engine sensors DODGE RAM 2003 Service User Guide

²Also to be considered part of the ignition system
are certain inputs from the Crankshaft Position, Cam-
shaft Position, Throttle Position and MAP Sensors
8.0L V-10 ENGINE
. The 8.0L V-10 engine is equipped with 2 remote
coil packs. Conventional spark plug cables are used
with the 8.0L engine. The 8.0L engine will not use a
conventional distributor
The ignition coils are individually fired, but each
coil is a dual output. Refer to Ignition Coil for addi-
tional information.Knock sensors are not used with the 8.0L engine.
The ignition system consists of:
²10 Spark Plugs
²2 Ignition Coil packs containing 10 individual
coils
²10 Secondary Ignition Cables
²Powertrain Control Module (PCM)
²Also to be considered part of the ignition system
are certain inputs from the Crankshaft Position,
Camshaft Position, Throttle Position and MAP Sen-
sors
SPECIFICATIONS
SPECIFICATIONS - TORQUE - IGNITION
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Camshaft Position Sensor - 3.7L V-6 Engine 12 - 106
Camshaft Position Sensor - 4.7L V-8 Engine 12 - 106
Camshaft Position Sensor - 5.7L V-8 Engine 12 9 105
Camshaft Position Sensor - 8.0L V-10 Engine 6 - 50
Crankshaft Position Sensor - 3.7L V-6 Engine 28 21 205
Crankshaft Position Sensor - 4.7L V-8 Engine 28 21 205
Crankshaft Position Sensor - 5.7L V-8 Engine 12 9 105
Crankshaft Position Sensor - 5.9L V-8 Engine 8 - 70
Crankshaft Position Sensor - 8.0L V-10 Engine 8 - 70
Distributor Hold Down Bolt - 5.9L V-8 Engine 23 17 -
Ignition Coil Mounting - 5.9L V-8 Engine
(if tapped bolts are used)5-50
Ignition Coil Mounting - 5.9L V-8 Engine
(if nuts/bolts are used)11 - 100
Ignition Coil Mounting - 3.7L V-6 Engine 8 - 70
Ignition Coil Mounting - 4.7L V-8 Engine 8 - 70
Ignition Coil Mounting - 5.7L V-8 Engine 12 9 105 (  20)
Ignition Coil Mounting - 8.0L V-10 Engine 10 - 90
* Knock Sensor - 3.7L V-6 Engine 20 15 176
* Knock Sensor - 4.7L V-8 Engine 20 15 176
* Knock Sensor - 5.7L V-8 Engine 20 15 176
Spark Plugs - 3.7L V-6 Engine 27 20 -
Spark Plugs - 4.7L V-8 Engine 27 20 -
** Spark Plugs - 5.7L V-8 Engine 18 (  3) 13 (  2) -
Spark Plugs - 5.9L V-8 Engine 41 30 -
Spark Plugs - 8.0L V-10 Engine 41 30 -
* Do not apply any sealant, thread-locker or adhesive
to bolts. Poor sensor performance may result.
** Torque critical tapered design. Do not exceed 15 ft.
lbs.
DRIGNITION CONTROL 8I - 3
IGNITION CONTROL (Continued)

(4) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(5) Remove distributor rotor from distributor shaft.
(6) Lift camshaft position sensor assembly from
distributor housing (Fig. 17).
8.0L V±10
The camshaft position sensor is located on the tim-
ing chain case/cover on the left-front side of the
engine (Fig. 18).
A thin plastic rib is molded into the face of the sen-
sor (Fig. 19) to position the depth of sensor to the
upper cam gear (sprocket). This rib can be found on
both the new replacement sensors and sensors that
were originally installed to the engine. The first timethe engine has been operated, part of this rib may be
sheared (ground) off. Depending on parts tolerances,
some of the rib material may still be observed after
removal.
Refer to either of the following procedures; Replac-
ing Old Sensor With Original, or Replacing With
New Sensor:
REPLACING OLD SENSOR WITH ORIGINAL
If the original camshaft position sensor is to be
removed and installed, such as when servicing the
timing chain, timing gears or timing chain cover, use
this procedure.
