gas gauge not reading DODGE RAM 1500 1998 2.G Workshop Manual

exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If the solution
is clean, drain the coolant into a clean container for
reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINECOOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of the top of the thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
DIAGNOSIS AND TESTING - COOLING SYSTEM DIESEL ENGINE
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW1. Vehicle is equipped with a heavy
duty cooling system.1. None. System operating normally.
NOTE: Information on dash cluster
is displayed based on broadcast
datd from ECM. DTC will be set for
engine sensore circuit concern.2. Thermostat stuck open 2. Inspect and test thermostat.
3. Coolant level low. 3. Fill cooling system. (Refer to 7 -
COOLING - STANDARD
PROCEDURE)
4. Temperature gauge not
functioning correctly.4. Check cluster (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
5. Engine sensor stuck in range 5. Monitor sensor with DRB III to
verify sensor reading changes with
increasing temperature.
6. Engine sensor failed out of
range.A DTC will be set.
7. Electronically Controlled Vicsous
Fan Drive not operating properly.7. Check Electronically Controlled
Viscous Fan Drive (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
DRCOOLING 7 - 7
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
HIGH. COOLANT MAY OR MAY
NOT BE LEAKING FROM SYSTEM1. Vehicle overloaded, high ambient
(outside) temperatures with A/C
turned on, stop and go driving or
prolonged operation at idle speeds.1. Temporary condition, repair not
required. Notify customer of vehicle
operation instructions located in
Owners Manual.
NOTE: Information on dash cluster
is displayed based on broadcast
information from ECM. DTC will be
set for engine sensor circuit
concern.2. Temperature gauge not
functioning correctly.2. Check cluster (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
3. Air trapped in cooling system 3. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) and refill (Refer to 7
- COOLING - STANDARD
PROCEDURE)
4. Radiator cap faulty. 4. Replace radiator cap.
5. Plugged A/C or radiator cooling
fins.5. Clean all debris away from A/C
and radiator cooling fins.
6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) refill with correct
mixture (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Thermostat stuck shut. 7. Inspect and test thermostat.
Replace thermostat if necessary.
8. Bug screen or winter front being
used.8. Remove bug screen or winter
front.
9. Electronically controlled viscous
fan drive not operating properly.9. Check viscous fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
10. Cylinder head gasket leaking. 10. Check for leaking head gaskets
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
11. Heater core leaking. 11. Replace heater core.
12. Cooling system hoses leaking. 12. Tighten clamps or Replace
hoses.
13. Brakes dragging. 13. Check brakes. (Refer to 5 -
BRAKES/HYDRAULIC/
MECHANICAL - DIAGNOSIS AND
TESTING)
14. Accessory drive belt. 14. Inspect. Replace as necessary.
15. Water Pump. 15. Inspect and replace as
necessary.
16. Engine sensor stuck in range. 16. Monitor sensor with DRBIII to
verify sensor reading changes
increase in temperature.
17. Temperature sensor failed out
of range.17. A DTC will be set.
7 - 8 COOLINGDR
COOLING (Continued)

COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
On-Board Diagnostics and DTC
information. Replace thermostat if
necessary.
2. Is the temperature sending unit
connected?2. Check the temperature sensor
connector. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - SCHEMATIC -
ELECTRICAL) Repair connector if
necessary.
3. Is the temperature gauge
operating OK?3. Check gauge operation. (Refer to
8 - ELECTRICAL/INSTRUMENT
CLUSTER/ENGINE
TEMPERATURE GAUGE -
DESCRIPTION). Repair as
necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.4. Check coolant level in the coolant
reserve/overflow tank or degas
bottle and the radiator. Inspect
system for leaks. Repair leaks as
necessary. Refer to the Coolant
section of the manual text for
WARNINGS and CAUTIONS
associated with removing the
radiator cap.
