Brake light JEEP GRAND CHEROKEE 2002 WJ / 2.G Owner's Manual

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION.........................41
OPERATION...........................41
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES............................42
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM......................42
SPECIFICATIONS
TORQUE CHART......................42
ELECTRIC BRAKE
DESCRIPTION.........................43
OPERATION...........................43
FRONT WHEEL SPEED SENSOR
DESCRIPTION.........................43
OPERATION...........................43
REMOVAL.............................43INSTALLATION.........................43
G-SWITCH
DESCRIPTION.........................44
OPERATION...........................44
REMOVAL.............................44
INSTALLATION.........................44
REAR WHEEL SPEED SENSOR
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................46
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................46
OPERATION...........................46
REMOVAL.............................47
INSTALLATION.........................47
BRAKES - ABS
DESCRIPTION
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The hydraulic system is a three channel design.
The front brakes are controlled individually and the
rear brakes in tandem.
The ABS electrical system is separate from other
vehicle electrical circuits. A separate controller oper-
ates the system.
OPERATION
The antilock CAB activates the system whenever
sensor signals indicate periods of high wheel slip.
High wheel slip can be described as the point where
wheel rotation begins approaching 20 to 30 percent of
actual vehicle speed during braking. Periods of high
wheel slip occur when brake stops involve high pedal
pressure and rate of vehicle deceleration.
Battery voltage is supplied to the CAB ignition ter-
minal when the ignition switch is turned to Run posi-
tion. The CAB performs a system initialization
procedure at this point. Initialization consists of a
static and dynamic self check of system electrical
components.
The static check occurs after the ignition switch is
turned to Run position. The dynamic check occurs
when vehicle road speed reaches approximately 30kph (18 mph). During the dynamic check, the CAB
briefly cycles the pump and solenoids to verify oper-
ation.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
ANTILOCK BRAKING
The antilock system prevents lockup during high
slip conditions by modulating fluid apply pressure to
the wheel brake units.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera-
tion. A sensor at each wheel converts wheel speed
into electrical signals. These signals are transmitted
to the CAB for processing and determination of
wheel slip and deceleration rate.
The ABS system has three fluid pressure control
channels. The front brakes are controlled separately
and the rear brakes in tandem. A speed sensor input
signal indicating a high slip condition activates the
CAB antilock program.
Two solenoid valves are used in each antilock con-
trol channel. The valves are all located within the
HCU valve body and work in pairs to either increase,
hold, or decrease apply pressure as needed in the
individual control channels.
The solenoid valves are not static during antilock
braking. They are cycled continuously to modulate
pressure. Solenoid cycle time in antilock mode can be
measured in milliseconds.
WJBRAKES - ABS 5 - 41

²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED
²STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increase engine speed for more air flow is recom-
mended.(1) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(2) AIR CONDITIONING; ADD-ON OR AFTER
MARKET:
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer's specifications.
(3) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump, or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only. Refer to the group text for information.
Fig. 4 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
7 - 4 COOLINGWJ
COOLING (Continued)

(5) Connect the two instrument panel wire harness
connectors to the BCM.
(6) Reinstall the instrument panel fuse cover to
the bottom of the BCM and JB unit. (Refer to 8 -
ELECTRICAL/POWER DISTRIBUTION/FUSE
COVER - INSTALLATION).
(7) Connect the battery negative cable.
COMMUNICATION
DESCRIPTION
The Programmable Communication Interface (PCI)
data bus system is a single wire multiplex system
used for vehicle communications. Multiplexing is a
system that enables the transmission of several mes-
sages over a single channel or circuit.
Many of the control modules in a vehicle require
information from the same sensing device. Multiplex-
ing reduces wire harness complexity, sensor current
loads and controller hardware because each sensing
device is connected to only one controller, which
reads and distributes the sensor information to the
other controllers over the data bus. Also, because
each controller on the data bus can access the con-
troller sensor inputs to every other controller on the
data bus, more function and feature capabilities are
possible.