(1) Disconnect sensor harness connector from sen-
sor.
(2) Remove sensor mounting bolt (Fig. 18).
(3) Carefully pry sensor from timing chain case/
cover in a rocking action with two small screwdriv-
ers.
(4) Remove sensor from vehicle.
(5) Check condition of sensor o-ring (Fig. 20).
REPLACING WITH NEW SENSOR
If a new replacement camshaft position sensor is to
be installed, use this procedure.
(1) Disconnect sensor wiring harness connector
from sensor.
(2) Remove sensor mounting bolt (Fig. 18).
(3) Carefully pry sensor from timing chain case/
cover in a rocking action with two small screwdriv-
ers.
(4) Remove sensor from vehicle.
Fig. 17 DISTRIBUTOR AND CMP LOCATION - 5.9L
1 - SYNC SIGNAL GENERATOR
2 - CAMSHAFT POSITION SENSOR
3 - PULSE RING
4 - DISTRIBUTOR ASSEMBLY
Fig. 18 CMP LOCATION - 8.0L
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLT
3 - TIMING CHAIN CASE/COVER
Fig. 19 SENSOR DEPTH POSITIONING RIB ± 8.0L
V-10 ENGINE
1 - CAMSHAFT POSITION SENSOR
2 - PAPER SPACER
3 - RIB MATERIAL (FOR SENSOR DEPTH POSITIONING)
DRIGNITION CONTROL 8I - 13
CAMSHAFT POSITION SENSOR (Continued)

4.7L V-8
Battery voltage is supplied to the 8 individual igni-
tion coils from the ASD relay. The Powertrain Con-
trol Module (PCM) opens and closes each ignition coil
ground circuit at a determined time for ignition coil
operation.
Base ignition timing is not adjustable.By con-
trolling the coil ground circuit, the PCM is able to set
the base timing and adjust the ignition timing
advance. This is done to meet changing engine oper-
ating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
Because of coil design, spark plug cables (second-
ary cables) are not used with the 4.7L V-8 engine.
5.7L V-8
The ignition system is controlled by the Powertrain
Control Module (PCM) on all engines.
A ªwasted sparkº system is used on the 5.7L
engine combining paired, or dual-firing coils, and 2
spark plugs per cylinder. The coils and spark plugs
are connected with paired, secondary high-voltage
cables.
Each cylinder is equipped with 1 dual-output coil.
Meaning one coil mounts directly over one of the
dual spark plugs for 1 high-voltage output. A second
high-voltage output is supplied directly from the
same coil (using a plug cable) to one of the dual
spark plugs on a corresponding (paired) cylinder on
the opposite cylinder bank.
Each coil fires 2 spark plugs simultaneously on
each of the cylinder banks (one cylinder on compres-
sion stroke and one cylinder on exhaust stroke).
EXAMPLE :When the #1 cylinder is on compression
stroke and ready for spark, the #1 coil will fire one of
the dual spark plugs on the #1 cylinder (directly
below the coil). The other dual spark plug on the #1
cylinder will be fired by the #6 coil. At the same
time, the #1 coil will fire a ªwasted sparkº to one of
the dual spark plugs at the #6 cylinder as coil #6 also
fires a ªwasted sparkº to one of the dual spark plugs
at the #6 cylinder.
The firing order is paired at cylinders 1/6, 2/3, 4/7,
5/8. Basic cylinder firing order is 1±8±4±3±6±5±7±2.
Battery voltage is supplied to all of the ignition
coils positive terminals from the ASD relay. If the
PCM does not see a signal from the crankshaft and
camshaft sensors (indicating the ignition key is ON
but the engine is not running), it will shut down the
ASD circuit.
Base ignition timing is not adjustable on the
5.7L V-8 engine.By controlling the coil ground cir-
cuits, the PCM is able to set the base timing andadjust the ignition timing advance. This is done to
meet changing engine operating conditions.