5. Improper operation of internal
heater doors or heater controls.5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING
& AIR CONDITIONING -
DIAGNOSIS AND TESTING) for
procedures.
TEMPERATURE GAUGE READS
HIGH OR THE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM THE
COOLING SYSTEM1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair. Refer to Possible
Causes (2-18).
2. Is the temperature gauge reading
correctly?2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - SCHEMATIC -
ELECTRICAL). Repair as
necessary.
DRCOOLING 7 - 11
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Temperature gauge reading is
inconsistent (fluctuates, cycles or is
erratic)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and
repair if necessary. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING).
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)3. A normal condition. No correction
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
REMOVAL).
8. Loose accessory drive belt.
(water pump slipping)8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK1. Pressure relief valve in radiator
cap is defective.1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
7 - 14 COOLINGDR
COOLING (Continued)

DIAGNOSIS AND TESTING - THERMOSTAT
The cooling system used with the diesel engine
provides the extra coolant capacity and extra cooling
protection needed for higher GVWR (Gross Vehicle
Weight Rating) and GCWR (Gross Combined Weight
Rating) vehicles.
This system capacity will not effect warm up or
cold weather operating characteristics if the thermo-
stat is operating properly. This is because coolant
will be held in the engine until it reaches the ther-
mostat ªsetº temperature.
Diesel engines, due to their inherent efficiency are
slower to warm up than gasoline powered engines,
and will operate at lower temperatures when the
vehicle is unloaded. Because of this, lower tempera-
ture gauge readings for diesel versus gasoline
engines may, at times be normal.
Typically, complaints of low engine coolant temper-
ature are observed as low heater output when com-
bined with cool or cold outside temperatures.
To help promote faster engine warm-up, the elec-
tric engine block heater must be used with cool or
cold outside temperatures. This will help keep the
engine coolant warm when the vehicle is parked.
A ªCold Weather Coverº is available from the parts
department through the Mopar Accessories product
line. This accessory cover is designed to block airflow
entering the radiator and engine compartment to
promote faster engine warm-up. It attaches to the
front of the vehicle at the grill opening.The cover is
to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result.Refer to the litera-
ture supplied with the cover for additional informa-
tion.
(1) To determine if the thermostat is defective, it
must be removed from the vehicle (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT THERMO-
STAT - REMOVAL).
(2) After the thermostat has been removed, exam-
ine the thermostat and inside of thermostat housing
for contaminants. If contaminants are found, the
thermostat may already be in a ªstuck openº position.
Flush the cooling system before replacing thermostat
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(3) Place the thermostat into a container filled
with water.
(4) Place the container on a hot plate or other suit-
able heating device.
(5) Place a commercially available radiator ther-
mometer into the water.
(6) Apply heat to the water while observing the
thermostat and thermometer.
(7) The thermostat will begin to open at 85.5 -
89.4ÉC. (186 - 193ÉF ). If the valve starts to movebefore this temperature is reached, it is opening too
early. Replace thermostat. The thermostat should be
fully open (valve will stop moving) at 97ÉC (207ÉF). If
the valve is still moving when the water temperature
reaches 97ÉC (207ÉF), it is opening too late. Replace
thermostat. If the valve refuses to move at any time,
replace thermostat.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(1) Disconnect the battery negative cables.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094).
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove radiator hose clamp and hose from
thermostat housing.
(4) Remove the three (3) water outlet-to-cylinder
head bolts and remove the water outlet connector
(Fig. 26).
(5) Clean the mating surfaces of the water outlet
connector and clean the thermostat seat groove at
the top of the thermostat housing (Fig. 26).
INSTALLATION
(1) Inspect thermostat seal for cuts or nicks.
Replace if damaged.
(2) Install the thermostat into the groove in the
top of the cylinder head (Fig. 26).
(3) Install the thermostat housing and bolts.
Tighten the bolts to 10 N´m (89 in. lbs.) torque.
(4) Install the radiator upper hose and clamp.
