instrument panel CHRYSLER VOYAGER 1996 User Guide

fluid accumulators temporarily store brake fluid that
is decayed from the wheel brakes during an ABS
cycle. This stored brake fluid is then used by the
pump in the HCU to provide build pressure for the
brake hydraulic system.
Additionally on vehicles that are equipped with
only ABS (non-traction control vehicles) there is a
mini brake fluid accumulator on the secondary
hydraulic circuit which protects the master cylinder's
seals during an ABS stop. There is also a noise
damping chamber on the primary hydraulic circuit.
On ABS equipped vehicles with traction control, in
addition to the brake fluid accumulators there are
also two noise damping chambers in the HCU.
HCU PUMP/MOTOR
The HCU (Fig. 4) contains 2 pump assemblies, one
for the primary and one for the secondary hydraulic
circuit of the brake system. Both pumps are driven
by a common electric motor (Fig. 4) which is part of
the HCU. The pumps draw brake fluid from the fluid
accumulators to supply build pressure to the brakes
during an ABS stop. The pump motor runs during
the drive-off cycle as a check and during an ABS stop
and is controlled by the CAB. The Pump/Motor
Assembly is not a serviceable item. If the pump/mo-
tor requires replacement the complete HCU (Fig. 4)
(minus the CAB) must be replaced.
ABS FUSES
The fuse for the ABS pump motor and the ABS system
are located in the power distribution center (PDC) (Fig. 5).
The PDC is located on the drivers side of the engine com-
partment forward of the strut tower. The fuse for the ABS
warning lamp in the instrument panel message center is
located in the junction block.
On vehicles equipped with traction control, the
fuse for the traction control switch is also located in
the junction block.The junction block is located on the left hand front
cowl panel on the vehicle.
ABS RELAYS
On the Teves Mark 20 Antilock Brake System both
the pump motor relay and the system relay are
located in the CAB. If either of the relays is diag-
nosed as not functioning properly the CAB will need
to be replaced. Refer to Controller Antilock Brakes in
the Removal And Installation Section in this group of
the service manual for the procedure.
PROPORTIONING VALVES
One assembly containing two proportioning valves
are used in the system, one for each rear brake
hydraulic circuit. The proportioning valve is located
on the frame rail next to the fuel tank, forward of the
right rear shock absorber (Fig. 6). Be sure replace-
ment proportioning valve assemblies have the same
split point and slope as the proportioning valve being
replaced.
WHEEL SPEED SENSORS
One Wheel Speed Sensor WSS is located at each
front and rear wheel of the vehicle (Fig. 7), (Fig. 8)
and (Fig. 9). The wheel speed sensor sends a small
AC signal to the CAB. This signal is generated by
magnetic induction created when a toothed sensor
ring (tone wheel) (Fig. 7), (Fig. 8) and (Fig. 9) passes
the stationary magnetic wheel speed sensor. The
CAB converts the AC signal generated at each wheel
into a digital signal. If a wheel locking tendency is
detected by the CAB, it will then modulate hydraulic
pressure via the HCU to prevent the wheel(s) from
locking.
Fig. 4 Teves Mark 20 HCU Pump/Motor
Fig. 5 Fuse Locations In Power Distribution Center
NSBRAKES 5 - 89
DESCRIPTION AND OPERATION (Continued)

The primary functions of the (CAB) are:
(1) Detect wheel locking or wheel slipping tenden-
cies by monitoring the speed of all four wheels of the
vehicle.
(2) Illuminate the TRAC lamp in the message cen-
ter on the instrument panel when a traction control
event is occurring.
(3) Control fluid modulation to the wheel brakes
while the system is in an ABS mode or the traction
control system is activated.
(4) Monitor the system for proper operation.
(5) Provide communication to the DRB Scan Tool
while in diagnostic mode.
(6) Store diagnostic information.
