ESP DODGE RAM 2003 Service Owner's Manual

5.9L V-8 Gas
The CMP sensor on the 5.9L V-8 engine contains a
hall effect device called a sync signal generator to
generate a fuel sync signal. This sync signal genera-
tor detects a rotating pulse ring (shutter) (Fig. 9) on
the distributor shaft. The pulse ring rotates 180
degrees through the sync signal generator. Its signal
is used in conjunction with the Crankshaft Position
(CKP) sensor to differentiate between fuel injection
and spark events. It is also used to synchronize the
fuel injectors with their respective cylinders.
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following occurs:
The interruption of magnetic field causes the voltage
to switch high resulting in a sync signal of approxi-
mately 5 volts.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following occurs:
The change of the magnetic field causes the sync sig-
nal voltage to switch low to 0 volts.
5.9L Diesel
The Camshaft Position Sensor (CMP) contains a
hall effect device. A rotating target wheel (tonewheel)
for the CMP is located on the front timing gear. This
hall effect device detects notches located on the tone-
wheel. As the tonewheel rotates, the notches pass the
tip of the CMP.
When the leading edge of the tonewheel notch
passes the tip of the CMP, the following occurs: The
interruption of magnetic field causes the voltage to
switch high resulting in a signal of approximately 5
volts.
When the trailing edge of the tonewheel notch
passes the tip of the CMP, the following occurs: Thechange of the magnetic field causes the signal voltage
to switch low to 0 volts.
The CMP (Fig. 10) provides a signal to the Engine
Control Module (ECM) at all times when the engine
is running. The ECM uses the CMP information pri-
marily on engine start-up. Once the engine is run-
ning, the ECM uses the CMP as a backup sensor for
engine speed. The Crankshaft Position Sensor (CKP)
is the primary engine speed indicator for the engine
after the engine is running.
8.0L V-10
The CMP sensor is used in conjunction with the
crankshaft position sensor to differentiate between
fuel injection and spark events. It is also used to syn-
chronize the fuel injectors with their respective cylin-
ders. The sensor generates electrical pulses. These
pulses (signals) are sent to the Powertrain Control
Module (PCM). The PCM will then determine crank-
shaft position from both the camshaft position sensor
and crankshaft position sensor.
A low and high area are machined into the cam-
shaft drive gear (Fig. 11). The sensor is positioned in
the timing gear cover so that a small air gap (Fig. 11)
exists between the face of sensor and the high
machined area of cam gear.
Fig. 9 CMP / PULSE RING - 5.9L GAS ENGINE
1 - SYNC SIGNAL GENERATOR
2 - CAMSHAFT POSITION SENSOR
3 - PULSE RING
4 - DISTRIBUTOR ASSEMBLY
Fig. 10 5.9L DIESEL CMP
1 - CMP
2 - FUEL INJECTION PUMP (BOTTOM)
3 - ELECTRONIC CONTROL MODULE (ECM)
4 - ECM ELEC. CONNECTOR
5 - CMP ELEC. CONNECTOR
6 - CMP MOUNTING BOLT
7 - BACK OF TIMING GEAR COVER
8I - 10 IGNITION CONTROLDR
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)

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)

CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Except 5.7L V-8 :With the engine running,
remove spark plug cable from spark plug (one at a
time) and hold next to a good engine ground. If the
cable and spark plug are in good condition, the
engine rpm should drop and the engine will run
poorly. If engine rpm does not drop, the cable and/or
spark plug may not be operating properly and should
be replaced. Also check engine cylinder compression.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire
length of all spark plug cables. If cables are cracked
or punctured, there will be a noticeable spark jump
from the damaged area to the test probe. The cable
running from the ignition coil to the distributor cap
can be checked in the same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by the words
ELECTRONIC SUPPRESSION printed on the cable
jacket.Use an ohmmeter to test for open circuits, exces-
sive resistance or loose terminals. If equipped,
remove the distributor cap from the distributor.Do
not remove cables from cap.Remove cable from
spark plug. Connect ohmmeter to spark plug termi-
nal end of cable and to corresponding electrode in
distributor cap. Resistance should be 250 to 1000
Ohms per inch of cable. If not, remove cable from dis-
tributor cap tower and connect ohmmeter to the ter-
minal ends of cable. If resistance is not within
specifications as found in the SPARK PLUG CABLE
RESISTANCE chart, replace the cable. Test all spark
plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
To test ignition coil-to-distributor cap cable (if
applicaple), do not remove the cable from the cap.
