2003 FORD MUSTANG instrument cluster

z
Is the voltage greater than 10 volts? No
REPAIR the circuit. TEST
the system for normal
operation.
V3 CHECK RUN/START POWER SUPPLY TO THE
INSTRUMENT CLUSTER z
Key in OFF position.
z Disconnect: Instrument Cluster C220b.
z Key in ON position.
z Measure the voltage between the instrument cluster C220b
pin 12, circuit 20 (WH/LB), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
V4 .
No
REPAIR the circuit. TEST
the system for normal
operation. V4 CHECK GROUND CIRCUIT 397 (BK/WH) FOR AN OPEN
z
Key in OFF position.
z Measure the resistance between the instrument cluster
C220b pin 20, circuit 397 (BK/WH), harness side and
ground.
z Is the resistance less than 5 ohms? Yes
GO to
V5 .
No
REPAIR the circuit. TEST
the system for normal
operation. V5 CHECK GROUND CIRCUIT 1205 (BK) FOR OPEN
z
Measure the resistance between the instrument cluster
C220b pin 1, circuit 1205 (BK), harness side and ground. Yes
GO to
V6 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 39 ba
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PINPOINT TEST W: NO COMMUNICATION WITH THE GENERIC
ELECTRONIC MODULE (GEM) z
Is the resistance less than 5 ohms? V6 CHECK FOR CORRECT INSTRUMENT CLUSTER
OPERATION z
Disconnect all instrument cluster connectors.
z Check for:
zcorrosion
z pushed- out pins
z Connect all instrument cluster connectors and make sure
they seat correctly.
z Operate the system and verify the concern is still present.
z Is the concern still present? Yes
INSTALL a new instrument
cluster. REFER to
Instrument Cluster
in this
section. TEST the system
for normal operation.
No
The system is operating
correctly at this time.
Concern may have been
caused by a loose or
corroded connector. CLEAR
the DTCs. REPEAT the self-
test. Test Step Result / Action to Take
CAUTION: Use the correct probe adapter(s) when making measurements. Failure to
use the correct probe adapter(s) may damage the connector. W1 CHECK THE GENERIC ELECTRONIC MODULE (GEM)
POWER SUPPLY z
Key in OFF position.
z Disconnect: Generic Electronic Module (GEM) C201a.
z Disconnect: GEM C201b.
z Key in ON position.
z Using the following table, measure the voltage between the
GEM, harness side and ground.
z Are the voltages greater than 10 volts? Connector Pin Circuit
C201a 4 400 (LB/BKK)
C201a 1 1006 (DG/WH)
C201b 2 1001 (WH/YE)
C201b 3 193 (YE/LG) Yes
GO to
W2 .
No
REPAIR the circuit(s) in
question. TEST the system
for normal operation. W2 CHECK THE GEM GROUND CIRCUIT 397 (BK/WH) FOR Klj . 40 ba
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REMOVAL AND INSTALLATION
Instrument Cluster
Removal and Installation
All vehicles
1. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to
these charges, damage may result.
Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the headlamp switch knob. zPull out the headlamp switch knob and insert a thin tool in the slot to release the knob
from the shaft.
3. Remove the screws and remove the instrument cluster finish panel. 4. Remove the screws and pull the instrument cluster forward to expose the electrical connector. SECTION 413-
01: Instrument Cluster 2003 Mustang Workshop Manual Klj . 1 ba
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Cobra only
5. Disconnect the electrical connectors and boost pressure line and remove the instrument cluster.
Except Cobra 6. Disconnect the electrical connectors and remove the instrument cluster.
All vehicles 7. To install, reverse the removal procedure. Klj . 2 ba
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REMOVAL AND INSTALLATION
Warning Indicator Bulb
Removal and Installation
1. Remove the instrument cluster. Refer to Instrument Cluster in this section.
2. Remove the necessary instrument cluster bulbs by rotating one quarter turn counterclockwise.
3. To install, reverse the removal procedure.
SECTION 413-
01: Instrument Cluster 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Instrument Cluster Lens
Removal and Installation
1. Remove the instrument cluster. Refer to Instrument Cluster in this section.
2. Remove the screws and remove the instrument cluster lens.
3. To install, reverse the removal procedure.
SECTION 413-
01: Instrument Cluster 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Gauges And Warning Devices
Refer to Wiring Diagrams Cell
59 , Generic Electronic Module for schematic and connector
information.
Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information.
Refer to Wiring Diagrams Cell 66 , Warning Chime for schematic and connector information.
Principles of Operation
Key- In-Ignition Warning Chime
The key- in-ignition warning chime activates when the generic electronic module (GEM) detects the
ignition switch circuits are in the OFF or ACC states and when the GEM detects the driver door is ajar
from the driver door ajar circuits. Refer to the Chime Duration Table in this section for audible output,
duration time, and priority ratings.
Airbag Warning Chime
The airbag warning chime activates when the GEM detects the ignition switch circuits are in the RUN
state and when the GEM detects a chime is requested from the airbag system circuit. Refer to the
Chime Duration Table for audible output, duration time, and priority ratings.
Door Ajar Warning Chime
The door ajar warning chime activates when the GEM detects the ignition switch circuits are in the
RUN state and when the GEM detects the driver or passenger door is ajar from the driver and
passenger door ajar circuits. Refer to the Chime Duration Table in this section for audible output,
duration time, and priority ratings.
Headlamps Left on Warning Chime
The headlamps left on warning chime activates when the GEM detects the ignition switch circuits are
in the KEYOUT state, when the GEM detects the driver door is ajar from the driver door ajar circuit, SECTION 413-
09: Warning Devices 2003 Mustang Workshop Manual Special Tool(s)
73III Automotive Meter
105-
R0057 or equivalent Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F048, or equivalent
diagnostic tool Klj . 1 ba
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and when the GEM detects the headlamps or parklamps are on from the exterior lamp circuits. Refer
to the Chime Duration Table in this section for audible output, duration time, and priority ratings.
Safety Belt Warning Chime
The safety belt warning chime and safety belt warning lamp activate when the GEM detects the
ignition switch circuits are in the RUN or START state and when the GEM detects the safety belt is
unbuckled from the safety belt circuit. The safety belt warning lamp indicator will prove out for three
seconds whenever the GEM detects that the ignition circuits make a transition to RUN from OFF, ACC,
or KEYOUT state. Refer to the Chime Duration Table in this section for audible output, duration time,
and priority ratings.
Belt Minder
NOTE:
Belt minder is a configurable item. If configuring using a diagnostic tool, refer to Section 418 -
01 . To configure without using a diagnostic tool, refer to
Belt Minder Deactivating/Activating in this
section.
The belt minder feature supplements the current safety belt warning function. The belt minder feature
is enabled after the current safety belt warning is complete. If the driver safety belt is not buckled
approximately five seconds after the safety belt warning light has turned off, the belt minder reminds
the driver that their safety belt is unbuckled by intermittently sound a chime and illuminating the safety
belt warning lamp in the instrument cluster. While activated, the belt minder alternates the chime and
indicator from on for six seconds to off for 30 seconds.
The belt minder reminder stops when:
zthe drive seat belt is buckled.
z the ignition is turned to OFF or ACC.
z five minutes have elapsed since belt minder has started.
Inspection and Verification
NOTE: Upon installation of a new GEM, the module must be reconfigured. For additional information,
refer to Section 418 - 01 .
1. The warning lamps are a GEM controlled system; refer to Section 419 - 10 .
2. Verify the customer concern by operating the system in question.
3. Visually inspect for the following obvious signs of mechanical and electrical damage.
Chime Duration Table Feature Audible Output Duration Priority
Safety belt Chime, 60/minute 740 Hz 6.0 seconds 1
Key-
in-ignition Chime, 120/minute 740 Hz Continuous 2
Headlamps left on Chime, 240/minute 740 Hz Continuous 3
Airbag Single tone, 1,000 Hz Continuous 4
Door ajar Single tone, 1,000 Hz 1.0 second 7 Klj . 2 ba
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