(7)The CAB continuously communicates with
the body controller by sending out a message to
the body controller on the CCD Bus. This mes-
sage is used for illumination of the yellow
antilock warning lamp. This is used if the ABS
controller communication is lost in the hard
wire between the body controller and the yel-
low antilock warning lamp. If the body control-
ler does not receive this message from the CAB,
the body controller will illuminate the antilock
yellow warning lamp.
The CAB continuously monitors the speed of each
wheel through the signals generated by the wheel
speed sensors to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the CAB commands the CAB command coils to actu-
ate. The CAB command coils then open and close the
valves in the HCU which modulate brake fluid pres-
sure in some or all of the hydraulic circuits. The CAB
continues to control pressure in individual hydraulic
circuits until a locking tendency is no longer present.
The ABS system is constantly monitored by the
CAB for proper operation. If the CAB detects a fault,
it will turn on the Amber ABS Warning Lamp anddisable the ABS braking system. The normal base
braking system will remain operational.
The CAB contains a self-diagnostic program which
will turn on the Amber ABS Warning Lamp when a
ABS system fault is detected. Faults are then stored
in a diagnostic program memory. There are multiple
fault messages which may be stored in the CAB and
displayed through the DRB Scan Tool. These fault
messages will remain in the CAB memory even after
the ignition has been turned off. The fault messages
can be read and or cleared from the CAB memory by
a technician using the DRB Scan Tool. The fault
occurrence and the fault code will also be automati-
cally cleared from the CAB memory after the identi-
cal fault has not been seen during the next 3500
miles of vehicle operation. Mileage though of the last
fault occurrence will not be automatically cleared.CONTROLLER ANTILOCK BRAKE INPUTS
²Four wheel speed sensors.
²Stop lamp switch.
²Ignition switch.
²System relay voltage.
²Ground.
²Traction Control Switch (If Equipped).
²Diagnostics Communications (CCD)
CONTROLLER ANTILOCK BRAKE OUTPUTS
²C2D Communication To Body Controller And
Instrument Cluster
²ABS warning lamp actuation.
²Traction Control Light (If Equipped).
²Diagnostic communication. (CCD)
ABS WARNING LAMP (YELLOW)
The ABS system uses a yellow colored ABS Warn-
ing Lamp. The ABS warning lamp is located on the
right side of the message center located at the top of
the instrument panel. The purpose of the warning
lamp is discussed in detail below.
The ABS warning lamp will turn on when the CAB
detects a condition which results in a shutdown of
ABS function or when the body controller does not
receive C2D messages from the CAB. When the igni-
tion key is turned to the on position, the ABS Warn-
ing Lamp is on until the CAB completes its self tests
and turns the lamp off (approximately 4 seconds
after the ignition switch is turned on). Under most
conditions, when the ABS warning lamp is on, only
the ABS function of the brake system is affected. The
standard brake system and the ability to stop the car
will not be affected when only the ABS warning lamp
is on.
The ABS warning lamp is controlled by the CAB
and the body controller through a diode located in
the wiring harness junction block. The junction block
is located under the instrument panel to the left of
Fig. 10 Controller Antilock Brake (CAB)
NSBRAKES 5 - 91
DESCRIPTION AND OPERATION (Continued)

If the brake system is to be bled using pressurized
bleeding equipment, refer to Bleeding Brake System
in the Service Adjustments section at the beginning
of this group for proper equipment usage and proce-
dures.
(1) Assemble and install all brake system compo-
nents on the vehicle making sure all hydraulic fluid
lines are installed and properly torqued.
(2) Connect the DRB Diagnostics Tester to the
diagnostics connector. The Teves Mark 20 ABS diag-
nostic connector is located under the instrument
panel to the left of the steering column cover.