Connect ohmmeter to rotor button (center contact) of
distributor cap and terminal at ignition coil end of
cable. If resistance is not within specifications as
found in the Spark Plug Cable Resistance chart,
remove the cable from the distributor cap. Connect
the ohmmeter to the terminal ends of the cable. If
resistance is not within specifications as found in the
Spark Plug Cable Resistance chart, replace the cable.
Inspect the ignition coil tower for cracks, burns or
corrosion.
REMOVAL
5.9L V-8 / 8.0L V-10
CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose
(Fig. 54). Grasp the boot (not the cable) and pull it
off with a steady, even force.
On 5.9L V-8 engines, spark plug cable heat shields
are pressed into the cylinder head to surround each
spark plug cable boot and spark plug (Fig. 53). These
shields protect the spark plug boots from damage
(due to intense engine heat generated by the exhaust
manifolds) and should not be removed. After the
spark plug cable has been installed, the lip of the
cable boot should have a small air gap to the top of
the heat shield (Fig. 53).
Fig. 53 HEAT SHIELDS - 5.9L V-8
1 - AIR GAP
2 - SPARK PLUG BOOT HEAT SHIELD
8I - 34 IGNITION CONTROLDR
SPARK PLUG CABLE (Continued)

molded plastic cluster housing serves as the carrier
for the cluster circuit board and circuitry, the cluster
connector receptacles, the RKE interface connector,
the gauges, a Light Emitting Diode (LED) for each
cluster indicator, two VFD units, an audible tone
generator, the cluster overlay, the gauge pointers, the
odometer/trip odometer switch and the switch button.
The cluster overlay is a laminated plastic unit. The
dark, visible, outer surface of the overlay is marked
with all of the gauge dial faces and graduations, but
this layer is also translucent. The darkness of this
outer layer prevents the cluster from appearing clut-
tered or busy by concealing the cluster indicators
that are not illuminated, while the translucence of
this layer allows those indicators and icons that are
illuminated to be readily visible. The underlying
layer of the overlay is opaque and allows light from
the LED for each of the various indicators and the
incandescent illumination lamps behind it to be visi-
ble through the outer layer of the overlay only
through predetermined stencil-like cutouts. A rectan-
gular opening in the overlay at the base of both the
speedometer and tachometer dial faces has a smoked
clear lens through which the illuminated VFD units
can be viewed.
Several versions of the EMIC module are offered
on this model. These versions accommodate all of the
variations of optional equipment and regulatory
requirements for the various markets in which the
vehicle will be offered. The microprocessor-based
EMIC utilizes integrated circuitry and information
carried on the Programmable Communications Inter-
face (PCI) data bus network along with several hard
wired analog and multiplexed inputs to monitor sen-
sors and switches throughout the vehicle. In response
to those inputs, the internal circuitry and program-
ming of the EMIC allow it to control and integrate
many electronic functions and features of the vehicle
through both hard wired outputs and the transmis-
sion of electronic message outputs to other electronic
modules in the vehicle over the PCI data bus. (Refer
to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/COMMUNICATION - DESCRIPTION -
PCI BUS).
Besides typical instrument cluster gauge and indi-
cator support, the electronic functions and features
that the EMIC supports or controls include the fol-
lowing:
²Audible Warnings- The EMIC electronic cir-
cuit board is equipped with an audible tone generator
and programming that allows it to provide various
audible alerts to the vehicle operator, including
chime tones and beep tones. An electromechanical
relay is also soldered onto the circuit board to pro-
duce audible clicks that emulate the sound of a con-
ventional turn signal or hazard warning flasher.(Refer to 8 - ELECTRICAL/CHIME/BUZZER -
DESCRIPTION).