(5) Fill the cooling system with coolant (Refer to 7
- COOLING - STANDARD PROCEDURE).
(6) Connect the battery negative cables.
DRENGINE 7 - 47
ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued)

cluster programming, a hard wired multiplex input
received by the cluster from the headlamp panel
lamps dimmer switch on the headlamp dimmer
switch mux circuit, and electronic unlock request
messages received from the optional Remote Keyless
Entry (RKE) receiver module. The cargo lamp indica-
tor Light Emitting Diode (LED) is completely con-
trolled by the instrument cluster logic circuit, and
that logic will allow only this indicator to operate
whenever the instrument cluster receives a battery
current input on the fused ignition switch output
(run-start) circuit. Therefore, the LED will always be
off when the ignition switch is in any position except
On or Start. The LED only illuminates when it is
provided a path to ground by the instrument cluster
transistor. The instrument cluster will turn on the
cargo lamp indicator for the following reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the cargo lamp indicator is
illuminated for about two seconds as a bulb test.
²Cargo Lamp-On Input- Each time the cluster
detects a cargo lamp-on input from the headlamp
switch on the headlamp dimmer switch mux circuit,
the cargo lamp and the cargo lamp indicator will be
illuminated. The cargo lamp and indicator remain
illuminated until the cluster receives a cargo lamp-off
input from the headlamp switch, or until the ignition
switch is turned to the Off position, whichever occurs
first.
²Actuator Test- Each time the cluster is put
through the actuator test, the cargo lamp indicator
will be turned on, then off again during the bulb
check portion of the test to confirm the functionality
of the LED and the cluster control circuitry.
The instrument cluster continually monitors the
headlamp dimmer switch circuit to determine the
proper interior lamps features and panel lamps illu-
mination levels to provide. The cluster then energizes
and de-energizes a low side driver circuit to control
the exterior cargo lamp. Each time the instrument
cluster energizes the cargo lamp driver and the igni-
tion switch is in the On or start positions, the cluster
also turns on the cargo lamp indicator. For further
diagnosis of the cargo lamp indicator or the instru-
ment cluster circuitry that controls the indicator,
(Refer to 8 - ELECTRICAL/INSTRUMENT CLUS-
TER - DIAGNOSIS AND TESTING). For proper
diagnosis of the cargo lamp or the headlamp switch
inputs to the instrument cluster that control the
cargo lamp indicator, a DRBIIItscan tool is required.
Refer to the appropriate diagnostic information.CHECK GAUGES INDICATOR
DESCRIPTION
A check gauges indicator is standard equipment on
all instrument clusters (Fig. 12). On vehicles
equipped with a gasoline engine, the check gauges
indicator is located near the lower edge of the instru-
ment cluster, between the tachometer and the speed-
ometer. On vehicles equipped with a diesel engine,
the check gauges indicator is located on the left side
of the instrument cluster, to the left of the voltage
gauge. The check gauges indicator consists of a sten-
cil-like cutout of the words ªCHECK GAGESº in the
opaque layer of the instrument cluster overlay. The
dark outer layer of the overlay prevents the indicator
from being clearly visible when it is not illuminated.
A red Light Emitting Diode (LED) behind the cutout
in the opaque layer of the overlay causes the
ªCHECK GAGESº text to appear in red through the
translucent outer layer of the overlay when the indi-
cator is illuminated from behind by the LED, which
is soldered onto the instrument cluster electronic cir-
cuit board. The check gauges indicator is serviced as
a unit with the instrument cluster.
