1.6 instrument cluster (ic) contentsmanual.startekinfo.com/volumes/ic1/1_6/content.pdf · oil level...

1.6 Instrument Cluster (IC) Contents ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––1.6 Model 202 up to 08/95

PageDiagnosisFunction Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/1Complaint Related Diagnostic Chart . . . . . . . . . . . . . . . . . . . 12/1

Electrical Test Program Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/1Preparation for Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/1Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/1

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b Diagnostic Manual • Information/Communication • 09/95 1.6 IC C/1

1.6 Instrument Cluster (IC) Model 202 up to 08/95 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Diagnosis – Function Test

General Information

Malfunction indicator/warning lamps

The instrument cluster is fully equipped with all lamps regardless ofactual vehicle equipment.

Bulb test

• Turn the ignition key to position “2”. All malfunction indicator/warninglamps must illuminate.

After 4 seconds, the SRS MIL will extinguish.After 30 seconds all other indicator/warning lamps will extinguish, withthe exception of the following: ABS, ASD or ASR, and generatorcharging lamps.

Start engine. At > 480 engine RPM, all indicator/warning lamps are toextinguish, indicating that all systems monitored are O.K.The indicator instruments must reflect the actual operating conditions.

a CAUTION!

Should the malfunction indicator/warning lamps remain illuminated and/orcome on while driving, it will be necessary to check the correspondingsystem with the Diagnostic Manual and/or the monitored fluid level asnecessary.

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b Diagnostic Manual • Information/Communication • 09/95 1.6 IC 11/1

1.6 Instrument Cluster (IC) Model 202 up to 08/95

Diagnosis – Complaint Related Diagnostic Chart

Complaint/Problem Possible cause Test step/Remedy 1)

Entire instrument cluster (A1) not functioning. Power supply,Instrument cluster (A1).

23 O 1.0

Indicator lamps for ABS, ASR, brake pad wear, brake fluid,parking brake, ASD/ASR and generator charge are notfunctioning.

Power supply,Instrument cluster (A1).

23 O 1.0

Illumination for odometer, clock and outside temperaturedisplay LCD not operating.

Bulbs,Exterior lamp switch (S1),Instrument cluster (A1).

23 O 1.0, 2.0

Instrument cluster illumination not operating. Bulbs,Exterior lamp switch (S1),Instrument cluster (A1).

23 O 2.0

Fuel level gauge (A1p2) inaccurate or not operating. Instrument cluster (A1),Fuel level sensor(s) (B4/1 or B4/2).

23 O 3.0

Tachometer (A1p5) inaccurate or not operating. Instrument cluster (A1),TN-signal.

23 O 4.0

Low engine oil level indicator lamp (A1e12) illuminated withproper engine oil level status.

Instrument cluster (A1),Oil level switch (S43).

23 O 5.0

Electronic speedometer (A1p8) false reading. Instrument cluster (A1),Vehicle speed signal (VSS).

23 O 6.0

Outside temperature display (A1p4) false reading or notoperating.

Outside temperature indicator temperature sensor (B14), Instrument cluster (A1).

23 O 7.0

1) Observe Preparation for Test, see 22.

b Diagnostic Manual • Information/Communication • Supplement 2 • 09/95 1.6 IC 12/1




ECT gauge (A1p1) inaccurate or not operating. ECT gauge sensor (B13),Instrument cluster (A1).

23 O 8.0

Low ECL indicator lamp (A1e11) illuminated or notfunctioning.

ECL switch (S41),Instrument cluster (A1).

23 O 9.0

Low windshield washer fluid level indicator lamp (A1e13) illuminated or not functioning.

Windshield washer fluid level switch (S42),Instrument cluster (A1).

23 O 10.0

Brake pad wear indicator lamp (A1e6) illuminated or notfunctioning.

Brake pads,Left/right front brake pad wear sensor (S10/1 or S10/2),Instrument cluster (A1).

23 O 11.0

Low brake fluid level/parking brake indicator lamp (A1e7)illuminated or not functioning.

Brake fluid level switch (S11),Parking brake switch (S12),Instrument cluster (A1).

23 O 12.0

Generator charge indicator lamp (A1e5) illuminated or notfunctioning.

Generator (G2),Instrument cluster (A1).