A multiplex system allows the information flowing
between controllers to be monitored using a diagnos-
tic scan tool. This system allows a control module to
broadcast message data out onto the bus where all
other control modules can read the messages that are
being sent. When a module reads a message on the
data bus that it requires, it relays that message to
its microprocessor. Each module ignores the mes-
sages on the data bus that it dosen't recognize.
OPERATION
Data exchange between modules is achieved by
serial transmission of encoded data over a single wire
broadcast network. The PCI data bus messages are
carried over the bus in the form of Variable Pulse
Width Modulated (VPWM) signals. The PCI data bus
speed is an average 10.4 Kilo-bits per second (Kbps).
The voltage network used to transmit messages
requires biasing and termination. Each module on
the PCI data bus system provides its own biasing
and termination. Each module (also referred to as a
node) terminates the bus through a terminating
resistor and a terminating capacitor. The Powertrain
Control Module (PCM) is the only dominant node for
the PCI data bus system.
The PCI bus uses low and high voltage levels to
generate signals. The voltage on the buss varies
between zero and seven and one-half volts. The lowand high voltage levels are generated by means of
variable-pulse width modulation to form signals of
varying length.
When a module is transmitting on the bus, it is
reading the bus at the same time to ensure message
integrity.
Each module is capable of transmitting and receiv-
ing data simultaneously.
The PCI data bus can be monitored using the
DRBIIItscan tool. It is possible for the bus to pass
all DRBIIIttests and still be faulty if the voltage
parameters are all within the specified range and
false messages are being sent.
CONTROLLER ANTILOCK
BRAKE
DESCRIPTION
The Controler Antilock Brake (CAB) is mounted to
the Hydraulic Control Unit (HCU) and operates the
ABS system (Fig. 4).
OPERATION
The CAB voltage is supplied by the ignition switch
in the RUN position. The CAB contains dual micro-
processors. A logic block in each microprocessor
receives identical sensor signals. These signals are
processed and compared simultaneously. The CAB
contains a self check program that illuminates the
ABS warning light when a system fault is detected.
Faults are stored in a diagnostic program memory
and are accessible with the DRBIIItscan tool. ABS
faults remain in memory until cleared, or until after
the vehicle is started approximately 50 times. Stored
Fig. 4 Controller Antilock Brakes
1 - HCU
2 - MOTOR
3 - CAB
8E - 6 ELECTRONIC CONTROL MODULESWJ
BODY CONTROL MODULE (Continued)

EMIC also uses several hard wired inputs in order to
perform its many functions. The EMIC module incor-
porates a blue-green digital Vacuum Fluorescent Dis-
play (VFD) for displaying odometer and trip
odometer information.
The EMIC houses six analog gauges and has pro-
visions for up to twenty indicators (Fig. 2). The
EMIC includes the following analog gauges:
²Coolant Temperature Gauge
²Fuel Gauge
²Oil Pressure Gauge
²Speedometer
²Tachometer
²Voltage Gauge
Some of the EMIC indicators are automatically
configured when the EMIC is connected to the vehi-
cle electrical system for compatibility with certain
optional equipment or equipment required for regula-
tory purposes in certain markets. While each EMIC
may have provisions for indicators to support every
available option, the configurable indicators will not
be functional in a vehicle that does not have the
equipment that an indicator supports. The EMIC
includes provisions for the following indicators (Fig.
2):
²Airbag Indicator (with Airbags only)
²Antilock Brake System (ABS) Indicator
²Brake Indicator
²Check Gauges Indicator
²Coolant Low Indicator (with Diesel Engine
only)
²Cruise Indicator
²Four-Wheel Drive Part Time Indicator
(with Selec-Trac NVG-242 Transfer Case only)
²Front Fog Lamp Indicator (with Front Fog
Lamps only)
²High Beam Indicator
²Low Fuel Indicator
²Malfunction Indicator Lamp (MIL)
²Overdrive-Off Indicator (except Diesel
Engine)
²Rear Fog Lamp Indicator (with Rear Fog
Lamps only)
²Seatbelt Indicator
²Sentry Key Immobilizer System (SKIS)
Indicator
²Transmission Overtemp Indicator (except
Diesel Engine)²Turn Signal (Right and Left) Indicators
²Wait-To-Start Indicator (with Diesel Engine
only)
²Water-In-Fuel Indicator (with Diesel Engine
only)
Many indicators in the EMIC are illuminated by a
dedicated Light Emitting Diode (LED) that is sol-
dered onto the EMIC electronic circuit board. The
LEDs are not available for service replacement and,
if damaged or faulty, the entire EMIC must be
replaced. Base cluster illumination is accomplished
by dimmable incandescent back lighting, which illu-
minates the gauges for visibility when the exterior
lighting is turned on. Premium cluster illumination
is accomplished by a dimmable electro-luminescent
lamp that is serviced only as a unit with the EMIC.