OPERATION
The check gauges indicator gives an indication to
the vehicle operator when certain instrument cluster
gauge readings reflect a condition requiring immedi-
ate attention. This indicator is controlled by a tran-
sistor on the instrument cluster circuit board based
upon cluster programming and electronic messages
received by the cluster from the Powertrain Control
Module (PCM) on vehicles equipped with a gasoline
engine, or from the Engine Control Module (ECM) on
vehicles equipped with a diesel engine over the Pro-
grammable Communications Interface (PCI) data
bus. The check gauges indicator Light Emitting
Diode (LED) is completely controlled by the instru-
ment cluster logic circuit, and that logic will only
allow this indicator to operate when the instrument
cluster receives a battery current input on the fused
ignition switch output (run-start) circuit. Therefore,
the LED will always be off when the ignition switch
is in any position except On or Start. The LED only
illuminates when it is provided a path to ground by
the instrument cluster transistor. The instrument
cluster will turn on the check gauges indicator for
the following reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the check gauges indicator
is illuminated for about two seconds as a bulb test.
Fig. 12 Check Gauges Indicator
DRINSTRUMENT CLUSTER 8J - 21
CARGO LAMP INDICATOR (Continued)

²Actuator Test- Each time the cluster is put
through the actuator test, the engine coolant temper-
ature gauge needle will be swept to several calibra-
tion points on the gauge scale in a prescribed
sequence in order to confirm the functionality of the
gauge and the cluster control circuitry.
On vehicles with a gasoline engine, the PCM con-
tinually monitors the engine coolant temperature
sensor to determine the engine operating tempera-
ture. On vehicles with a diesel engine, the ECM con-
tinually monitors the engine coolant temperature
sensor to determine the engine operating tempera-
ture. The PCM or ECM then sends the proper engine
coolant temperature messages to the instrument
cluster. For further diagnosis of the engine coolant
temperature gauge or the instrument cluster cir-
cuitry that controls the gauge, (Refer to 8 - ELEC-
TRICAL/INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING). If the instrument cluster turns on
the check gauges indicator due to a high engine tem-
perature gauge reading, it may indicate that the
engine or the engine cooling system requires service.
For proper diagnosis of the engine coolant tempera-
ture sensor, the PCM, the ECM, the PCI data bus, or
the electronic message inputs to the instrument clus-
ter that control the engine coolant temperature
gauge, a DRBIIItscan tool is required. Refer to the
appropriate diagnostic information.
ETC INDICATOR
DESCRIPTION
An Electronic Throttle Control (ETC) indicator is
standard equipment on all gasoline engine instru-
ment clusters (Fig. 16). However, on vehicles not
equipped with the optional 5.7 liter gasoline engine,
this indicator is electronically disabled. The ETC
indicator is located on the right side of the instru-
ment cluster, to the right of the engine temperature
gauge. The ETC indicator consists of a stencil-like
cutout of the International Control and Display Sym-
bol icon for ªElectronic Throttle Controlº in the
opaque layer of the instrument cluster overlay. The
dark outer layer of the overlay prevents the indicator
from being clearly visible when it is not illuminated.
A red Light Emitting Diode (LED) behind the cutout
in the opaque layer of the overlay causes the icon to
appear in red through the translucent outer layer of
the overlay when the indicator is illuminated from
behind by the LED, which is soldered onto theinstrument cluster electronic circuit board. The ETC
indicator is serviced as a unit with the instrument
cluster.
OPERATION
The Electronic Throttle Control (ETC) indicator
gives an indication to the vehicle operator when the
ETC system is faulty or inoperative. The ETC indi-
cator is controlled by a transistor on the instrument
cluster circuit board based upon cluster programming
and electronic messages received by the cluster from
the Powertrain Control Module (PCM) over the Pro-
grammable Communications Interface (PCI) data
bus. The ETC indicator Light Emitting Diode (LED)
is completely controlled by the instrument cluster
logic circuit, and that logic will only allow this indi-
cator to operate when the instrument cluster receives
a battery current input on the fused ignition switch
output (run-start) circuit. Therefore, the LED will
always be off when the ignition switch is in any posi-
tion except On or Start. The LED only illuminates
when it is provided a path to ground by the instru-
ment cluster transistor. The instrument cluster will
turn on the ETC indicator for the following reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the ETC indicator is illu-
minated for about six seconds. The entire six second
bulb test is a function of the PCM.