23 O 13.0

SRS MIL (A1e15) not functioning. SRS control module (N2/2),Instrument cluster (A1).

23 O 14.0

ABS MIL (A1e17) not functioning. ABS control module (N30),Instrument cluster (A1).

23 O 15.0

ASD MIL (A1e24) not functioning. ASD control module (N30/2),Instrument cluster (A1).

23 O 16.0

ASR MIL (A1e22) not functioning. ASR control module (N30/1),Instrument cluster (A1).

23 O 17.0






ASD warning lamp (A1e25) not functioning. ASD control module (N30/2),Instrument cluster (A1).

23 O 18.0

ASR warning lamp (A1e21) not functioning. ASR control module (N30/1),Instrument cluster (A1).

23 O 19.0

“CHECK ENGINE” MIL (A1e26) illuminated or not functioning. Diagnostic module (OBD S) (N59/1),Instrument cluster (A1).

23 O 20.0



1.6 Instrument Cluster (IC) Model 202 up to 08/95 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Electrical Test Program – Component Locations

P54-6555-57

Figure 1

A1 Instrument clusterB14 Outside temperature indicator temperature sensorS43 Oil level sensor

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1.6 Instrument Cluster (IC) Model 202 up to 08/95 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Electrical Test Program – Component Locations

P54-6095-57

Figure 2

S11 Brake fluid level switchS41 ECL switchX26/25 Engine/chassis connector (24-pole)

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P54-6096-57

Figure 3

S10/1x1 Left front brake pad wear sensor connectorS10/2x1 Right front brake pad wear sensor connectorS12 Parking brake switch

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P54-6097-57

Figure 4

N3/4 Engine control module (HFM-SFI)N30 ABS control moduleN30/1 ABS/ASR control moduleW16/6 Ground (component compartment - right)X11/4 Data link connector (DTC readout)

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P54-6125-57

Figure 5

B4/1 Left fuel level sensorB4/2 Right fuel level sensor

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P54-6554-57

Figure 6

N30/2 ASD control moduleN59/1 Diagnostic module (OBD S)S42 Windshield washer fluid level switchW3 Ground (left front wheelhousing)

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1.6 Instrument Cluster (IC) Model 202 up to 08/95 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Electrical Test Program – Preparation for Test

Preparation for Test:1. Battery voltage 11 – 14 V.2. Check fuses.3. Systems and fluid levels are o.k.

Note:In order to avoid damage to the control modules listed in 23, pleaseensure that the ignition is OFF, prior to connecting or disconnecting anyelectrical leads.

Electrical Wiring Diagrams:See Electrical Troubleshooting Manual, Model 202, Vol. 1, group 54

Special Tools

Electrical connecting set

201 589 00 99 00

Ohm decade

124 589 09 63 00

Extraction hook

140 589 02 33 00

Adapter

140 589 14 63 00

Conventional tools, test equipment

Description Brand, model, etc.

Multimeter 1) Fluke models 23, 83, 85, 87

Signal generator 1) SUN DTR-8416

1) Available through the MBUSA Standard Equipment Program.

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Electrical Test Program – Test

O Test scope Test connection Test condition Nominal value Possible cause/Remedy

1.0 Instrument cluster (A1)Voltage supplyCircuit 30

19 L(1.19)

A1c L 17

(1.17)

Remove A1.Disconnect connector 1,(Figure 1 and 4).

11 – 14 VWiring,O 1.1

1.1 Voltage supplyCircuit 15, unfused

19 L(1.19)

A1c L 1

(1.1)

Remove A1.Disconnect connector 1.Ignition: ON 11 – 14 V

Wiring,O 1.2

1.2 Voltage supplyCircuit 15

19 L(1.19)

A1c L 18

(1.18)

Remove A1.Disconnect connector 1.Ignition: ON 11 – 14 V

Wiring,A1

2.0 Instrument cluster (A1)IlluminationLCD display illumination 19 L

(1.19)

A1c L 24

(1.24)

Remove A1.Disconnect connector 1(Figure 1 and 4).Ignition: ONTurn on parking lights.

11 – 14 V

Wiring.

