fuel FORD MUSTANG 2003 Workshop Manual

Instrument Cluster—
Base 4.6L Engine transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Voltmeter gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator
13 — ABS warning indicator Klj . 2 ba
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Instrument Cluster—
Cobra 14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Boost gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator Klj . 3 ba
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13 — ABS warning indicator
14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator Klj . 4 ba
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z
air bag warning indicator
z BRAKE warning indicator
z charging system indicator
z fail safe cooling warning indicator
z low coolant level indicator
z low fuel warning indicator
z traction control indicator
Instrument Cluster Replacement
When it is necessary to install a new instrument cluster, contact the Instrument Cluster Program.
Gauge Indication Systems
Tachometer
Engine rpm information is relayed to the instrument cluster from the powertrain control module (PCM)
over the standard corporate protocol (SCP) network.
Speedometer
The instrument cluster receives the vehicle speed signal from the PCM over the SCP network and
displays it on the speedometer gauge. If the instrument cluster receives no vehicle speed signal after
one second, the speedometer defaults to 0.0 km/h (0.0 mph).
Odometer
The instrument cluster receives an odometer message from the PCM and stores the mileage in
memory. When the instrument cluster fails to receive the odometer message for more than two
seconds, the odometer will display dashes.
Fuel Gauge
The fuel sender is hardwired to the fuel gauge. When the instrument cluster fails to receive the fuel
level signal for more than 33 seconds, the fuel level gauge will move below E (empty). If the fuel level
signal operates correctly for more than 33 seconds, the fuel gauge will return to the correct position.
Fuel fills of less than 9.5 liters (2.5 gallons) require at least 10 minutes to update the fuel gauge
indication.
Engine Coolant Temperature Gauge
Engine coolant temperature information is received by the instrument cluster from the PCM over the
SCP network. Engine coolant temperatures above 121°C (250°F) will cause the gauge to indicate
above the normal band. If the engine coolant temperature information is missing or invalid for five
seconds, the temperature gauge will indicate below the cold (C) position.
Voltage Gauge (except Cobra)
The voltage gauge displays the system voltage as measured at the instrument cluster run input. Boost Gauge (Cobra only) Klj . 2 ba
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The boost pressure gauge on the instrument cluster receives and measures the boost pressure
directly from the intake manifold. The boost pressure gauge will display between 0.0-
0.48 kpa (0.0-10
psi) boost pressure dependent upon accelerator position, engine load, and engine rpm.
LOW FUEL Level Indicator
The low fuel level indicator is hardwired from the fuel sender to the instrument cluster. The instrument
cluster will illuminate the low fuel indicator when the usable fuel quantity is less than 1/8 tank (15%) of
fuel tank capacity.
Oil Pressure Gauge
The oil pressure gauge is hardwired from the oil pressure switch to the instrument cluster. The oil
pressure gauge will indicate either normal or no oil pressure.
CHECK FUEL CAP
The CHECK FUEL CAP indicator is used to indicate significant leaks in the fuel tank evaporative
system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM. If a leak is detected the
PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a
loose fuel cap and the CHECK FUEL CAP indicator is illuminated, the indicator will remain illuminated
until the fuel cap is secured and the vehicle has been running for several minutes. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
BRAKE Warning Indicator
The BRAKE warning indicator activates when the generic electronic module (GEM) detects the ignition
switch circuits are in the RUN state, when the GEM detects low brake fluid level, or that the parking
brake is applied. The BRAKE warning indicator will prove out starting when the GEM detects that the
ignition circuits have made a transition to RUN or START from OFF, ACC, or keyout and ending when
either three seconds have elapsed or when the GEM detects the ignition circuits have made a
transition to OFF, ACC, or keyout.
Safety Belt Warning Indicator
The safety belt switch is hardwired to the GEM. The safety belt warning indicator will be illuminated
when the GEM sends a ground signal to the instrument cluster.
ABS Warning Indicator
The ABS warning indicator will be illuminated when the anti- lock brake control module sends a ground
signal to the instrument cluster. The prove- out of the ABS indicator is controlled by the anti- lock brake
control module.
SERVICE ENGINE SOON Indicator
The SERVICE ENGINE SOON indicator receives its signal from the PCM over the SCP network. If the
instrument cluster does not receive a message from the PCM within five seconds, the instrument
cluster will illuminate the SERVICE ENGINE SOON indicator and log a diagnostic trouble code (DTC).
High Beam Indicator
The high beam indicator will illuminate when the steering column multifunction switch is in the high
beam position by sending a battery signal to the instrument cluster. Right and Left Turn Indicator Klj . 3 ba
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The right and left turn indicators will illuminate when the steering column multifunction switch is in
either turn signal position or hazard lamps position by sending a battery signal to the instrument
cluster.