The PCM adjusts ignition timing based on inputs it
receives from:
²The engine coolant temperature sensor
²The crankshaft position sensor (engine speed)
²The camshaft position sensor (crankshaft posi-
tion)
²The manifold absolute pressure (MAP) sensor
²The throttle position sensor
²Transmission gear selection
5.9L V-8
A single ignition coil is used. The Powertrain Con-
trol Module (PCM) opens and closes the ignition coil
ground circuit for ignition coil operation.
Battery voltage is supplied to the ignition coil pos-
itive terminal from the ASD relay. If the PCM does
not see a signal from the crankshaft and camshaft
sensors (indicating the ignition key is ON but the
engine is not running), it will shut down the ASD cir-
cuit.
Base ignition timing is not adjustable on any
engine.By controlling the coil ground circuit, the
PCM is able to set the base timing and adjust the
ignition timing advance. This is done to meet chang-
ing engine operating conditions.
Conventional spark plug cables (secondary cables)
are used with the 5.9L V-8 engine.
8.0L V-10
When one of the 5 independent coils discharges, it
fires two paired cylinders at the same time (one cyl-
inder on compression stroke and the other cylinder
on exhaust stroke).
Coil firing is paired together on cylinders:
²Number 5 and 10
²Number 9 and 8
²Number 1 and 6
²Number 7 and 4
²Number 3 and 2
The ignition system is controlled by the Powertrain
Control Module (PCM) on all engines.
Battery voltage is supplied to all of the ignition
coils positive terminals from the ASD relay. If the
PCM does not see a signal from the crankshaft and
camshaft sensors (indicating the ignition key is ON
but the engine is not running), it will shut down the
ASD circuit.
Conventional spark plug cables (secondary cables)
are used with the 8.0L V-10 engine.
Base ignition timing is not adjustable on the
8.0L V-10 engine.By controlling the coil ground cir-
cuits, the PCM is able to set the base timing and
adjust the ignition timing advance. This is done to
meet changing engine operating conditions.
8I - 22 IGNITION CONTROLDR
IGNITION COIL (Continued)

(6)If necessary, install throttle body air tube or box.
KNOCK SENSOR
DESCRIPTION
The sensors are used only with 3.7L V-6, 4.7L V-8
and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8
engines, the 2 knock sensors are bolted into the cyl-
inder block under the intake manifold.
On 5.7L V-8 engines, 2 knock sensors are also
used. These are bolted into each side of the cylinder
block (outside) under the exhaust manifold.
OPERATION
3.7L V-6 / 4.7L V-8 / 5.7L V-8 Engines Only
Two knock sensors are used; one for each cylinder
bank. When the knock sensor detects a knock in one
of the cylinders on the corresponding bank, it sends
an input signal to the Powertrain Control Module
(PCM). In response, the PCM retards ignition timing
for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal's vibration increases, the
knock sensor output voltage also increases.The voltage signal produced by the knock sensor
increases with the amplitude of vibration. The PCM
receives the knock sensor voltage signal as an input.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock
sensor voltage exceeds a preset value, the PCM
retards ignition timing for all cylinders. It is not a
selective cylinder retard.
The PCM ignores knock sensor input during engine
idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.
Knock retard uses its own short term and long
term memory program.
Long term memory stores previous detonation
information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
ing retard can be calibrated.
Short term memory is allowed to retard timing up
to a preset amount under all operating conditions (as
long as rpm is above the minimum rpm) except at
Wide Open Throttle (WOT). The PCM, using short
term memory, can respond quickly to retard timing
when engine knock is detected. Short term memory
is lost any time the ignition key is turned off.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors.
REMOVAL
3.7L V-6 / 4.7L V-8
The 2 knock sensors are bolted into the cylinder
block under the intake manifold (Fig. 39). or (Fig.
40).
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Disconnect knock sensor dual pigtail harness
from engine wiring harness. This connection is made
near rear of engine.
(2) Remove intake manifold. Refer to Engine sec-
tion.
(3) Remove sensor mounting bolts (Fig. 39), or
(Fig. 40). Note foam strip on bolt threads. This foam
is used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound to
these bolts.