Each of the incandescent bulbs is secured by an inte-
gral bulb holder to the electronic circuit board from
the back of the cluster housing. The incandescent
bulb/bulb holder units are available for service
replacement.
Hard wired circuitry connects the EMIC to the
electrical system of the vehicle. These hard wired cir-
cuits are integral to several wire harnesses, which
are routed throughout the vehicle and retained by
many different methods. These circuits may be con-
nected to each other, to the vehicle electrical system
and to the EMIC through the use of a combination of
soldered splices, splice block connectors, and many
different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
The EMIC modules for this model are serviced only
as complete units. The EMIC module cannot be
adjusted or repaired. If a gauge, an LED indicator,
the VFD, the electronic circuit board, the circuit
board hardware, the cluster overlay, the electro-lumi-
nescent lamp (premium model only) or the EMIC
housing are damaged or faulty, the entire EMIC mod-
ule must be replaced. The cluster lens, hood and
mask unit and the individual incandescent lamp
bulbs with holders are available for service replace-
ment.
WJINSTRUMENT CLUSTER 8J - 3
INSTRUMENT CLUSTER (Continued)

OPERATION
The ElectroMechanical Instrument Cluster (EMIC)
is designed to allow the vehicle operator to monitor
the conditions of many of the vehicle components and
operating systems. The gauges and indicators in the
EMIC provide valuable information about the various
standard and optional powertrains, fuel and emis-
sions systems, cooling systems, lighting systems,
safety systems and many other convenience items.
The EMIC is installed in the instrument panel so
that all of these monitors can be easily viewed by the
vehicle operator when driving, while still allowing
relative ease of access for service. The microproces-
sor-based EMIC hardware and software uses various
inputs to control the gauges and indicators visible on
the face of the cluster. Some of these inputs are hard
wired, but most are in the form of electronic mes-
sages that are transmitted by other electronic mod-ules over the Programmable Communications
Interface (PCI) data bus network. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/COMMUNICATION - OPERATION).
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 low or high bat-
tery voltage, low oil pressure or high coolant temper-
ature, the algorithm can drive the gauge pointer to
an extreme position and the microprocessor turns on
the Check Gauges indicator to provide a distinct
visual indication of a problem to the vehicle operator.
The instrument cluster circuitry also sends electronic
chime tone request messages over the PCI data bus
to the Body Control Module (BCM) when it monitors
Fig. 2 EMIC Gauges & Indicators
1 - BRAKE INDICATOR 15 - TRANSMISSION OVERTEMP INDICATOR
2 - REAR FOG LAMP INDICATOR 16 - PART TIME 4WD INDICATOR
3 - WATER-IN-FUEL INDICATOR 17 - CHECK GAUGES INDICATOR
4 - VOLTAGE GAUGE 18 - ENGINE TEMPERATURE GAUGE
5 - LEFT TURN INDICATOR 19 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
6 - TACHOMETER 20 - ODOMETER/TRIP ODOMETER DISPLAY
7 - HIGH BEAM INDICATOR 21 - WAIT-TO-START INDICATOR
8 - AIRBAG INDICATOR 22 - OVERDRIVE-OFF INDICATOR
9 - SPEEDOMETER 23 - SEATBELT INDICATOR
10 - RIGHT TURN INDICATOR 24 - ABS INDICATOR
11 - OIL PRESSURE GAUGE 25 - FUEL GAUGE
12 - SKIS INDICATOR 26 - FRONT FOG LAMP INDICATOR
13 - MALFUNCTION INDICATOR LAMP (MIL) 27 - LOW FUEL INDICATOR
14 - CRUISE INDICATOR 28 - COOLANT LOW INDICATOR
8J - 4 INSTRUMENT CLUSTERWJ
INSTRUMENT CLUSTER (Continued)

The VFD is diagnosed using the EMIC self-diag-
nostic actuator test. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - DIAGNOSIS AND
TESTING). Proper testing of the PCI data bus and
the data bus message inputs to the EMIC that con-
trol the VFD functions requires the use of a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation. Specific operation details for the odometer
and trip odometer 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 circuit