²Brake Lamp Control- The EMIC provides
electronic brake lamp request messages to the Front
Control Module (FCM) located on the Integrated
Power Module (IPM) for brake lamp control, exclud-
ing control of the Center High Mounted Stop Lamp
(CHMSL), which remains controlled by a direct hard
wired output of the brake lamp switch.
²Brake Transmission Shift Interlock Control
- The EMIC monitors inputs from the brake lamp
switch, ignition switch, and the Transmission Range
Sensor (TRS), then controls a high-side driver output
to operate the Brake Transmission Shift Interlock
(BTSI) solenoid that locks and unlocks the automatic
transmission gearshift selector lever on the steering
column.
²Cargo Lamp Control- The EMIC provides
direct control of cargo lamp operation with a load
shedding (battery saver) feature which will automat-
ically turn off the cargo lamp if it remains on after a
timed interval.
²Central Locking- The EMIC provides support
for the central locking feature of the power lock sys-
tem. This feature will lock or unlock all doors based
upon the input from the door cylinder lock switch.
Door cylinder lock switches are used only on models
equipped with the optional Vehicle Theft Security
System (VTSS).
²Door Lock Inhibit- The EMIC inhibits locking
of the doors with the power lock switch when the key
is in the ignition switch and the driver side front
door is ajar. However, operation of the door locks is
not inhibited under the same conditions when the
Lock button of the optional RKE transmitter is
depressed.
²Enhanced Accident Response- The EMIC
monitors an input from the Airbag Control Module
(ACM) and, following an airbag deployment, will
immediately disable the power lock output, unlock all
doors by activating the power unlock output, then
enables the power lock output if the power lock
switch input remains inactive for two seconds. This
feature, like all other enhanced accident response
features, is dependent upon a functional vehicle elec-
trical system following the vehicle impact event.
²Exterior Lighting Control- The EMIC pro-
vides electronic head lamp and/or park lamp request
messages to the Front Control Module (FCM) located
on the Integrated Power Module (IPM) for the appro-
priate exterior lamp control of standard head and
park lamps, as well as optional front fog lamps. This
includes support for headlamp beam selection and
the optical horn feature, also known as flash-to-pass.
²Exterior Lighting Fail-safe- In the absence of
a headlamp switch input, the EMIC will turn on the
DRINSTRUMENT CLUSTER 8J - 3
INSTRUMENT CLUSTER (Continued)

cluster illumination lamps and provide electronic
headlamp low beam and park lamp request messages
to the Front Control Module (FCM) located on the
Integrated Power Module (IPM) for default exterior
lamp operation. The FCM will also provide default
park lamp and headlamp low beam operation and the
EMIC will turn on the cluster illumination lamps if
there is a failure of the electronic data bus commu-
nication between the EMIC and the FCM.
²Heated Seat Control- The EMIC monitors
inputs from the ignition switch and electronic engine
speed messages from the Powertrain Control Module
(PCM) to control a high side driver output to the
heated seat switch Light Emitting Diode (LED) indi-
cators. This input allows the heated seat switches to
wake up the heated seat module if the switch is actu-
ated. The EMIC will de-energize the heated seat
switch LED indicators, which deactivates the heated
seat system, if the ignition switch is turned to any
position except On or Start, or if the engine speed
message indicates zero. (Refer to 8 - ELECTRICAL/
HEATED SEATS - DESCRIPTION).
²Interior Lamp Load Shedding- The EMIC
provides a battery saver feature which will automat-
ically turn off all interior lamps that remain on after
a timed interval of about fifteen minutes.
²Interior Lamps - Enhanced Accident
Response- The EMIC monitors inputs from the Air-
bag Control Module (ACM) and the Powertrain Con-
trol Module (PCM) to automatically turn on the
interior lighting after an airbag deployment event
ten seconds after the vehicle speed is zero. The inte-
rior lighting remains illuminated until the ignition
switch is turned to the Off position, at which time
the interior lighting returns to normal operation and
control. This feature, like all other enhanced accident
response features, is dependent upon a functional
vehicle electrical system following the vehicle impact
event.