(3) Using the DRB, check to make sure the CAB
does not have any fault codes stored. If it does,
remove them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYS-
TEM WEAR SAFETY GLASSES. A CLEAR BLEED
TUBE MUST BE ATTACHED TO THE BLEEDER
SCREWS AND SUBMERGED IN A CLEAR CON-
TAINER FILLED PART WAY WITH CLEAN BRAKE
FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY
FROM THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME
OUT OF THE BLEEDER SCREWS WHEN OPENED.
(4) Bleed the base brake system using the stan-
dard pressure or manual bleeding procedure as out-
lined in the Service Adjustments section of this
service manual.
(5) Using the DRB, go to the9Bleed ABS9routine.
Apply the brake pedal firmly and initiate the9Bleed
ABS9cycle one time. Release the brake pedal.
(6) Bleed the base brake system again, as in step
Step 4 above.
(7) Repeat steps Step 5 and Step 6 above until
brake fluid flows clear and is free of any air bubbles.
Check brake fluid level in reservoir periodically to
prevent reservoir from running low on brake fluid.
(8) Test drive the vehicle to be sure brakes are
operating correctly and that brake pedal is solid.
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS
CAUTION: Review this entire section prior to per-
forming any mechanical work on a vehicle equipped
with the ITT Tevis Mark 20 ABS brake system. This
section contains information on precautions per-
taining to potential component damage, vehicle
damage and personal injury which could result
when servicing an ABS equipped vehicle.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
CAUTION: Certain components of the ABS System
are not intended to be serviced individually.
Attempting to remove or disconnect certain system
components may result in improper system opera-
tion. Only those components with approved
removal and installation procedures in this manual
should be serviced.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash off with water immediately.
CAUTION: When performing any service procedure
on a vehicle equipped with ABS do not apply a 12
volt power source to the ground circuit of the pump
motor in the CAB. Doing this will damage the pump
motor and will require replacement of the HCU.
The following are general cautions which should be
observed when servicing the ABS system and/or
other vehicle systems. Failure to observe these pre-
cautions may result in ABS System component dam-
age.
If welding work is to be performed on the vehicle,
using an electric arc welder, the CAB connector
should be disconnected during the welding operation.
The CAB 25 way connector connector should never
be connected or disconnected with the ignition switch
in the ON position.
Many components of the ABS System are not ser-
viceable and must be replaced as an assembly. Do not
disassemble any component which is not designed to
be serviced.
HYDRAULIC CONTROL UNIT
REMOVE
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
(3) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
5 - 100 BRAKESNS
SERVICE PROCEDURES (Continued)

DESCRIPTION AND OPERATION
CLUTCH RELEASE SYSTEM
CLUTCH CABLE Ð LHD
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear (Fig. 7). This adjuster mechanism is
located within the clutch cable assembly. The preload
spring maintains tension on the cable. This tension
keeps the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
HYDRAULIC CLUTCH Ð RHD
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage to disengage and engage the modular clutch
assembly.
The modular clutch assembly contains the cover,
diaphragm spring, pressure plate, disc and flywheel
in one unit. The modular clutch also uses a drive
plate and is bolted to and driven by the drive plate.
The clutch linkage uses hydraulic pressure to oper-
ate the clutch. The clutch master cylinder push rod is
connected to the clutch pedal and the slave cylinder
push rod is connected to the release lever in the
clutch housing.
Depressing the clutch pedal develops fluid pressure
in the clutch master cylinder. This pressure is trans-
mitted to the slave cylinder through a connecting
line. In turn, the slave cylinder operates the clutch
release lever.
The clutch release bearing is mounted on the
transmission front bearing retainer. The bearing is
attached to the release lever, which moves the bear-
ing into contact with the clutch cover diaphragm
spring.Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc. The
clutch disc is disengaged and not driven at this point.
The process of clutch engagement is simply the
reverse of what occurs during disengagement. Releas-
ing pedal pressure removes clutch linkage pressure.
The release bearing moves away from the diaphragm
spring which allows the pressure plate to exert
clamping force on the clutch disc.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged.
The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch.
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 8).