²ETC Lamp-On Message- Each time the clus-
ter receives a lamp-on message from the PCM, the
ETC indicator will be illuminated. The indicator can
be flashed on and off, or illuminated solid, as dic-
tated by the PCM message. The indicator remains
illuminated solid or continues to flash for about
twelve seconds or until the cluster receives a lamp-off
message from the PCM, whichever is longer. If the
indicator is illuminated solid with the engine run-
ning the vehicle will usually remain drivable. If the
indicator is flashing with the engine running the
vehicle may require towing. A flashing indicator
means the ETC system requires immediate service.
²Communication Error- If the cluster receives
no ETC lamp messages for three consecutive seconds,
the ETC indicator is illuminated. The indicator
remains illuminated until the cluster receives a sin-
gle lamp-off message from the PCM.
²Actuator Test- Each time the cluster is put
through the actuator test, the ETC indicator will be
turned on, then off again during the bulb check por-
tion of the test to confirm the functionality of the
LED and the cluster control circuitry. The actuator
test illumination of the ETC indicator is a function of
the PCM.
The PCM continually monitors the ETC system cir-
cuits and sensors to decide whether the system is in
good operating condition. The PCM then sends the
Fig. 16 ETC Indicator
DRINSTRUMENT CLUSTER 8J - 25
ENGINE TEMPERATURE GAUGE (Continued)

the trip odometer reset switch button is pressed in
order to toggle to the engine hours display. The
engine hours will remain displayed for about thirty
seconds, until the engine speed message is greater
than zero, or until the ignition switch is turned to
the Off position, whichever occurs first.
²Trip Odometer Reset- When the trip odome-
ter reset switch button is pressed and held for longer
than about two seconds with the ignition switch in
the On or Start positions, the trip odometer will be
reset to 0.0 kilometers (miles). The VFD must be dis-
playing the trip odometer information in order for
the trip odometer information to be reset.
²Communication Error- If the cluster fails to
receive a distance message during normal operation,
it will hold and display the last data received until
the ignition switch is turned to the Off position. If
the cluster does not receive a distance message
within one second after the ignition switch is turned
to the On position, it will display the last distance
message stored in the cluster memory. If the cluster
is unable to display distance information due to an
error internal to the cluster, the VFD display will be
dashes.
²Actuator Test- Each time the cluster is put
through the actuator test, the odometer VFD will dis-
play all of its segments simultaneously during the
VFD portion of the test to confirm the functionality
of each of the VFD segments and the cluster control
circuitry.
The PCM continually monitors the vehicle speed
pulse information received from the vehicle speed
sensor and engine speed pulse information received
from the crankshaft position sensor, then sends the
proper distance and engine speed messages to the
instrument cluster. For further diagnosis of the
odometer/trip odometer or the instrument cluster cir-
cuitry that controls these functions, (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER - DIAGNO-
SIS AND TESTING). For proper diagnosis of the
vehicle speed sensor, the crankshaft position sensor,
the PCM, the PCI data bus, or the electronic message
inputs to the instrument cluster that control the
odometer/trip odometer, a DRBIIItscan tool is
required. Refer to the appropriate diagnostic infor-
mation.
OIL PRESSURE GAUGE
DESCRIPTION
An oil pressure gauge is standard equipment on all
instrument clusters. The oil pressure gauge is locatedin the upper right quadrant of the instrument clus-
ter, above the coolant temperature gauge. The oil
pressure gauge consists of a movable gauge needle or
pointer controlled by the instrument cluster circuitry
and a fixed 90 degree scale on the cluster overlay
that reads left-to-right from ªLº (or Low) to ªHº (or
High) for gasoline engines. On vehicles with a diesel
engine the scale reads from ª0º kPa to ª760º kPa in
markets where a metric instrument cluster is speci-
fied, or from ª0º psi to ª110º psi in all other markets.