²Interior Lighting Control- The EMIC moni-
tors inputs from the interior lighting switch, the door
ajar switches, the cargo lamp switch, the reading
lamp switches, and the Remote Keyless Entry (RKE)
module to provide courtesy lamp control. This
includes support for timed illuminated entry with
theater-style fade-to-off and courtesy illumination
defeat features.
²Lamp Out Indicator Control- The EMIC
monitors electronic lamp outage messages from the
Front Control Module (FCM) located on the Inte-
grated Power Module (IPM) in order to provide lamp
out indicator control for the headlamps (low and high
beams), turn signal lamps, and the brake lamps
(excluding CHMSL).
²Panel Lamps Dimming Control- The EMIC
provides a hard wired 12-volt Pulse-Width Modulated(PWM) output that synchronizes the dimming level
of all panel lamps dimmer controlled lamps with that
of the cluster illumination lamps.
²Parade Mode- The EMIC provides a parade
mode (also known as funeral mode) that allows all
Vacuum-Fluorescent Display (VFD) units in the vehi-
cle to be illuminated at full (daytime) intensity while
driving during daylight hours with the exterior
lamps turned on.
²Power Locks- The EMIC monitors inputs from
the power lock switches and the Remote Keyless
Entry (RKE) receiver module (optional) to provide
control of the power lock motors through high side
driver outputs to the power lock motors. This
includes support for rolling door locks (also known as
automatic door locks), automatic door unlock, a door
lock inhibit mode, and central locking (with the
optional Vehicle Theft Security System only). (Refer
to 8 - ELECTRICAL/POWER LOCKS - DESCRIP-
TION).
²Remote Keyless Entry- The EMIC supports
the optional Remote Keyless Entry (RKE) system fea-
tures, including support for the RKE Lock, Unlock
(with optional driver-door-only unlock, and unlock-
all-doors), Panic, audible chirp, optical chirp, illumi-
nated entry modes, an RKE programming mode, as
well as optional Vehicle Theft Security System
(VTSS) arming (when the proper VTSS arming con-
ditions are met) and disarming.
²Remote Radio Switch Interface- The EMIC
monitors inputs from the optional remote radio
switches and then provides the appropriate electronic
data bus messages to the radio to select the radio
operating mode, volume control, preset station scan
and station seek features.
²Rolling Door Locks- The EMIC provides sup-
port for the power lock system rolling door locks fea-
ture (also known as automatic door locks). This
feature will automatically lock all unlocked doors
each time the vehicle speed reaches twenty-four kilo-
meters-per-hour (fifteen miles-per-hour) and, follow-
ing an automatic lock event, will automatically
unlock all doors once the ignition is turned to the Off
position and the driver side front door is opened.
²Turn Signal & Hazard Warning Lamp Con-
trol- The EMIC provides electronic turn and hazard
lamp request messages to the Front Control Module
(FCM) located on the Integrated Power Module (IPM)
for turn and hazard lamp control. The EMIC also
provides an audible click at one of two rates to emu-
late normal and bulb out turn or hazard flasher oper-
ation based upon electronic lamp outage messages
from the FCM, and provides an audible turn signal
on chime warning if a turn is signalled continuously
for more than about 1.6 kilometers (one mile) and
8J - 4 INSTRUMENT CLUSTERDR
INSTRUMENT CLUSTER (Continued)

The EMIC microprocessor smooths the input data
using algorithms to provide gauge readings that are
accurate, stable and responsive to operating condi-
tions. These algorithms are designed to provide
gauge readings during normal operation that are con-
sistent with customer expectations. However, when
abnormal conditions exist such as high coolant tem-
perature, the algorithm can drive the gauge pointer
to an extreme position and the microprocessor can
sound a chime through the on-board audible tone
generator to provide distinct visual and audible indi-
cations of a problem to the vehicle operator. The
instrument cluster circuitry may also produce audi-
ble warnings for other electronic modules in the vehi-
cle based upon electronic tone request messages
received over the PCI data bus. Each audible warn-
ing is intended to provide the vehicle operator with
an audible alert to supplement a visual indication.The EMIC circuitry operates on battery current
received through a fused B(+) fuse in the Integrated
Power Module (IPM) on a non-switched fused B(+)
circuit, and on battery current received through a
fused ignition switch output (run-start) fuse in the
IPM on a fused ignition switch output (run-start) cir-
cuit. This arrangement allows the EMIC to provide
some features regardless of the ignition switch posi-
tion, while other features will operate only with the
ignition switch in the On or Start positions. The
EMIC circuitry is grounded through a ground circuit
and take out of the instrument panel wire harness
with an eyelet terminal connector that is secured by
a ground screw to a ground location near the center
of the instrument panel structural support.