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION
SWITCH±ELECTRICAL TEST
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
Fig. 7 Clutch Cable Ð LHD
Fig. 8 Clutch Pedal Position Switch and
Components Ð LHD Shown
6 - 4 CLUTCHNS/GS

COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
COOLANT PRESSURE BOTTLE............ 1
COOLING SYSTEM Ð 2.0L GASOLINE...... 1
COOLING SYSTEM Ð 2.5L VM DIESEL..... 1
LOW COOLANT LEVEL SENSOR........... 1
RADIATOR............................ 2
DESCRIPTION AND OPERATION
AUTOMATIC BELT TENSIONER............ 6
BELT TENSION......................... 5
COOLANT PERFORMANCE............... 5
PRESSURE/VENT CAP................... 4
THERMOSTAT OPERATION............... 4
THERMOSTAT......................... 6
WATER PUMP......................... 3
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT........... 7
DRAINING COOLING SYSTEM............. 7
REFILLING COOLING SYSTEM............ 7
REMOVAL AND INSTALLATION
ENGINE THERMOSTATÐ 2.0L GASOLINE . . . 9GENERATOR/POWER STEERING BELT Ð 2.5L
VM DIESEL......................... 10
RADIATOR Ð 2.5L VM DIESEL........... 9
THERMOSTAT Ð 2.5L VM DIESEL......... 9
WATER PUMP BELT Ð 2.5L VM DIESEL . . . 10
WATER PUMP Ð 2.0L GASOLINE......... 7
WATER PUMP Ð 2.5L VM DIESEL........ 8
CLEANING AND INSPECTION
WATER PUMP........................ 10
ADJUSTMENTS
BELT TENSION CHART................. 11
BELT TENSION GAUGE METHOD......... 11
SPECIFICATIONS
COOLING SYSTEM CAPACITY............ 12
TORQUE CHART...................... 12
SPECIAL TOOLS
COOLING............................ 12
GENERAL INFORMATION
COOLING SYSTEM Ð 2.0L GASOLINE
The 2.0L gasoline engine cooling system consists of
an engine cooling module, thermostat, coolant, a
water pump to circulate the coolant. The engine cool-
ing module may consist of a radiator, electric fan
motors, fan, shroud, coolant reserve system, hoses,
clamps, air condition condenser.
²When the Engine is cold: The thermostat is
closed; the cooling system has no flow through the
radiator. The coolant flows through the engine,
heater system and bypass.
²When the Engine is warm: Thermostat is open;
the cooling system has flow through radiator, engine,
heater system and bypass.
COOLING SYSTEM Ð 2.5L VM DIESEL
The cooling system has a radiator, coolant, electric
fan motors, shroud, pressure cap, thermostat, coolant
pressure bottle, hoses, a water pump to circulate the
coolant, to complete the circuit. Coolant flow for the
VM diesel engine is shown in (Fig. 1).
COOLANT PRESSURE BOTTLE
2.5L VM DIESEL
This system works with the pressure cap to use
thermal expansion and contraction of the coolant to
keep the coolant free of trapped air. It provides some
reserve coolant to cover minor leaks and evaporation
or boiling losses. The coolant pressure bottle location
for 2.5L diesel is above the cylinder head cover (Fig.
2).
LOW COOLANT LEVEL SENSOR
The low coolant level sensor checks for low coolant
level in the coolant tank. A signal will be sent from
this sensor to the Body Control Module (BCM). When
the BCM determines low coolant level for 30 contin-
uous seconds, the instrument panel mounted low
coolant level warning lamp will be illuminated. The
sensor is located on the front side of the coolant tank
(Fig. 4). For information, refer to Group 8E, Instru-
ment Panel and Gauges.
If this lamp is illuminated, it indicates the need to
fill the coolant tank and check for leaks.