board. The turn signal indicators are hard wired. The
brake indicator is controlled by PCI data bus mes-
sages from the Controller Antilock Brake (CAB) as
well as by hard wired park brake switch and brake
fluid level switch inputs to the EMIC. The Malfunc-
tion Indicator Lamp (MIL) is normally controlled by
PCI data bus messages from the Powertrain Control
Module (PCM); however, if the EMIC loses PCI data
bus communication, the EMIC circuitry will automat-
ically turn the MIL on until PCI data bus communi-
cation is restored. The EMIC uses PCI data bus
messages from the Airbag Control Module (ACM), the
BCM, the PCM, the CAB, the Sentry Key Immobi-
lizer Module (SKIM), and the Transmission Control
Module (TCM) to control all of the remaining indica-
tors.
The various indicators are controlled by different
strategies; some receive fused ignition switch output
from the EMIC circuitry and have a switched ground,
others are grounded through the EMIC circuitry and
have a switched battery feed, while still others are
completely controlled by the EMIC microprocessor
based upon various hard wired and electronic mes-
sage inputs. Some indicators are illuminated at a
fixed intensity, while the illumination intensity of
others is synchronized with that of the EMIC general
illumination lamps.
The hard wired indicators are diagnosed using con-
ventional diagnostic methods. The EMIC and PCI
bus message controlled indicators 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 each indicator
require the use of a DRBIIItscan tool. Refer to the
appropriate diagnostic information. Specific details of
the operation for each indicator may be found else-
where in this service information.CLUSTER ILLUMINATION
Two types of general cluster illumination are avail-
able in this model. Base versions of the EMIC have
several incandescent illumination lamps, while pre-
mium versions of the EMIC have a single electro-lu-
minescent lamp. Both types of lamps provide cluster
back lighting whenever the exterior lighting is
turned On with the control knob on the left (lighting)
multi-function switch control stalk. The illumination
intensity of these lamps is adjusted by the EMIC
microprocessor based upon electronic dimming level
messages received from the Body Control Module
(BCM) over the PCI data bus. The BCM provides
electronic dimming level messages to the EMIC
based upon internal programming and inputs it
receives when the control ring on the left (lighting)
multi-function switch control stalk is rotated (down
to dim, up to brighten) to one of six available minor
detent positions.
The incandescent illumination lamps receive bat-
tery current at all times, while the ground for these
lamps is controlled by a 12-volt Pulse Width Modu-
lated (PWM) output of the EMIC electronic circuitry.
The illumination intensity of these bulbs and of the
vacuum-fluorescent electronic display are controlled
by the instrument cluster microprocessor based upon
dimming level messages received from the Body Con-
trol Module (BCM) over the PCI data bus. The BCM
uses inputs from the headlamp and panel dimmer
switches within the left (lighting) multi-function
switch control stalk and internal programming to
decide what dimming level message is required. The
BCM then sends the proper dimming level messages
to the EMIC over the PCI data bus.
The electro-luminescent lamp unit consists of lay-
ers of phosphor, carbon, idium tin oxide, and dielec-
tric applied by a silk-screen process between two
polyester membranes and includes a short pigtail
wire and connector. The lamp pigtail wire is con-
nected to a small connector receptacle on the EMIC
circuit board through a small clearance hole in the
cluster housing rear cover. The EMIC electronic cir-
cuitry also uses a PWM strategy to control the illu-
mination intensity of this lamp; however, the EMIC
powers this lamp with an Alternating Current (AC)
rated at 80 volts rms (root mean squared) and 415
Hertz, which excites the phosphor particles causing
them to luminesce.