The EMIC also has a self-diagnostic actuator test
capability, which will test each of the PCI bus mes-
sage-controlled functions of the cluster by lighting
the appropriate indicators, positioning the gauge nee-
Fig. 4 Gauges & Indicators - Diesel Engine
1 - MALFUNCTION INDICATOR LAMP 14 - ENGINE TEMPERATURE GAUGE
2 - VOLTAGE GAUGE 15 - SECURITY INDICATOR
3 - LEFT TURN INDICATOR 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES
CRUISE & UPSHIFT INDICATORS)
4 - TACHOMETER 17 - WATER-IN-FUEL INDICATOR
5 - AIRBAG INDICATOR 18 - BRAKE INDICATOR
6 - HIGH BEAM INDICATOR 19 - WAIT-TO-START INDICATOR
7 - SEATBELT INDICATOR 20 - ODOMETER/TRIP ODOMETER DISPLAY (INCLUDES
ENGINE HOURS, WASHER FLUID, LAMP OUTAGE,
OVERDRIVE-OFF & SERVICE 4x4 INDICATORS)
8 - SPEEDOMETER 21 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
9 - RIGHT TURN INDICATOR 22 - FUEL GAUGE
10 - OIL PRESSURE GAUGE 23 - LOW FUEL INDICATOR
11 - CARGO LAMP INDICATOR 24 - TRANSMISSION OVERTEMP INDICATOR
12 - DOOR AJAR INDICATOR 25 - CHECK GAUGES INDICATOR
13 - ABS INDICATOR
DRINSTRUMENT CLUSTER 8J - 7
INSTRUMENT CLUSTER (Continued)

dles at several predetermined calibration points
across the gauge faces, and illuminating all segments
of the odometer/trip odometer and gear selector indi-
cator Vacuum-Fluorescent Display (VFD) units.
(Refer to 8 - ELECTRICAL/INSTRUMENT CLUS-
TER - DIAGNOSIS AND TESTING). See the owner's
manual in the vehicle glove box for more information
on the features, use and operation of the EMIC.
GAUGES
All gauges receive battery current through the
EMIC circuitry only when the ignition switch is in
the On or Start positions. With the ignition switch in
the Off position battery current is not supplied to
any gauges, and the EMIC circuitry is programmed
to move all of the gauge needles back to the low end
of their respective scales. Therefore, the gauges do
not accurately indicate any vehicle condition unless
the ignition switch is in the On or Start positions.
All of the EMIC gauges are air core magnetic
units. Two fixed electromagnetic coils are located
within each gauge. These coils are wrapped at right
angles to each other around a movable permanent
magnet. The movable magnet is suspended within
the coils on one end of a pivot shaft, while the gauge
needle is attached to the other end of the shaft. One
of the coils has a fixed current flowing through it to
maintain a constant magnetic field strength. Current
flow through the second coil changes, which causes
changes in its magnetic field strength. The current
flowing through the second coil is changed by the
EMIC circuitry in response to messages received over
the PCI data bus. The gauge needle moves as the
movable permanent magnet aligns itself to the
changing magnetic fields created around it by the
electromagnets.