NS/GSCOOLING SYSTEM 7 - 1

INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER................... 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 2
HEADLAMP SWITCH..................... 2
SELF DIAGNOSTIC TEST.................. 2
TRACTION CONTROL SWITCH............. 17
REMOVAL AND INSTALLATION
BODY CONTROL MODULE (BCM).......... 18
CONVENIENCE BIN - CUP HOLDER......... 17
CONVENIENCE BIN LAMP................ 17
CONVENIENCE BIN TRACK............... 18
GLOVE BOX LAMP AND SWITCH.......... 19
GLOVE BOX LOCK STRIKER.............. 20
GLOVE BOX........................... 19
HEADLAMP SWITCH LAMP(S)............ 21
HEADLAMP SWITCH.................... 20
HVAC CONTROL LAMP.................. 21
INSTRUMENT CLUSTER BACK PANEL...... 21
INSTRUMENT CLUSTER BEZEL............ 21
INSTRUMENT CLUSTER ELECTRONIC
ODOMETER AND TRANSMISSION RANGE
INDICATOR.......................... 19
INSTRUMENT CLUSTER LAMPS........... 22
INSTRUMENT CLUSTER LENS - MECHANICAL
TRANSMISSION RANGE INDICATOR
(PRND21)........................... 19
INSTRUMENT CLUSTER LENS............. 22INSTRUMENT CLUSTER PRINTED CIRCUIT
BOARD.............................. 23
INSTRUMENT CLUSTER SUBDIAL.......... 23
INSTRUMENT CLUSTER SUBDIALÐ
MECHANICAL TRANSMISSION RANGE
INDICATOR.......................... 23
INSTRUMENT CLUSTER WITH ELECTRONIC
TRANSMISSION RANGE INDICATOR...... 23
INSTRUMENT CLUSTER WITH MECHANICAL
TRANSMISSION RANGE INDICATOR...... 24
INSTRUMENT PANEL LEFT END COVER..... 27
INSTRUMENT PANEL LOUVERS........... 27
INSTRUMENT PANEL RIGHT END COVER.... 29
INSTRUMENT PANEL TOP COVER.......... 29
INSTRUMENT PANEL.................... 25
JUNCTION BLOCK...................... 30
KNEE BLOCKER REINFORCEMENT......... 30
LOWER CONSOLE...................... 30
LOWER INSTRUMENT PANEL............. 31
LOWER STEERING COLUMN COVER........ 31
MECHANICAL TRANSMISSION RANGE
INDICATOR.......................... 32
MESSAGE CENTER LAMP................ 32
MESSAGE CENTER...................... 32
OUTLET (12 VOLT) BASE................. 32
OVER STEERING COLUMN BEZEL.......... 32
POWER MIRROR SWITCH LAMP.......... 34
POWER MIRROR SWITCH................ 34
RADIO BEZEL AND HVAC CONTROL........ 34
REAR HEATER-A/C SWITCH LAMP......... 35
REAR HEATER-A/C SWITCH............... 35
TRACTION CONTROL SWITCH............. 35
GENERAL INFORMATION
INTRODUCTION
The instrumentation gauges on NS vehicles are
contained in a subdial assemblies within the instru-
ment cluster. The individual gauges are not serviced
separately. If one of the cluster gauges becomes
faulty the entire subdial would require replacement
and all gauges will have to be calibrated. Refer to the
proper Body Diagnostic Procedure Manual for cali-
bration procedures.
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER
The mechanical instrument cluster with a tachom-
eter is equipped with a electronic vacuum fluorescent
transmission range indicator (PRND3L), odometer,
and trip odometer display.
The mechanical instrument cluster without a
tachometer is equipped with a cable operated trans-
mission range indicator (PRND21).
NSINSTRUMENT PANEL AND SYSTEMS 8E - 1

The instrument cluster is equipped with the follow-
ing warning lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
NS vehicle instrument clusters are equipped with a
self diagnostic test feature to help identify electronic
problems. Prior to any test, perform Self Diagnostic
Test. The self diagnostic system monitors the CCD
bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in
the odometer window of the cluster.