The BCM also has several hard wired panel lamp
driver outputs and sends the proper panel lamps
dimming level messages over the PCI data bus to
coordinate the illumination intensity of all of the
instrument panel lighting and the VFDs of other
electronic modules on the PCI data bus. Vehicles
equipped with the Auto Headlamps option have an
automatic parade mode. In this mode, the BCM uses
8J - 6 INSTRUMENT CLUSTERWJ
INSTRUMENT CLUSTER (Continued)

tor will be turned on for the duration of the test to
confirm the functionality of the bulb and the cluster
control circuitry.
²ABS Diagnostic Test- The ABS indicator is
blinked on and off based upon 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
ABS indicator lamp-on or lamp-off messages to the
instrument cluster. If the ABS indicator fails to light
during the bulb test, replace the bulb with a known
good unit. If the CAB sends an ABS indicator
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 indi-
cator fails to illuminate due to an open or short in
the cluster ABS indicator circuit or bulb, 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 anti-lock
brake system, the CAB, the PCI data bus, or the
electronic message inputs to the instrument cluster
that control the ABS indicator, a DRBIIItscan tool is
required. Refer to the appropriate diagnostic infor-
mation.
AIRBAG INDICATOR
DESCRIPTION
An airbag indicator is standard equipment on all
instrument clusters. However, the instrument cluster
is programmed to automatically enable this indicator
only on vehicles equipped with the airbag system,
which is not available in some markets. The airbag
indicator is located on the upper edge of the instru-
ment cluster, between the speedometer and the
tachometer. The airbag indicator consists of the
words ªAIR BAGº imprinted on a red lens. The lens
is located behind a cutout 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. The ªAIR BAGº
text appears silhouetted against a red field through
the translucent outer layer of the overlay when the
indicator is illuminated from behind by a Light Emit-
ting Diode (LED), which is soldered onto the instru-
ment cluster electronic circuit board. The airbag
indicator lens is serviced as a unit with the instru-
ment cluster lens, hood and mask unit.
OPERATION
The airbag indicator gives an indication to the
vehicle operator when the airbag system is faulty or
inoperative. The airbag indicator is controlled by a
transistor on the instrument cluster circuit board
based upon cluster programming and electronic mes-
sages received by the cluster from the Airbag Control
Module (ACM) over the Programmable Communica-
tions Interface (PCI) data bus. The airbag indicator
Light Emitting Diode (LED) is completely controlled
by the instrument 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) cir-
cuit. Therefore, the indicator will always be off when
the ignition switch is in any position except On or
Start. The LED only illuminates when it is switched
to ground by the instrument cluster transistor. The
instrument cluster will turn on the airbag indicator
for the following reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the ACM sends an elec-
tronic airbag indicator lamp-on message to the clus-
ter which will illuminate the airbag indicator for
about six seconds as a bulb test. The entire six sec-
ond bulb test is a function of the ACM.
²Airbag Indicator Lamp-On Message- Each
time the cluster receives an airbag indicator lamp-on
message from the ACM, the airbag indicator will be
illuminated. The indicator remains illuminated for
about twelve seconds or until the cluster receives an
airbag indicator lamp-off message from the ACM,
whichever is longer.
²Communication Error- If the cluster receives
no airbag indicator lamp-on or lamp-off messages for
six consecutive seconds, the airbag indicator is illu-
minated. The indicator remains illuminated until the
cluster receives a single valid airbag indicator lamp-
off message from the ACM.
²Actuator Test- Each time the cluster is put
through the actuator test, the airbag 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 airbag indicator is also a
function of the ACM.
The ACM continually monitors the airbag system
circuits and sensors to decide whether the system is
in good operating condition. The ACM then sends the
proper airbag indicator lamp-on or lamp-off messages
to the instrument cluster. If the ACM sends an air-
bag indicator lamp-on message after the bulb test, it
indicates that the ACM has detected a system mal-
function. Such a malfunction could mean that the
airbags may not deploy when required, or may
deploy when not required. The ACM will store a
8J - 14 INSTRUMENT CLUSTERWJ
ABS INDICATOR (Continued)

Diagnostic Trouble Code (DTC) for any malfunction it
detects. Each time the airbag indicator fails to illu-
minate due to an open or short in the cluster airbag
indicator circuit, the cluster sends a message notify-
ing the ACM of the condition, then the instrument
cluster and the ACM will each store a DTC. For
proper diagnosis of the airbag system, the ACM, the
PCI data bus, or the electronic message inputs to the
instrument cluster that control the airbag indicator,
a DRBIIItscan tool is required. Refer to the appro-
priate diagnostic information.