Fig. 38 SPARK PLUG CABLE ORDER - 8.0L V-10
DRIGNITION CONTROL 8I - 25
IGNITION COIL (Continued)

(4) Remove sensors from engine.5.7L V8
Two sensors are used. Each sensor is bolted into
the outside of cylinder block below the exhaust man-
ifold (Fig. 41).
(1) Raise vehicle.
(2) Disconnect knock sensor electrical connector.
(3) Remove sensor mounting bolt (Fig. 41). Note
foam strip on bolt threads. This foam is used only to
retain the bolts to sensors for plant assembly. It is
not used as a sealant. Do not apply any adhesive,
sealant or thread locking compound to these bolts.
(4) Remove sensor from engine.
INSTALLATION
3.7L V-6 / 4.7L V-8
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Thoroughly clean knock sensor mounting holes.
(2) Install sensors into cylinder block.
Fig. 39 KNOCK SENSOR Ð 3.7L V-6
1 - KNOCK SENSORS (2)
2 - MOUNTING BOLTS
Fig. 40 KNOCK SENSOR Ð 4.7L V-8
1 - KNOCK SENSORS (2)
2 - MOUNTING BOLTS
3 - INTAKE MANIFOLD (CUTAWAY)
4 - PIGTAIL CONNECTOR
Fig. 41 5.7L KNOCK SENSOR (RIGHT SENSOR
SHOWN)
1 - KNOCK SENSOR (RIGHT SENSOR SHOWN)
2 - MOUNTING BOLT
3 - EXHAUST MANIFOLD
4 - RIGHT ENGINE MOUNT
5 - ELEC. CONNECTOR
8I - 26 IGNITION CONTROLDR
KNOCK SENSOR (Continued)

NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) Install and tighten mounting bolts. Refer to
torque specification.
(4) Install intake manifold. Refer to Engine sec-
tion.
(5) Connect knock sensor wiring harness to engine
harness at rear of intake manifold.
5.7L V-8
(1) Thoroughly clean knock sensor mounting hole.
(2) Install sensor into cylinder block.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) Install and tighten mounting bolt. Refer to
torque specification.
(4) Install electrical connector to sensor.
SPARK PLUG
DESCRIPTION
Resistor type spark plugs are used on all engines.
Sixteen spark plugs (2 per cylinder) are used with
5.7L V-8 engines.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
To prevent possible pre-ignition and/or mechanical
engine damage, the correct type/heat range/number
spark plug must be used.
Always use the recommended torque when tighten-
ing spark plugs. Incorrect torque can distort the
spark plug and change plug gap. It can also pull the
plug threads and do possible damage to both the
spark plug and the cylinder head.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. A sin-
gle plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
the Lubrication and Maintenance section.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
Spark plug resistance values range from 6,000 to
20,000 ohms (when checked with at least a 1000 volt
spark plug tester).Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
(Fig. 42). There will not be evidence of electrode
burning. Gap growth will not average more than
approximately 0.025 mm (.001 in) per 3200 km (2000
miles) of operation. Spark plugs that have normal
wear can usually be cleaned, have the electrodes
filed, have the gap set and then be installed.
Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
misdiagnosed as being caused by coolant in the com-
bustion chamber. Spark plug performance may be
affected by MMT deposits.
DRIGNITION CONTROL 8I - 27
KNOCK SENSOR (Continued)

NOTE: Certain indicators in this instrument cluster
are automatically configured. This feature allows
those indicators to be activated or deactivated for
compatibility with certain optional equipment. If the
problem being diagnosed involves improper illumi-
nation of the cruise indicator, the electronic throttle
control indicator, the overdrive-off indicator, the
service four-wheel drive indicator, the transmission
overtemp indicator, the upshift indicator, the secu-
rity indicator or the gear selector indicator, discon-
nect and isolate the battery negative cable. After
about five minutes, reconnect the battery negative
cable and turn the ignition switch to the On posi-
tion. The instrument cluster should automatically
relearn the equipment in the vehicle and properly
configure the configurable indicators accordingly.