The following CCD bus messages are continuously
monitored by the diagnostic system:
²Body Control Module
²Powertrain Control Module
²Transmission Control Module, if equipped
HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode
test to perform the Headlamp Switch Test below (Fig.
1).
Switch position possibilities are open (no continu-
ity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine
meter setting. If Headlamp Switch is not within spec-
ifications replace as necessary.
The Chrysler Town and Country is available with
optional Automatic Headlamps. For diagnosis, refer
to the proper Body Diagnostic Procedures Manual.
SELF DIAGNOSTIC TEST
To activate self diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP and RESET buttons.
(2) While holding the TRIP and RESET button
turn the ignition switch to the ON position.
(3) Continue to hold the TRIP and RESET buttons
until the word CODE appears in the odometer win-
dows (about five seconds) then release the buttons. If
a problem exists, the system will display Diagnostic
Trouble Codes (DTC's). If no problem exists, the code
999 (End Test) will momentarily appear.
DIM TEST
When CHEC-0 is displayed in the odometer win-
dow, the cluster's vacuum fluorescent (VF) displayswill dim down. If the VF display brightness does no
change, a problem exists in the cluster.
Fig. 1 Headlamp Switch Test
8E - 2 INSTRUMENT PANEL AND SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)

CLUSTER CALIBRATION TABLE
Speedometer Calibration Point
1 ............................0mph(0Km/h)
2 ..........................20mph(40Km/h)
3 ..........................55mph(80Km/h)
4 .........................75mph(120 Km/h)
Tachometer Calibration Point
1....................................0rpm
2 .................................1000 rpm
3 .................................3000 rpm
4 .................................6000 rpm
Fuel Gauge Calibration Point
1.................................Empty (E)
2 .................................1/8 Filled
3 .................................1/4 Filled
4...................................Full (F)
Temperature Gauge Calibration Point
1 ..................................Cold (C)
2...............................Low Normal
3 ..............................High Normal
4...................................Hot (H)
CALIBRATION TEST
When CHEC-1 is displayed in the odometer win-
dow, each of the cluster's gauge pointers will move
sequentially through each calibration point. The Cal-
ibration Table contains the proper calibration points
for each gauge. If the gauge pointers are not cali-
brated, a problem exists in the cluster. If any gauge
is out of calibration it will have to be calibrated using
a scan tool (DRB III). Refer to the proper Body Diag-
nostic Procedure Manual for calibration procedures.
ODOMETER SEGMENT TEST
When CHEC-2 is displayed in the odometer win-
dow, each digit of the odometer will illuminate
sequentially. If a segment in the odometer does not
illuminate normally, a problem exists in the display.
ELECTRONIC TRANSMISSION RANGE
INDICATOR SEGMENT TEST
When CHEC-3 is displayed in the odometer win-
dow, each segment of the transmission range indica-
tor will illuminate sequentially. If a segment in the
transmission range indicator does not illuminate nor-
mally, a problem exists in the display board.
CONDITIONS
Refer to the following tables:
²Instrument Cluster
²Speedometer
²Tachometer
²Fuel Gauge
²Temperature Gauge
²Odometer
²Electronic Transmission Range Indicator
(PRND3L)
²Mechanical Transmission Range Indicator
(PRND21)
for possible/problems/causes and corrections.
INSTRUMENT CLUSTER DTC TABLE
DTC DESCRIPTION
110 Memory Fault in cluster
111 Calibration fault in cluster
905 No CCD bus messages from TCM
921 Odometer fault from BCM
940 No CCD bus messages from PCM
999 End of Codes
INSTRUMENT CLUSTER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INSTRUMENT CLUSTER
INOPERATIVE-NO
RESPONSENo CCD bus messages
from the Body Control
Module (BCM).1. Use a scan tool to check the BCM. If OK, look for
another possible cause for cluster failure. If not OK,
refer to the proper Body Diagnostic Procedure Manual.
