.

NO GO to P2 .

P2 CHECK THE ENGINE WARNING INDICATOR BULB

Measure for continuity between the terminals of the engine warning indicator bulb.



PINPOINT TEST Q: LH TURN SIGNAL INDICATOR INOPERATIVE


YES GO to P3 .


P3 CHECK CIRCUIT 658 (PK/LG) FOR OPEN


Measure the resistance between breakout box pin 2 and instrument cluster C288-7, circuit 658 (PK/LG), (early production) or instrument cluster C287-11, circuit 658 (PK/LG), (late production).



NO REPAIR circuit 658 (PK/LG). TEST the system for normal operation.


Q1 CHECK THE POWER TO THE INSTRUMENT CLUSTER


Place the multi-function switch in the LH turn signal position.



Measure the voltage between instrument cluster C287-5, circuit 3 (LG/W), and ground.


YES GO to Q2 .

NO REPAIR circuit 3 (LG/W). TEST the system for normal operation.

Q2 CHECK THE GROUND TO THE INSTRUMENT CLUSTER

Measure the resistance between instrument cluster C287-7, circuit 57 (BK), (early production), or instrument cluster C286-9, circuit 57 (BK), (late production), and ground.


YES GO to Q3 .


Q3 CHECK THE LH TURN INDICATOR BULB

Measure for continuity between the terminals of the LH turn indicator bulb.






PINPOINT TEST R: RH TURN SIGNAL INDICATOR INOPERATIVE


R1 CHECK THE POWER TO THE INSTRUMENT CLUSTER


Place the multi-function switch in the RH turn signal position.

Measure the voltage between instrument cluster C286-10, circuit 2 (W/LB), and ground.


YES GO to R2 .

NO REPAIR circuit 2 (W/LB). TEST the system for normal operation.

R2 CHECK THE GROUND TO THE INSTRUMENT CLUSTER

Measure the resistance between instrument cluster C286-7, circuit 57 (BK), (early production), or instrument cluster C286-9, circuit 57 (BK), (late production), and ground.


YES GO to R3 .



PINPOINT TEST S: OVERDRIVE OFF INDICATOR INOPERATIVE


R3 CHECK THE RH TURN INDICATOR BULB

Measure for continuity between the terminals of the RH turn indicator bulb.





S1 CHECK THE OVERDRIVE (O/D) OFF INDICATOR CONTROL CIRCUIT


Verify the headlamp switch is in the off position.

Connect a jumper wire between breakout box pin 79 and pin 24.

� Does the O/D OFF indicator illuminate?


NO GO to S2 .

S2 CHECK THE POWER TO THE HEADLAMP SWITCH

Headlamp Switch C216

Measure the voltage between headlamp switch C216-4, circuit 192 (BR/W), and ground.




YES GO to S5 .

NO GO to S3 .

S3 CHECK THE POWER TO THE DIMMER CONTROL RELAY SWITCH

Dimmer Control Relay

Measure the voltage between dimmer control relay connector pin 4, circuit 640 (R/Y), and ground.


YES GO to S4 .


S4 CHECK THE DIMMER CONTROL RELAY

Measure the resistance between dimmer control relay terminal 3 and terminal 4.


YES REPAIR circuit 192 (BR/W). TEST the system for normal operation.

NO REPLACE the dimmer control relay. TEST the system for normal operation.

S5 CHECK CIRCUIT 19 (LB/R) FOR OPEN



Pulse Width Dimmer Module C219

Measure the resistance between pulse width dimmer module C219-4, circuit 19 (LB/R), and headlamp switch C216-9, circuit 19 (LB/R).


YES GO to S6 .

NO REPAIR circuit 19 (LB/R). TEST the system for normal operation.

S6 CHECK THE HEADLAMP SWITCH

Verify the headlamp switch is in the OFF position.

Measure the resistance between headlamp switch C216 terminal 4 and terminal 8.

Turn the headlamp switch to the on position.



YES GO to S7 .

NO REPLACE the headlamp switch. TEST the system for normal operation.

S7 CHECK CIRCUIT 484 (O/BK) FOR OPEN


Measure the resistance between instrument cluster C286-5, circuit 484 (O/BK), and headlamp switch C216-8, circuit 484 (O/BK).


YES GO to S8 .

NO REPAIR circuit 484 (O/BK). TEST the system for normal operation.

S8 CHECK CIRCUIT 911 (W/LG) FOR OPEN

Measure the resistance between instrument cluster C286-1, circuit 911 (W/LG), and breakout box pin 79, circuit 911



PINPOINT TEST T: SPEED CONTROL INDICATOR INOPERATIVE

(W/LG).


YES GO to S9 .

NO REPAIR circuit 911 (W/LG). TEST the system for normal operation.

S9 CHECK THE OVERDRIVE OFF INDICATOR BULB

Measure for continuity between the terminals of the overdrive off indicator bulb.





T1 CHECK THE SPEED CONTROL INDICATOR CONTROL CIRCUIT

Speed Control Servo C171

Connect a jumper wire between speed control servo C171-1, circuit 203 (O/LB), and ground.

� Does the speed control indicator illuminate?

YES REPLACE the speed control servo (9C735). TEST the system for normal operation.

NO GO to T2 .

T2 CHECK THE POWER TO THE HEADLAMP SWITCH



Headlamp Switch C216

Measure the voltage between headlamp switch C216-4, circuit 192 (BR/W), and ground.


YES GO to T5 .

NO GO to T3 .