BRAKE/PARK BRAKE
INDICATOR
DESCRIPTION
A brake indicator is standard equipment on all
instrument clusters. The brake indicator is located
near the left edge of the instrument cluster, to the
left of the tachometer. There are two versions of the
brake indicator. The version used depends upon the
market for which the vehicle is manufactured. The
version of the brake indicator used for vehicles man-
ufactured for the United States consists of the word
ªBRAKEº imprinted on a red lens. The Rest-Of-World
(ROW) market version of this indicator has two
International Control and Display Symbol icons
imprinted on the red lens; one is the icon for ªBrake
Failureº, and the other is the icon for ªParking
Brakeº. In either case, the lens is located behind a
cutout 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. The ªBRAKEº text or the two icons
appear silhouetted against a red field through the
translucent outer layer of the overlay when the indi-
cator is illuminated from behind by a Light Emitting
Diode (LED), which is soldered onto the instrument
cluster electronic circuit board. The brake indicator
lens is serviced as a unit with the instrument cluster
lens, hood and mask unit.
OPERATION
The brake indicator gives an indication to the vehi-
cle operator when the parking brake is applied, when
the fluid level of the brake hydraulic system is low,
or if there are certain malfunctions of the Anti-lock
Brake System (ABS). This indicator is controlled by a
transistor on the instrument cluster electronic circuit
board based upon cluster programming, electronic
messages received by the cluster from the Controller
Anti-lock Brake (CAB) over the Programmable Com-
munications Interface (PCI) data bus, and a hard
wired input to the cluster from the park brake
switch. The brake indicator Light Emitting Diode(LED) is completely controlled by the instrument
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 indi-
cator will always be off when the ignition switch is in
any position except On or Start. The LED only illu-
minates when it is provided a path to ground by the
instrument cluster transistor. The instrument cluster
will turn on the brake indicator for the following rea-
sons:
²Bulb Test- Each time the ignition switch is
turned to the On position the brake indicator is illu-
minated by the instrument cluster for about three
seconds as a bulb test.
²Brake Indicator Lamp-On Message- Each
time the cluster receives a brake indicator lamp-on
message from the CAB, the brake indicator will be
illuminated. The indicator remains illuminated until
the cluster receives a brake indicator lamp-off mes-
sage from the CAB.
²Park Brake Switch Input- Each time the
cluster logic circuit detects ground on the park brake
switch sense circuit (park brake switch closed = park
brake applied or not fully released) the brake indica-
tor is illuminated. The indicator remains illuminated
until the park brake switch sense input to the cluster
is an open circuit (park brake switch open = park
brake fully released), or until the ignition switch is
turned to the Off position, whichever occurs first.
²Communication Error- If the cluster receives
no brake indicator lamp-on or lamp-off messages
from the CAB for six consecutive seconds, the brake
indicator is illuminated. The indicator remains illu-
minated until the cluster receives a single valid
brake indicator lamp-off message from the CAB.
²Actuator Test- Each time the cluster is put
through the actuator test, the brake indicator will be
turned on for the duration of the test to confirm the
functionality of the LED and the cluster control cir-
cuitry.
The park brake switch on the park brake pedal
mechanism provides a hard wired ground input to
the instrument cluster circuitry through the red
brake warning indicator driver circuit whenever the
park brake is applied or not fully released. The CAB
continually monitors the input from the brake fluid
level switch and the circuits of the anti-lock brake
system, then sends the proper brake indicator
lamp-on or lamp-off messages to the instrument clus-
ter. If the CAB sends a brake indicator lamp-on mes-
sage after the bulb test, it indicates that the CAB
has detected a brake hydraulic 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.