An International Control and Display Symbol icon for
ªEngine Oilº is located on the cluster overlay, directly
below the left end of the gauge scale (Fig. 24). The oil
pressure gauge graphics are black against a white
field except for two red graduations at the low end of
the gauge scale, making them clearly visible within
the instrument cluster in daylight. When illuminated
from behind by the panel lamps dimmer controlled
cluster illumination lighting with the exterior lamps
turned On, the black graphics appear blue and the
red graphics still appear red. The orange gauge nee-
dle is internally illuminated. Gauge illumination is
provided by replaceable incandescent bulb and bulb
holder units located on the instrument cluster elec-
tronic circuit board. The oil pressure gauge is ser-
viced as a unit with the instrument cluster.
OPERATION
The oil pressure gauge gives an indication to the
vehicle operator of the engine oil pressure. This
gauge is controlled by the instrument cluster circuit
board based upon cluster programming and elec-
tronic messages received by the cluster from the
Powertrain Control Module (PCM) on vehicles with a
gasoline engine, or from the Engine Control Module
(ECM) on vehicles equipped with a diesel engine over
the Programmable Communications Interface (PCI)
data bus. The oil pressure gauge is an air core mag-
netic unit that receives battery current on the instru-
ment cluster electronic circuit board through the
fused ignition switch output (run-start) circuit when-
ever the ignition switch is in the On or Start posi-
tions. The cluster is programmed to move the gauge
needle back to the low end of the scale after the igni-
tion switch is turned to the Off position. The instru-
ment cluster circuitry controls the gauge needle
position and provides the following features:
²Engine Oil Pressure Message- The instru-
ment cluster circuitry restricts the oil pressure gauge
needle operation in order to provide readings that
are consistent with customer expectations. Each time
the cluster receives a message from the PCM or ECM
indicating the engine oil pressure is above about 41
kPa (6 psi) the cluster holds the gauge needle at a
point near the middle increment within the normal
range on the gauge scale.
Fig. 24 Engine Oil Icon
DRINSTRUMENT CLUSTER 8J - 33
ODOMETER (Continued)

²Engine Oil Pressure Low Message- Each
time the cluster receives a message from the PCM or
ECM indicating the engine oil pressure is below
about 41 kPa (6 psi), the gauge needle is moved to
the graduation at the far left end of the gauge scale,
the check gauges indicator is illuminated, and a sin-
gle chime tone is generated. The gauge needle
remains at the left end of the gauge scale and the
check gauges indicator remains illuminated until the
cluster receives a message from the PCM or ECM
indicating that the engine oil pressure is above about
41 kPa (6 psi), or until the ignition switch is turned
to the Off position, whichever occurs first. The clus-
ter will only turn the check gauges indicator on in
response to an engine oil pressure low message if the
engine speed message is greater than zero.
²Communication Error- If the cluster fails to
receive an engine oil pressure message, it will hold
the gauge needle at the last indication about five sec-
onds or until the ignition switch is turned to the Off
position, whichever occurs first. After five seconds,
the cluster will move the gauge needle to the left end
of the gauge scale.
²Actuator Test- Each time the cluster is put
through the actuator test, the oil pressure gauge nee-
dle will be swept to several calibration points on the
gauge scale in a prescribed sequence in order to con-
firm the functionality of the gauge and the cluster
control circuitry.
On vehicles with a gasoline engine, the PCM con-
tinually monitors the engine oil pressure sensor to
determine the engine oil pressure. On vehicles with a
diesel engine, the ECM continually monitors the
engine oil pressure sensor to determine the engine oil
pressure. The PCM or ECM then sends the proper
engine oil pressure messages to the instrument clus-
ter. For further diagnosis of the oil pressure gauge or
the instrument cluster circuitry that controls the
gauge, (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND TESTING). If the
instrument cluster turns on the check gauges indica-
tor due to a low oil pressure gauge reading, it may
indicate that the engine or the engine oiling system
requires service. For proper diagnosis of the engine
oil pressure sensor, the PCM, the ECM, the PCI data
bus, or the electronic message inputs to the instru-
ment cluster that control the oil pressure gauge, a
DRBIIItscan tool is required. Refer to the appropri-
ate diagnostic information.