Values OK:Bulbs,Bulbs for LCD display,Exterior lamp switch (S1),A1





3.0 Fuel level gauge (A1p2)Wiring and contacts 2

2 w

B4/1u

B4/2B

3

L 3

Ignition: OFFDisconnect connector ofleft fuel level sensor (B4/1)( 21, Figure 5).Jumper connect sockets,then remove connector forright fuel level sensor(B4/2) ( 21, Figure 5).Connect resistancesubstitution unit.Ignition: ONResistance substitutionunit setting:

8 +6 ]27 ± 5.3 ]

46.5 ± 10.5 ]96 ± 11.7 ]

145.5 ± 13.2 ]189 – 7.8 ]

Display in A1p2:

y 01)

y Res.1)

y 1/4y 1/2y 3/4y 1/1

Wiring,Instrument cluster (A1),O 3.1

[3.0] Vehicles (as of 03/94) withrecalibrated resistancevalues.

Resistance substitutionunit setting:

6 +6.6 ]24 ± 5.3 ]

51 ± 10.5 ]100.5 ± 11.7 ]145.5 ± 13.2 ]

189 – 7.8 ]

Display in A1p2:

y 01)

y Res.1)

y 1/4y 1/2y 3/4y 1/1

1) Fuel reserve warning lamp illuminates.





3.1 Left fuel level sensor (B4/1).

Right fuel level sensor (B4/2).

2 v

2 v

B4/1b

B4/2b

K 3

K 3

Disconnect connector atB4/1.

Disconnect connector atB4/2.

3 (± 1) ] Empty97.5 (± 3) ] Full

3 (± 1) ] Empty97.5 (± 3) ] Full

B4/1

B4/2

4.0 Tachometer (A1p5)Wiring and contacts W16/6 y

X11/4L 17

Ignition: OFFDisconnect all connectorsfrom N3/4 ( 21, Figure4).

Connect signal generatorand set to a voltageamplitude of approx. 10 V(Figure 6).Ignition: ON

Engine 11130 Hz y1000/rpm130 Hz y4000/rpm200 Hz y6200/rpm

Engine 10450 Hz y1000/rpm195 Hz y4000/rpm315 Hz y6400/rpm

Wiring,Instrument cluster (A1).

Values OK:N3/4,Engine 104: D.M., Engines, Vol. 2– 1.1,Engine 111: D.M., Engines, Vol. 2– 1.2).





5.0 Low engine oil levelindicator lamp (A1e12,Figure 2)Wiring and contacts

W3 uS43

1Oil level is OK.Disconnect connector fromoil level switch (S43).

Engine: at Idle A1e12 does notilluminate.

Wiring,S43,Instrument cluster (A1),O 5.1

5.1 Wiring and contacts Engine: at IdleDisconnect connector fromS43 ( 21, Figure 1).

A1e12illuminates after60± 10seconds.

A1e12,Wiring,A1,O 5.2

5.2W3 b

S43K 1 Connector unplugged at

S43.0 ]

S43.





6.0 Electronic speedometer (A1p8)Wiring and contacts

Vehicles with ASR or ETSas of 06/94:Left front axle VSS sensor(L6/1) connected toASR/SPS or ETS/SPScontrol module (N47-1 orN47-2).See D.M., Chassis andDrivetrain, Vol. 3, 9.2 23

ABSW16/6

ABS/ASRW16/6

ASR/SPSorETS/SPSW16/6

y

y

y

N30L 5

(1.5)

N30/1L 18

(1.18)

N47-1N47-2

L

Ignition: OFFDisconnect connector fromABS control module (N30)or ASR control module(N30/1), ASR/SPS orETS/SPS control module(N47-1, N47-2) ( 21, Figure 4).

Connect signal generatorand set to a voltageamplitude of approx. 10 V(Figure 6).Ignition: ON

With increasingfrequence inputthe vehiclespeed indicatedmust alsoincrease.

Wiring,Instrument cluster (A1).

Values OK:N30 or N30/1,D.M., Chassis and Drivetrain,Vol. 2, 5.3 or 6.3 23

N47-1 or N47-2D.M., Chassis and Drivetrain,Vol. 3 – 9.2 23





7.0 Outside temperatureindicator temperaturesensor (B14)( 21, Figure 1)Wiring and contacts

1 w(2.1)

A1b L 2

(2.2)

Remove A1.Disconnect connector 2(Figure 4).Measure ambient airtemperature at B14,( 21, Figure 1).