WJINSTRUMENT CLUSTER 8J - 15
AIRBAG INDICATOR (Continued)

For further diagnosis of the brake indicator or the
instrument cluster circuitry that controls the indica-
tor, (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND TESTING). The park
brake switch input to the instrument cluster can be
diagnosed using conventional diagnostic tools and
methods. For proper diagnosis of the brake fluid level
switch input to the CAB, the anti-lock brake system,
the CAB, the PCI data bus, or the electronic message
inputs to the instrument cluster that control the
brake indicator, a DRBIIItscan tool is required.
Refer to the appropriate diagnostic information.
DIAGNOSIS AND TESTING - BRAKE INDICATOR
The diagnosis found here addresses an inoperative
park brake indicator condition. If there are problems
with several indicators in the instrument cluster,
(Refer to 8 - ELECTRICAL/INSTRUMENT CLUS-
TER - DIAGNOSIS AND TESTING). If the brake
indicator stays on with the ignition switch in the On
position and the park brake released, or comes on
while driving, (Refer to 5 - BRAKES - DIAGNOSIS
AND TESTING). If no brake system problem is
found, the following procedures will help to locate a
shorted or open circuit, or a faulty park brake switch
input. Refer to the appropriate wiring information.
The wiring information includes wiring diagrams,
proper wire and connector repair procedures, details
of wire harness routing and retention, connector pin-
out information and location views for the various
wire harness connectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
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.
INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES
NOT WHEN PARK BRAKE APPLIED
(1) Disconnect and isolate the battery negative
cable. Disconnect the instrument panel wire harness
connector for the park brake switch from the switch
terminal. Apply the parking brake. Check for conti-nuity between the park brake switch terminal and a
good ground. There should be continuity. If OK, go to
Step 2. If not OK, replace the faulty park brake
switch.
(2) Disconnect the instrument panel wire harness
connector for the instrument cluster from the cluster
connector receptacle. Check for continuity between
the red brake warning indicator driver circuit cavi-
ties of the instrument panel wire harness connector
for the park brake switch and the instrument panel
wire harness connector for the instrument cluster.
There should be continuity. If not OK, repair the
open red brake warning indicator driver circuit
between the park brake switch and the instrument
cluster as required.
INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM
CHECKS OK
(1) Disconnect and isolate the battery negative
cable. Disconnect the instrument panel wire harness
connector for the park brake switch from the park
brake switch terminal. Check for continuity between
the terminal of the park brake switch and a good
ground. There should be no continuity with the park
brake released, and continuity with the park brake
applied. If OK, go to Step 2. If not OK, replace the
faulty park brake switch.
(2) Disconnect the instrument panel wire harness
connector for the instrument cluster from the cluster
connector receptacle. Check for continuity between
the red brake warning indicator driver circuit cavity
of the instrument panel wire harness connector for
the park brake switch and a good ground. There
should be no continuity. If not OK, repair the shorted
red brake warning indicator driver circuit between
the park brake switch and the instrument cluster as
required.
CHECK GAUGES INDICATOR
DESCRIPTION
A check gauges indicator is standard equipment on
all instrument clusters. The check gauges indicator is
located on the right edge of the instrument cluster, to
the right of the speedometer. The check gauges indi-
cator consists of the words ªCHECK GAGESº
imprinted on a red lens. The lens is located behind a
cutout 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. The ªCHECK GAGESº text appears sil-
houetted against a red field through the translucent
outer layer of the overlay when the indicator is illu-
minated from behind by a Light Emitting Diode
(LED), which is soldered onto the instrument cluster
electronic circuit board. The check gauges indicator
8J - 16 INSTRUMENT CLUSTERWJ
BRAKE/PARK BRAKE INDICATOR (Continued)

OPERATION
The speedometer gives an indication to the vehicle
operator of the vehicle road speed. This gauge is con-
trolled by the instrument cluster electronic circuit
board based upon cluster programming and elec-
tronic messages received by the cluster from the
Powertrain Control Module (PCM) over the Program-
mable Communications Interface (PCI) data bus. The
speedometer is an air core magnetic unit that
receives battery current on the instrument cluster
electronic circuit board through the fused ignition
switch output (run-start) circuit whenever the igni-
tion switch is in the On or Start positions. The clus-
ter is programmed to move the gauge needle back to
the low end of the scale after the ignition switch is
turned to the Off position. The instrument cluster
circuitry controls the gauge needle position and pro-
vides the following features:
²Vehicle Speed Message- Each time the clus-
ter receives a vehicle speed message from the PCM it
will calculate the correct vehicle speed reading and
position the gauge needle at that speed position on
the gauge scale. The cluster will receive a new vehi-
cle speed message and reposition the gauge pointer
accordingly about every 86 milliseconds. The gauge
needle will continue to be positioned at the actual
vehicle speed position on the gauge scale until the
ignition switch is turned to the Off position.