ABS INDICATOR
DESCRIPTION
An Antilock Brake System (ABS) indicator is stan-
dard equipment on all instrument clusters. However,
the instrument cluster can be programmed to disable
this indicator on vehicles that are not equipped with
the ABS or Rear Wheel Anti-Lock (RWAL) brake sys-
tems, which are not available in some markets. On
vehicles equipped with a gasoline engine, the ABS
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 ABS indicator is located on the right side of the
instrument cluster, to the right of the engine temper-
ature gauge. The ABS indicator consists of a stencil-
like cutout of the International Control and Display
Symbol icon for ªFailure of Anti-lock Braking Sys-
temº 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. An amber Light Emitting Diode (LED)
behind the cutout in the opaque layer of the overlay
causes the icon to appear in amber 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 ABS indicator is serviced as a unit
with the instrument cluster.
OPERATION
The ABS indicator gives an indication to the vehi-
cle operator when the ABS system is faulty or inop-
erative. This indicator is controlled by a transistor on
the instrument cluster circuit board based upon clus-
ter programming and electronic messages received by
the cluster from the Controller Antilock Brake (CAB)over the Programmable Communications Interface
(PCI) data bus. The ABS 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 ABS indicator for the follow-
ing reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the ABS indicator is illu-
minated by the cluster for about two seconds as a
bulb test.
²ABS Lamp-On Message- Each time the clus-
ter receives a lamp-on message from the CAB, the
ABS indicator will be illuminated. The indicator
remains illuminated until the cluster receives a
lamp-off message from the CAB, or until the ignition
switch is turned to the Off position, whichever occurs
first.
²Communication Error- If the cluster receives
no lamp-on or lamp-off messages from the CAB for
three consecutive seconds, the ABS indicator is illu-
minated. The indicator remains illuminated until the
cluster receives a valid message from the CAB, or
until the ignition switch is turned to the Off position,
whichever occurs first.
²Actuator Test- Each time the instrument clus-
ter is put through the actuator test, the ABS indica-
tor 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.
²ABS Diagnostic Test- The ABS indicator is
blinked on and off by lamp-on and lamp-off messages
from the CAB during the performance of the ABS
diagnostic tests.
The CAB continually monitors the ABS circuits
and sensors to decide whether the system is in good
operating condition. The CAB then sends the proper
lamp-on or lamp-off messages to the instrument clus-
ter. If the CAB sends a lamp-on message after the
bulb test, it indicates that the CAB has detected a
system malfunction and/or that the ABS system has
become inoperative. The CAB will store a Diagnostic
Trouble Code (DTC) for any malfunction it detects.
Each time the ABS indicator fails to light due to an
open or short in the cluster ABS indicator circuit, the
cluster sends a message notifying the CAB of the
condition, then the instrument cluster and the CAB
will each store a DTC. For proper diagnosis of the
antilock brake system, the CAB, the PCI data bus, or
the electronic message inputs to the instrument clus-
DRINSTRUMENT CLUSTER 8J - 17
INSTRUMENT CLUSTER (Continued)

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
electronic circuit board. The ETC indicator is ser-
viced 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
proper lamp-on or lamp-off messages to the instru-
ment cluster. If the PCM sends a lamp-on message
after the bulb test, it indicates that the PCM has
detected a system malfunction and/or that the ETC
system is inoperative. The PCM will store a Diagnos-
tic Trouble Code (DTC) for any malfunction it
detects. Each time the ETC indicator fails to illumi-
nate due to an open or short in the cluster ETC indi-
cator circuit, the cluster sends a message notifying
the PCM of the condition, the instrument cluster and
the PCM will each store a DTC. For proper diagnosis
of the ETC system, the PCM, the PCI data bus, or
the electronic message inputs to the instrument clus-
ter that control the ETC indicator, a DRBIIItscan
tool is required. Refer to the appropriate diagnostic
information.