AIR BAG Warning Indicator
The AIR BAG warning indicator will be illuminated when the restraint control module (RCM) sends a
ground signal to the instrument cluster. The prove-
out of the AIR BAG warning indicator is controlled
by the RCM.
THEFT Indicator
The THEFT indicator provides a passive anti- theft system (PATS) prove-out. The THEFT indicator will
prove out for three seconds following the ignition switch cycle and will flash following an ignition switch
OFF transition to indicate that PATS is active.
Charging System Indicator
The charging system indicator will be illuminated when the generator provides a ground signal to the
instrument cluster. The instrument cluster provides a prove- out when the ignition switch is in the RUN
position with the engine off. When the engine is started, the generator removes the ground to the
instrument cluster and extinguishes the charging system indicator.
Overdrive Off (O/D OFF) Indicator
The O/D OFF indicator is controlled by the off/on message sent from the PCM over the SCP network.
The instrument cluster does not provide a prove- out for the O/D OFF indicator, but will remain
illuminated if the overdrive has been commanded off following the instrument cluster prove- out.
Traction Control Indicator
During initialization, the instrument cluster will receive the traction control system state status message
from the traction control module to determine if the vehicle is equipped with traction control. If the
vehicle is equipped with traction control, this information will be stored in random access memory
(RAM) and the indicator will prove out for three seconds during each ignition cycle. If this message is
not received, the instrument cluster will assume that the vehicle is not traction control equipped and
the indicator will remain off. When the traction control is active, the traction control module sends the
instrument cluster a traction control active signal and the instrument cluster illuminates the traction
control indicator. When the traction control is inactive, the traction control module removes the traction
control active signal and the instrument cluster turns off the indicator.
In the event of a traction control failure, the traction control indicator will remain off and the ABS
indicator will illuminate.
Inspection and Verification 1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Visual Inspection Chart Mechanical Electrical
z
Fuel tank z
Central junction box (CJB) fuse(s): Klj . 4 ba
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Odometer
Display Description
GAGE Activates gauge sweep of all gauges, then displays present gauge values. Also
carries out the checksum tests on ROM and EE. All segments
illuminated Illuminates all odometer segments.
bulb Illuminates all micro-controlled indicators and LEDs. Install a new indicator or LED as
necessary. r Returns to normal operation of all micro-
controlled indicators and LEDs and displays
hexadecimal value for ROM level (used when requesting assistance from the hotline). EE Displays hexadecimal value for EE level (used when requesting assistance from the
hotline). dt Displays hexadecimal coding of final manufacturing test date (used when requesting
assistance from the hotline). dtc Displays continuous DTCs in hexadecimal format. Pressing the SELECT/RESET
button will display any DTCs stored before proceeding to the next step. enG Displays the English speed in mph. Speedometer will indicate present speed within
tolerances. Display will show 0 if input is not received, if input received is invalid for one second or more, or if speed is 0. m Displays the metric speed data (km/h). Speedometer will indicate present speed
within tolerances. Display will show 0 if input is not received, if input received is invalid for one second or more, or if speed is 0. tAc Displays the tachometer data received from the PCM via the SCP network within
tolerances. Tachometer will indicate present rpm. Display will show 0 if input is not received, if input received is invalid for one second or more, or if engine rpm is 0. FUEL Displays the code (0-255) for the fuel sender input to the instrument cluster. The fuel
gauge will display a filtered fuel level value. This filter will keep the pointer from moving suddenly or erratically.
z255 = open send +/- 0
z 232 = full stop +/- 0
z 215 = full mark +/- 10
z 178 = 3/4 mark +/- 8
z 138 = 1/2 mark +/- 7
z 93 = 1/4 mark +/- 5
z 41 = E mark +/- 4
z 54=LOW FUEL (0- 59)
z 0-18=short (0- 20 max) OIL Displays the code (0-
250) for the oil pressure switch input to the instrument cluster.
Oil pressure gauge will indicate present oil pressure. Normal oil pressure (greater
than 6 psi) will display a value between 000 and 176. A low oil pressure or an
inoperative engine oil pressure switch (less than 6 psi) will display a value greater
than 176. dEGC Display of engine temperature in degrees C input from cylinder head temperature
sensor.
z 49 C = "C" mark
z 60 C = normal band start
z 120 C = normal band end
z -40 C = no SCP message for 5 seconds bAtt Displays the code (0-255) for the battery voltage input to the instrument cluster.