²Communication Error- If the cluster fails to
receive a speedometer message, it will hold the gauge
needle at the last indication for about six seconds, or
until the ignition switch is turned to the Off position,
whichever occurs first. If a new speed message is not
received after about six seconds, the gauge needle
will return to the far left (low) end of the scale.
²Actuator Test- Each time the cluster is put
through the actuator test, the gauge needle will be
swept across the entire gauge scale and back in order
to confirm the functionality of the gauge and the
cluster control circuitry.
The PCM continually monitors the vehicle speed
information received from the Controller Anti-lock
Brake (CAB) to determine the vehicle road speed,
then sends the proper vehicle speed messages to the
instrument cluster. For further diagnosis of the
speedometer or the instrument cluster circuitry that
controls the gauge, (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - DIAGNOSIS AND TEST-
ING). For proper diagnosis of the CAB, the PCM, the
PCI data bus, or the electronic message inputs to the
instrument cluster that control the speedometer, a
DRBIIItscan tool is required. Refer to the appropri-
ate diagnostic information.
TACHOMETER
DESCRIPTION
A tachometer is standard equipment on all instru-
ment clusters. The tachometer is located to the left of
the speedometer in the instrument cluster. The
tachometer consists of a movable gauge needle or
pointer controlled by the instrument cluster circuitry,
and a fixed 255 degree scale on the gauge dial face
that reads left-to-right from 0 to 7 for gasoline
engines, or from 0 to 6 for diesel engines. The text ªX
1000º (base cluster) or ªRPM X 1000º (premium clus-
ter) imprinted on the cluster overlay directly below
the hub of the tachometer needle identifies that each
number on the tachometer scale is to be multiplied
by 1000 rpm. The gasoline engine tachometer has a
red zone beginning at 5800 RPM, while the red zone
for the diesel engine tachometer begins at 4200 RPM.
The tachometer in the premium version cluster for
certain engine and market applications also includes
red text located in the center of the gauge dial face
just above the hub of the tachometer needle that
specifies a special fuel requirement.
The tachometer graphics are either white, gray
and orange against a black gauge dial face (base
cluster) or black, gray and red against a taupe gauge
dial face (premium cluster), making them clearly vis-
ible within the instrument cluster in daylight. When
illuminated from behind by the panel lamps dimmer
controlled cluster illumination lighting with the exte-
rior lamps turned On, the base cluster white gauge
graphics appear blue-green and the orange graphics
still appear orange, while the premium cluster taupe
gauge dial face appears blue-green with the black
graphics silhouetted against the illuminated back-
ground and the red graphics still appear red. The
gray gauge graphics for both versions of the cluster
are not illuminated. The orange gauge needle in the
base cluster gauge is internally illuminated, while
the black gauge needle in the premium cluster gauge
is not.
Base cluster gauge illumination is provided by
replaceable incandescent bulb and bulb holder units
located on the instrument cluster electronic circuit
board. Premium cluster gauge illumination is pro-
vided by an integral electro-luminescent lamp that is
serviced as a unit with the instrument cluster. The
tachometer is serviced as a unit with the instrument
cluster.
OPERATION
The tachometer gives an indication to the vehicle
operator of the engine speed. This gauge is controlled
by the instrument cluster electronic circuit board
based upon cluster programming and electronic mes-
sages received by the cluster from the Powertrain
WJINSTRUMENT CLUSTER 8J - 31
SPEEDOMETER (Continued)