FUEL GAUGE
DESCRIPTION
A fuel gauge is standard equipment on all instru-
ment clusters. The fuel gauge is located in the lower
left quadrant of the instrument cluster, below the
voltage gauge. The fuel 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 ªEº (or
Empty) to ªFº (or Full). An International Control and
Display Symbol icon for ªFuelº is located on the clus-
ter overlay, directly below the right end of the gauge
scale. An arrowhead pointed to the left side of the
vehicle is imprinted on the cluster overlay next to the
ªFuelº icon in the fuel gauge to provide the driver
with a reminder as to the location of the fuel filler
access. On vehicles equipped with a diesel engine,
text that specifies ªDIESEL ONLYº is located across
the fuel gauge below the gauge scale, but above the
hub of the gauge needle. The fuel gauge graphics are
black against a white field except for a single red
graduation 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 graph-
ics appear blue and the red graphics still appear red.
The orange gauge needle is internally illuminated.
Gauge illumination is provided by replaceable incan-
descent bulb and bulb holder units located on the
instrument cluster electronic circuit board. The fuel
gauge is serviced as a unit with the instrument clus-
ter.
DRINSTRUMENT CLUSTER 8J - 25
ETC INDICATOR (Continued)

²Actuator Test- Each time the cluster is put
through the actuator test, the low fuel 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.
On vehicles with a gasoline engine, the PCM con-
tinually monitors the fuel tank sending unit to deter-
mine the level of fuel in the fuel tank. On vehicles
with a diesel engine, the ECM continually monitors
the fuel tank sending unit to determine the level of
fuel in the fuel tank. The PCM or ECM then sends
the proper fuel level messages to the instrument
cluster. For further diagnosis of the low fuel indicator
or the instrument cluster circuitry that controls the
LED, (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND TESTING). For
proper diagnosis of the fuel tank sending unit, the
PCM, the ECM, the PCI data bus, or the electronic
message inputs to the instrument cluster that control
the low fuel indicator, a DRBIIItscan tool is
required. Refer to the appropriate diagnostic infor-
mation.
MALFUNCTION INDICATOR
LAMP (MIL)
DESCRIPTION
A Malfunction Indicator Lamp (MIL) is standard
equipment on all instrument clusters. The MIL is
located on the left side of the instrument cluster, to
the left of the voltage gauge. The MIL consists of a
stencil-like cutout of the International Control and
Display Symbol icon for ªEngineº 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. An amber
Light Emitting Diode (LED) behind the cutout in the
opaque layer of the overlay causes the icon to appear
in amber 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 electronic circuit board. The MIL
is serviced as a unit with the instrument cluster.
OPERATION
The Malfunction Indicator Lamp (MIL) gives an
indication to the vehicle operator when the Power-
train Control Module (PCM) on vehicles with a gaso-
line engine, or the Engine Control Module (ECM) on
vehicles with a diesel engine has recorded a Diagnos-
tic Trouble Code (DTC) for an On-Board Diagnostics
II (OBDII) emissions-related circuit or component
malfunction. The MIL is controlled by a transistor on
the instrument cluster circuit board based upon clus-
ter programming and electronic messages received bythe cluster from the PCM or ECM over the Program-
mable Communications Interface (PCI) data bus. The
MIL Light Emitting Diode (LED) is completely con-
trolled by the instrument cluster logic circuit, and
that logic will only allow this indicator to operate
when the instrument cluster receives a battery cur-
rent 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 pro-
vided a path to ground by the instrument cluster
transistor. The instrument cluster will turn on the
MIL for the following reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the indicator is illuminated
for about two seconds as a bulb test. The entire two
second bulb test is a function of the PCM or ECM.
²MIL Lamp-On Message- Each time the clus-
ter receives a MIL lamp-on message from the PCM
or ECM, the indicator will be illuminated. The indi-
cator can be flashed on and off, or illuminated solid,
as dictated by the PCM or ECM message. For some
DTC's, if a problem does not recur, the PCM or ECM
will send a lamp-off message automatically. Other
DTC's may require that a fault be repaired and the
PCM or ECM be reset before a lamp-off message will
be sent. For more information on the PCM, the ECM,
and the DTC set and reset parameters, (Refer to 25 -
EMISSIONS CONTROL - OPERATION).