The gauges are diagnosed using the EMIC self-di-
agnostic actuator test. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - DIAGNOSIS AND
TESTING). Proper testing of the PCI data bus and
the electronic data bus message inputs to the EMIC
that control each gauge require the use of a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation. Specific operation details for each gauge may
be found elsewhere in this service information.
VACUUM-FLUORESCENT DISPLAYS
The Vacuum-Fluorescent Display (VFD) units are
soldered to the EMIC electronic circuit board. With
the ignition switch in the Off or Accessory positions,
the odometer display is activated when the driver
door is opened (Rental Car mode) and is deactivated
when the driver door is closed. Otherwise, both dis-
play units are active when the ignition switch is in
the On or Start positions, and inactive when the igni-
tion switch is in the Off or Accessory positions.The illumination intensity of the VFD units is con-
trolled by the EMIC circuitry based upon an input
from the headlamp switch and a dimming level input
received from the headlamp dimmer switch. The
EMIC synchronizes the illumination intensity of
other VFD units with that of the units in the EMIC
by sending electronic dimming level messages to
other electronic modules in the vehicle over the PCI
data bus.
The EMIC VFD units have several display capabil-
ities including odometer, trip odometer, engine hours,
gear selector indication (PRNDL) for models with an
automatic transmission, several warning or reminder
indications, and various diagnostic information when
certain fault conditions exist. An odometer/trip odom-
eter switch on the EMIC circuit board is used to con-
trol some of the display modes. This switch is
actuated manually by depressing the odometer/trip
odometer switch button that extends through the
lower edge of the cluster lens, just left of the tachom-
eter. Actuating this switch momentarily with the
ignition switch in the On position will toggle the
VFD between the odometer and trip odometer modes.
Depressing the switch button for about two seconds
while the VFD is in the trip odometer mode will
reset the trip odometer value to zero. While in the
odometer mode with the ignition switch in the On
position and the engine not running, depressing this
switch for about six seconds will display the engine
hours information. Holding this switch depressed
while turning the ignition switch from the Off posi-
tion to the On position will initiate the EMIC self-di-
agnostic actuator test. Refer to the appropriate
diagnostic information for additional details on this
VFD function. The EMIC microprocessor remembers
which display mode is active when the ignition
switch is turned to the Off position, and returns the
VFD display to that mode when the ignition switch is
turned On again.
The VFD units are diagnosed using the EMIC self-
diagnostic actuator test. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - DIAGNOSIS AND
TESTING). Proper testing of the PCI data bus and
the electronic data bus message inputs to the EMIC
that control some of the VFD functions requires the
use of a DRBIIItscan tool. Refer to the appropriate
diagnostic information. Specific operation details for
the odometer, the trip odometer, the gear selector
indicator and the various warning and reminder indi-
cator functions of the VFD may be found elsewhere
in this service information.
INDICATORS
Indicators are located in various positions within
the EMIC and are all connected to the EMIC elec-
tronic circuit board. The cargo lamp indicator, door
8J - 8 INSTRUMENT CLUSTERDR
INSTRUMENT CLUSTER (Continued)

ajar indicator, high beam indicator, and turn signal
indicators operate based upon hard wired inputs to
the EMIC. The brake indicator is controlled by PCI
data bus messages from the Controller Antilock
Brake (CAB) as well as by hard wired park brake
switch inputs to the EMIC. The seatbelt indicator is
controlled by the EMIC programming, PCI data bus
messages from the Airbag Control Module (ACM),
and a hard wired seat belt switch input to the EMIC.
The Malfunction Indicator Lamp (MIL) is normally
controlled by PCI data bus messages from the Pow-
ertrain Control Module (PCM); however, if the EMIC
loses PCI data bus communication, the EMIC cir-
cuitry will automatically turn the MIL on until PCI
data bus communication is restored. The EMIC uses
PCI data bus messages from the Front Control Mod-
ule (FCM), the PCM, the diesel engine only Engine
Control Module (ECM), the ACM, the CAB, and the
Sentry Key Immobilizer Module (SKIM) to control all
of the remaining indicators.