Spread terminal(s) on
wiring harness cluster
connector.1. Remove cluster from instrument panel and check
wiring harness connector for spread terminal. If OK,
look for another possible cause for the cluster failure. If
not OK, repair connector.
Body Control Module
(BCM) is not receiving
proper input from the
ignition switch.1. Use a scan tool to verify ignition switch status into
the BCM. If not OK, go to Step (2). If OK, look at
another possible cause of failure.
2. Check ignition switch function and wiring.
Internal cluster failure. 1. Replace main cluster pc board and use a scan tool
to calibrate cluster.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 3
DIAGNOSIS AND TESTING (Continued)

SPEEDOMETER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT1. Internal cluster failure. 1. (a) Perform cluster self diagnostic test and check for
fault codes.
²If speedometer pointer moves to calibration points
during test and fault codes 110 or 111 don't appear in
the odometer display then failure is not in the cluster.
Look for another possible cause of failure.
²If the pointer doesn't move during test, go to Step
(b).
²If fault code 110 is displayed in the odometer, go to
Step (b).
²If fault code 111 is displayed in the odometer then go
to Step (f).
²If fault codes 905, 920, or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault and repair module.
(b) Replace main cluster pc board. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, complete installation. If not OK,
go to Step (e).
(e) Replace subdial assembly and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the speedometer failure.
(f) Use a scan tool to calibrate speedometer and
perform Self Diagnostic Test. If OK, stop. If not OK, go
to Step (b).
2. No speed CCD Bus
Message or Zero mph
CCD Speed Bus
Message.2. (a) Check the Body Control Module (BCM) using a
scan tool. If OK, go to Step (b). If not OK, refer to the
BCM section of the service manual to repair the BCM.
(b) Check the Powertrain Control Module (PCM) using
a scan tool. If OK, go to Step (c). If not OK, refer to the
PCM section of the service manual to repair the PCM.
(c) Check the speed signal input into the PCM. The
speed signal originates from one of the following
sources:
²A distance sensor for vehicles with 3 speed automatic
transmission. Check continuity from distance sensor to
PCM. If OK, replace distance sensor. If not OK, repair
wiring.
²The Electronic Transmission Control Module (TCM)
for vehicles with the 4 speed electronic transmissions.
Check continuity from TCM to PCM. If OK, use a scan
tool to check TCM. Refer to the electronic TCM section
of the service manual to repair the TCM. If not OK,
repair wiring.
8E - 4 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT1. Erratic Message from
another Module.1. (a) Check the BCM using a scan tool If OK, go to
Step (b). If not OK, refer to the BCM section of the
service manual to repair the BCM.
(b) Check the PCM using a scan tool. If OK, go to Step
(c). If not OK, refer to the PCM section of the service
manual to repair the PCM.
(c) Check the speed signal input into the PCM. The
speed signal originates from one of the following
sources:
²A distance sensor for vehicles with 3 speed automatic
transmission. Check continuity from distance sensor to
PCM. If OK, replace distance sensor. If not OK, repair
wiring.
²The Electronic Transmission Control Module (TCM)
vehicles with the 4 speed electronic transmissions.
Check continuity from TCM to engine controller. If OK,
use a scan tool to check TCM. Refer to the electronic
section of the service manual to repair the TCM. If not
OK, repair wiring.
2. Internal Cluster Failure. 2. (a) Perform cluster self diagnostic test and check for
fault codes.
²If the pointer moves during test but still appears
erratic and fault codes 110 or 111 don't appear in the
odometer display, then go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (e).
²If fault code 111 appears in the odometer display go
to Step (d).
²If fault codes 905, 920, or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault and repair module.
(b) Replace cluster subdial assembly. To Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the speedometer failure.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 5
DIAGNOSIS AND TESTING (Continued)