²Communication Error- If the cluster receives
no lamp-on message from the PCM or ECM for ten
seconds, the MIL is illuminated by the instrument
cluster to indicate a loss of bus communication. The
indicator remains controlled and illuminated by the
cluster until a valid lamp-on message is received
from the PCM or ECM.
²Actuator Test- Each time the cluster is put
through the actuator test, the MIL indicator will be
turned on during the bulb check portion of the test to
confirm the functionality of the LED and the cluster
control circuitry.
On vehicles with a gasoline engine, the PCM con-
tinually monitors the fuel and emissions system cir-
cuits and sensors to decide whether the system is in
good operating condition. On vehicles with a diesel
engine, the ECM continually monitors the fuel and
emissions system circuits and sensors to decide
whether the system is in good operating condition.
The PCM or ECM then sends the proper lamp-on or
lamp-off messages to the instrument cluster. For fur-
ther diagnosis of the MIL or the instrument cluster
circuitry that controls the LED, (Refer to 8 - ELEC-
TRICAL/INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING). If the instrument cluster turns on
the MIL after the bulb test, it may indicate that a
malfunction has occurred and that the fuel and emis-
8J - 30 INSTRUMENT CLUSTERDR
LOW FUEL INDICATOR (Continued)

(ISO) micro relay (Fig. 7). Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions. The relay is contained within a small, rect-
angular, molded plastic housing and is connected to
all of the required inputs and outputs by five integral
male spade-type terminals that extend from the bot-
tom of the relay base.
The front fog lamp relay cannot be adjusted or
repaired and, if faulty or damaged, the unit must be
replaced.
OPERATION
The front fog lamp relay is an electromechanical
switch that uses a low current input from the Front
Control Module (FCM) to control a high current out-
put to the front fog lamps. The movable common feed
contact point is held against the fixed normally
closed contact point by spring pressure. When the
relay coil is energized, an electromagnetic field is
produced by the coil windings. This electromagnetic
field draws the movable relay contact point away
from the fixed normally closed contact point, and
holds it against the fixed normally open contact
point. When the relay coil is de-energized, spring
pressure returns the movable contact point back
against the fixed normally closed contact point. A
resistor is connected in parallel with the relay coil in
the relay, and helps to dissipate voltage spikes and
electromagnetic interference that can be generated as
the electromagnetic field of the relay coil collapses.
The front fog lamp relay terminals are connected
to the vehicle electrical system through a connector
receptacle in the Power Distribution Center (PDC).
The inputs and outputs of the front fog lamp relay
include:
²Common Feed Terminal- The common feed
terminal (30) receives battery voltage at all times
from a fuse in the PDC through a fused B(+) circuit.
²Coil Ground Terminal- The coil ground termi-
nal (85) is connected to a control output of the Front
Control Module (FCM) through a front fog lamp relay
control circuit. The FCM controls front fog lamp oper-
ation by controlling a ground path through this cir-
cuit.
²Coil Battery Terminal- The coil battery ter-
minal (86) receives battery voltage at all times from
a fuse in the PDC through a fused B(+) circuit.
²Normally Open Terminal- The normally open
terminal (87) is connected to the front fog lamps
through a front fog lamp relay output circuit and
provides battery voltage to the front fog lamps when-
ever the relay is energized.
²Normally Closed Terminal- The normally
closed terminal (87A) is not connected in this appli-
cation.The front fog lamp relay can be diagnosed using
conventional diagnostic tools and methods.
DIAGNOSIS AND TESTING - FRONT FOG LAMP
RELAY
The front fog lamp relay (Fig. 8) is located in the
Power Distribution Center in the engine compart-
ment. Refer to the appropriate wiring information.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Remove the front fog lamp relay from the PDC.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/FRONT FOG LAMP RELAY - REMOV-
AL).
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
Fig. 8 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8L - 12 LAMPS/LIGHTING - EXTERIORDR
FOG LAMP RELAY (Continued)