The various EMIC indicators are controlled by dif-
ferent strategies; some receive fused ignition switch
output from the EMIC circuitry and have a switched
ground, while others are grounded through the EMIC
circuitry and have a switched battery feed. However,
all indicators are completely controlled by the EMIC
microprocessor based upon various hard wired and
electronic message inputs. All indicators are illumi-
nated at a fixed intensity, which is not affected by
the selected illumination intensity of the EMIC gen-
eral illumination lamps.
In addition, certain indicators in this instrument
cluster are automatically configured or self-config-
ured. This feature allows the configurable indicators
to be enabled by the EMIC circuitry for compatibility
with certain optional equipment. The EMIC defaults
for the ABS indicator and airbag indicator are
enabled, and these configuration settings must be
programmatically disabled in the EMIC using a
DRBIIItscan tool for vehicles that do not have this
equipment. The automatically configured or self-con-
figured indicators remain latent in each EMIC at all
times and will be active only when the EMIC
receives the appropriate PCI message inputs for that
optional system or equipment.
The hard wired indicator inputs may be diagnosed
using conventional diagnostic methods. However, the
EMIC circuitry and PCI bus message controlled indi-
cators are diagnosed using the EMIC self-diagnostic
actuator test. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - DIAGNOSIS AND TESTING).
Proper testing of the PCI data bus and the electronic
message inputs to the EMIC that control an indicator
requires the use of a DRBIIItscan tool. Refer to the
appropriate diagnostic information. Specific details ofthe operation for each indicator may be found else-
where in this service information.
CLUSTER ILLUMINATION
The EMIC has several illumination lamps that are
illuminated when the exterior lighting is turned on
with the headlamp switch. The illumination intensity
of these lamps is adjusted when the interior lighting
thumbwheel on the headlamp switch is rotated (down
to dim, up to brighten) to one of six available minor
detent positions. The EMIC monitors a resistor mul-
tiplexed input from the headlamp switch on a dim-
mer input circuit. In response to that input, the
EMIC electronic circuitry converts a 12-volt input it
receives from a fuse in the Integrated Power Module
(IPM) on a hard wired panel lamps dimmer switch
signal circuit into a 12-volt Pulse Width Modulated
(PWM) output. The EMIC uses this PWM output to
power the cluster illumination lamps and the VFD
units on the EMIC circuit board, then provides a syn-
chronized PWM output on the various hard wired
fused panel lamps dimmer switch signal circuits to
control and synchronize the illumination intensity of
other incandescent illumination lamps in the vehicle.
The cluster illumination lamps are grounded at all
times.
The EMIC also sends electronic dimming level
messages over the PCI data bus to other electronic
modules in the vehicle to control and synchronize the
illumination intensity of their VFD units to that of
the EMIC VFD units. In addition, the thumbwheel
on the headlamp switch has a Parade Mode position
to provide a parade mode. The EMIC monitors the
request for this mode from the headlamp switch,
then sends an electronic dimming level message over
the PCI data bus to illuminate all VFD units in the
vehicle at full (daytime) intensity for easier visibility
when driving in daylight with the exterior lighting
turned on.
The hard wired headlamp switch and EMIC panel
lamps dimmer inputs and outputs may be diagnosed
using conventional diagnostic methods. However,
proper testing of the PWM output of the EMIC and
the electronic dimming level messages sent by the
EMIC over the PCI data bus requires the use of a
DRBIIItscan tool. Refer to the appropriate diagnos-
tic information.
INPUT AND OUTPUT CIRCUITS
HARD WIRED INPUTS
The hard wired inputs to the EMIC include the fol-
lowing:
²Brake Lamp Switch Output
²Driver Cylinder Lock Switch Sense
²Driver Door Ajar Switch Sense
DRINSTRUMENT CLUSTER 8J - 9
INSTRUMENT CLUSTER (Continued)