SEATBELT INDICATOR
DESCRIPTION
A seatbelt indicator is standard equipment on all
instrument clusters (Fig. 25). The seatbelt indicatoris located on the upper edge of the instrument clus-
ter, between the tachometer and the speedometer.
The seatbelt indicator consists of a stencil-like cutout
of the International Control and Display Symbol icon
for ªSeat Beltº in the opaque layer of the instrument
cluster overlay. The dark outer layer of the overlay
prevents the indicator from being clearly visible
when it is not illuminated. A red Light Emitting
Diode (LED) behind the cutout in the opaque layer of
the overlay causes the icon to appear in red through
the translucent outer layer of the overlay when the
indicator is illuminated from behind by the LED,
which is soldered onto the instrument cluster elec-
tronic circuit board. The seatbelt indicator is serviced
as a unit with the instrument cluster.
OPERATION
The seatbelt indicator gives an indication to the
vehicle operator of the status of the driver side front
seatbelt. This indicator is controlled by a transistor
on the instrument cluster circuit board based upon
cluster programming and a hard wired input from
the seatbelt switch in the driver side front seatbelt
buckle through the seat belt indicator driver circuit.
The seatbelt indicator also includes a programmable
enhanced seatbelt reminder or ªbeltminderº feature
that is enabled when the vehicle is shipped from the
factory. This beltminder feature can be disabled and
enabled by the customer using a specific program-
ming event sequence, or by the dealer using a
DRBIIItscan tool. The seatbelt indicator Light Emit-
ting Diode (LED) is completely controlled by the
instrument cluster logic circuit, and that logic will
only allow this indicator to operate when the instru-
ment cluster receives a battery current input on the
fused ignition switch output (run-start) circuit.
Therefore, the LED will always be off when the igni-
tion switch is in any position except On or Start. The
LED only illuminates when it is provided a path to
ground by the instrument cluster transistor. The
instrument cluster will turn on the seatbelt indicator
for the following reasons:
²Seatbelt Reminder Function- Each time the
cluster receives a battery current input on the fused
ignition switch output (run-start) circuit, the indica-
tor will be illuminated as a seatbelt reminder for
about six seconds, or until the ignition switch is
turned to the Off position, whichever occurs first.
This reminder function will occur regardless of the
status of the seatbelt switch input to the cluster.
²Driver Side Front Seatbelt Not Buckled -
Beltminder Active- Following the seatbelt
Fig. 25 Seatbelt Indicator
8J - 34 INSTRUMENT CLUSTERDR
OIL PRESSURE GAUGE (Continued)

for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 29).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out:
²The galley at the oil filter adaptor hole.
²The front and rear oil galley holes.
²The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
threads of the front and rear oil galley plugs. Tighten
the 1/4 inch NPT plugs to 20 N´m (177 in. lbs.)
torque. Tighten the 3/8 inch NPT plugs to 27 N´m
(240 in. lbs.) torque.
INSPECTION
(1) It is mandatory to use a dial bore gauge to
measure each cylinder bore diameter. To correctly
select the proper size piston, a cylinder bore gauge,
capable of reading in 0.003 mm (.0001 in.) INCRE-
MENTS is required. If a bore gauge is not available,
do not use an inside micrometer (Fig. 30).
Fig. 29 CYLINDER BORE CROSSHATCH PATTERN
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
Fig. 30 BORE GAUGE-TYPICAL
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
DRENGINE - 3.7L 9 - 39
ENGINE BLOCK (Continued)