Battery voltage gauge will indicate present battery voltage. Klj . 6 ba
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To exit the instrument cluster self-
diagnostic mode, turn the ignition switch to the OFF position or press
and hold the SELECT/RESET button for three or more seconds and release. z
93- 102 = 6.9- 9.1 volts (low voltage)
z 115- 124 = 8.5- 10.7 volts (norm band start)
z 215- 225 = 15.8- 18 volts (norm band end)
z 230- 241 = 16.9- 19.1 volts (high voltage) rhEo Displays the present decimal rheostat dimming input, 0-
255 (used when requesting
assistance from the hotline). rhi
rhS rho Not used.
Cr Displays the present RUN/START sense input. Display will show -
h for high input with
the ignition switch in the START position and - L for low input with the ignition switch in
the RUN position. PA-
PE7 Not used.
GAGE Repeats test display cycle.
Instrument Cluster Diagnostic Trouble Code (DTC) Index Diagnostic
Tool
Displayed DTC Self-
Diagnostic
Mode Displayed DTC Description Source Action
B1202 9202 Fuel Sender
Open Circuit Instrument
Cluster Go To Pinpoint Test B .
B1204 9204 Fuel Sender
Short to Ground Instrument
Cluster Go To Pinpoint Test B .
B1317 9317 Battery Voltage
High Instrument
Cluster Section 414 - 00 .
B1318 9318 Battery Voltage
Low Instrument
Cluster Section 414 - 00 .
B1342 9342 ECU is Defective Instrument
Cluster INSTALL a new instrument
cluster; REFER to Instrument Cluster in this section. TEST the
system for normal operation. B1343 9343 Heated Backlight
Input Circuit Failure Instrument
Cluster Section 501 - 11 .
B1356 9356 Ignition Run
Circuit Open Instrument
Cluster Go To Pinpoint Test A .
B1364 9364 Ignition Start
Circuit Open Instrument
Cluster Go To Pinpoint Test A .
B2143 A143 Odometer NVM
Mmory Failure Instrument
Cluster Go To Pinpoint Test J .
C1284 5284 Oil Pressure
Switch Failure Instrument
Cluster Go To Pinpoint Test C .
P1197 1197 Mileage Switch
Circuit Failure Instrument
Cluster Go To Pinpoint Test J . Klj . 7 ba
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(20A).
z Battery junction
box (BJB) fuse
12 (40A).
z Circuitry.
z GEM.
z No communication with
the instrument cluster z
Central junction
box (CJB) fuse
(s):
„11
(15A).
„ 21 (5A).
„ 34
(20A).
z Circuitry.
z Standard
corporate
protocol (SCP)
network.
z Instrument
cluster. z
Go To Pinpoint Test A .
z Incorrect fuel gauge
indication z
Circuitry.
z Fuel pump
module.
z Instrument
cluster. z
Go To Pinpoint Test B .
z Incorrect oil pressure
gauge indication z
Circuitry.
z Engine oil
pressure
switch.
z Instrument
cluster. z
Go To Pinpoint Test C .
z Incorrect temperature
gauge indication z
Circuitry.
z Engine coolant
temperature
sensor.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test D .
z Incorrect voltage gauge
indication— except
Cobra z
Circuitry.
z Generator.
z Standard
corporate
protocol (SCP)
network.
z Instrument
cluster. z
Go To Pinpoint Test E .
z Incorrect tachometer
indication z
Standard
corporate
protocol (SCP)
network.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test F .
z Incorrect boost gauge zPressure line. zGo To Pinpoint Test G . Klj . 10 ba
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indication—
Cobra only zInstrument
cluster.
z The LOW FUEL warning
indicator is never/always
on z
LOW FUEL
warning
indicator bulb.
z Standard
corporate
protocol (SCP)
network.
z Instrument
cluster. z
Go To Pinpoint Test H .
z Oil gauge reads normal
with engine off z
Instrument
cluster. z
INSTALL a new instrument
cluster. REFER to
Instrument Cluster in this
section. TEST the system
for normal operation.
z The speedometer is
inoperative z
Standard
corporate
protocol (SCP)
network.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test I .
z The odometer is
inoperative z
Circuitry.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test J .
z The safety belt warning
indicator is inoperative
(chime is
operative)/does not
operate correctly z
Circuitry.
z Generic
electronic
module (GEM).
z Instrument
cluster. z
Go To Pinpoint Test K .
z Inaccurate speedometer
reading z
Instrument
cluster.
z Powertrain
control module
(PCM). z
Go To Pinpoint Test L .
z The O/D OFF indicator
is never on z
Circuitry.
z O/D cancel
switch.
z O/D OFF
indicator bulb.
z Standard
corporate
protocol (SCP)
network.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test M .
z The O/D OFF indicator
is always on z
Circuitry.
z O/D cancel
switch. z
REFER to the Powertrain
Control/Emissions
Diagnosis (PC/ED) Klj . 11 ba
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