T3 CHECK THE POWER TO THE DIMMER CONTROL RELAY SWITCH

Dimmer Control Relay

Measure the voltage between dimmer control relay connector pin 4, circuit 640 (R/Y), and ground.


YES GO to T4 .


T4 CHECK THE DIMMER CONTROL RELAY

Measure the resistance between dimmer control relay terminal 3 and terminal 4.


YES REPAIR circuit 192 (BR/W). TEST the system for normal operation.

NO REPLACE the dimmer control relay. TEST the system for normal operation.

T5 CHECK CIRCUIT 19 (LB/R) FOR OPEN



Pulse Width Dimmer Module C219

Measure the resistance between pulse width dimmer module C219-4, circuit 19 (LB/R), and headlamp switch C216-9, circuit 19 (LB/R).


YES GO to T6 .

NO REPAIR circuit 19 (LB/R). TEST the system for normal operation.

T6 CHECK THE HEADLAMP SWITCH

Verify the headlamp switch is in the OFF position.


Turn the headlamp switch to the ON position.



YES GO to T7 .

NO REPLACE the headlamp switch. TEST the system for normal operation.

T7 CHECK CIRCUIT 484 (O/BK) FOR OPEN


Measure the resistance between instrument cluster C286-5, circuit 484 (O/BK), and headlamp switch C216-8, circuit 484 (O/BK).


YES GO to T8 .



PINPOINT TEST U: RED BRAKE WARNING INDICATOR INOPERATIVE

NO REPAIR circuit 484 (O/BK). TEST the system for normal operation.

T8 CHECK CIRCUIT 203 (O/LB) FOR OPEN

Measure the resistance between instrument cluster C286-4, circuit 203 (O/LB), and speed control servo C171-1, circuit 203 (O/LB).


YES GO to T9 .

NO REPAIR circuit 203 (O/LB). TEST the system for normal operation.

T9 CHECK THE SPEED CONTROL INDICATOR BULB

Measure for continuity between the terminals of the speed control indicator bulb.





U1 CHECK THE PARKING BRAKE SWITCH CONTROL CIRCUIT

Set the parking brake.

� Does the red brake warning indicator illuminate?

YES RELEASE the parking brake. GO to U2 .

NO GO to U5 .

U2 CHECK THE RED BRAKE WARNING INDICATOR CONTROL CIRCUIT

Brake Fluid Level Switch C143

Connect a jumper wire between brake fluid level switch C143, circuit 977 (P/W), and ground.




YES Refer to Section 206-00 .

NO GO to U3 .

U3 CHECK CIRCUIT 977 (P/W) FOR OPEN


Measure the resistance between instrument cluster C288-5, circuit 977 (P/W), and brake fluid level switch C143, circuit 977 (P/W).


YES GO to U4 .

NO REPAIR circuit 977 (P/W). TEST the system for normal operation.

U4 CHECK THE RED BRAKE WARNING INDICATOR BULB

Measure for continuity between the terminals of the red brake warning indicator bulb.




U5 CHECK THE PARKING BRAKE SWITCH

Parking Brake Switch C211

Connect a jumper wire between parking brake switch C211, circuit 162 (LG/R), and ground.




YES REPLACE the parking brake switch. TEST the system for normal operation.

NO GO to U6 .

U6 CHECK THE RED BRAKE WARNING INDICATOR BULB

Measure for continuity between the terminals of the red brake warning indicator bulb.


YES For vehicles equipped without daytime running lamps (DRL), GO to U7 . For vehicles equipped with DRL, GO to U8 .




Measure the resistance between instrument cluster C288-5, circuit 977 (P/W), and parking brake switch C211, circuit 162 (LG/R).



NO REPAIR circuit 977 (P/W) and/or circuit 162 (LG/R). TEST the system for normal operation.

U8 CHECK CIRCUIT 162 (LG/R) FOR OPEN

DRL Module C134

Measure the resistance between DRL module C134-4, circuit 162 (LG/R), and the parking brake switch C211, circuit 162 (LG/R).



PINPOINT TEST V: CHECK GAGE INDICATOR INOPERATIVE


YES GO to U9 .

NO REPAIR circuit 162 (LG/R). TEST the system for normal operation.



Measure the resistance between instrument cluster C288-5, circuit 977 (P/W), and DRL module C134-5, circuit 977 (P/W).


YES GO to U10 .

NO REPAIR circuit 977 (P/W). TEST the system for normal operation.

U10 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Instrument Cluster

Measure the resistance between the red brake warning indicator bulb socket and instrument cluster printed circuit terminals C287-8 and C288-5.


YES REPLACE the DRL module. TEST the system for normal operation.



V1 CHECK GAUGES

� Are the gauges OK?

YES GO to V2 .

NO REFER to the Symptom Chart.

V2 CHECK THE CHECK GAGE INDICATOR BULB



Measure for continuity between the terminals of the CHECK GAGE indicator bulb.


YES GO to V3 .


V3 CHECK THE INSTRUMENT CLUSTER PRINTED CIRCUIT

Instrument Cluster


Measure the resistance of the instrument cluster printed circuit between the following:

� CHECK GAGE indicator bulb socket and instrument cluster printed circuit terminal C287-8.

� CHECK GAGE indicator bulb and instrument cluster gauge amplifier.


YES REPLACE the fuel gauge and instrument cluster gauge amplifier. TEST the system for normal operation.




Documents

~Www2.justanswer.com/uploads/fordguy4u/2011-12-19_183312_a1.pdf · 12/19/2011 · Is the resistance greater than 10,000 ohms? YES REPAIR circuit 29 (Y/W). TEST the system for normal