° F at B14– 4 ° F

+ 32 ° F+ 68 ° F

+ 104 ° F

y 29 k ]

y 9.8 k ]

y 3.7 k ]

y 1.6 k ]

Wiring,B14

Values OK: A1

8.0 ECT gauge (A1p1)Wiring and contacts W3 B

X26/25L 2

(B2)

Separate engine/chassisconnector (X26/25)( 21, Figure 2) andconnect in the resistancesubstitution unit.Ignition: ON

130 ]70 ]38 ]22 ]

Display (∞ C) inA1p1:

y 60 °Cy 80 °Cy 100 °Cy 120 °C

Wiring, A1

Values OK:ECT gauge sensor (B13).





9.0 Low ECL indicator lamp (A1e11, Figure 2)Wiring and contacts

Disconnect connector atECL switch (S41) ( 21, Figure 2).Engine: at Idle A1e11 does not

illuminate.

Wiring, A1

Values OK: ECL switch (S41),O 9.1

9.1 Wiring and contacts1

S41u 2

Disconnect connector atS41 Engine: at Idle A1e11

illuminates afterapprox. 5 – 60sec.

A11e1,Wiring,A1

Values OK:S41

10.0 Low windshield washerfluid level indicator lamp(A1e13, Figure 2)Wiring and contacts

Disconnect connector atwindshield washer fluidlevel switch (S42) ( 21, Figure 6).

Engine: at Idle A1e13 doesnot illuminate.

Wiring,A1

Values OK:S42,O 10.1






S42u 2

Disconnect connector atS42.

Engine: at Idle A1e13 illuminates.

A1e13,Wiring,A1

Values OK: S42

11.0 Brake pad wear indicatorlamp (A1e6, Figure 2)Wiring and contacts

Disconnect connector atleft front brake pad wearsensor connector(S10/1x1)( 21, Figure 3).Disconnect connector atright front brake pad wearsensor connector(S10/2x1)( 21, Figure 3).

Engine: at Idle

A1e6 does notilluminate.

Wiring,A1

Values OK: S10/1 or S10/2,O 11.1





11.1 Wiring and contacts

1

1

S10/1x1u

S10/2x1u

2

2

Disconnect connector atS10/1x1.Engine: at Idle

Disconnect connector atS10/2x1.Engine: at Idle

A1e6 illuminates.

A1e6 illuminates.

Brake pad wear indicator lamp (A1e6),Wiring,A1

Values OK:S10/1 or S10/2,Left or right front brake pads.

12.0 Low brake fluid level/parking brake indicator lamp (A1e7, Figure 2)Wiring and contacts

Disconnect connector atbrake fluid level switch(S11, 21, Figure 2) aswell as flat pin connectorat parking brake switch(S12, 21, Figure 3).

Engine: at Idle A1e7 does notilluminate.

Wiring,O 12.1






S11u 2

Disconnect connector atS11.Engine: at Idle Set parking brake.

Connect flat pin connectorat S12 ( 21, Figure 3)Engine: at Idle

A1e7 does notilluminate.

A1e7illuminates.

A1e7,Wiring,A1Values OK: S11,S12

13.0 Generator charge indicatorlamp (A1e5, Figure 3)Wiring and contacts

Disconnect D+ connectorat generator (G2).Ignition: ON A1e5 does not

illuminate.

Wiring,A1,O 13.1

13.1 Wiring and contacts Disconnect D+ connectorat generator (G2), andtouch to ground.Ignition: ON

A1e5illuminates.

A1e5,Wiring,A1Values OK: Generator (G2).





14.0 SRS MIL (A1e15, Figure 3)Wiring and contacts

W16/6 uX11/4

30

Connect socket 30 of 38-pole data link connector(X11/4, Figure 6) to groundin right of componentcompartment (W16/6, 21, Figure 4).Engine: at Idle A1e15

illuminates.

A1e15,Wiring,A1Values OK: D.M., Body andAccessories, Vol. 3 – 16.3

15.0 ABS MIL (A1e17, Figure 3)Wiring and contacts

W16/6 uN30

29(1.29)

Ignition: OFFDisconnect connector atABS control module (N30, 21, Figure 4).Engine: at Idle A1e17

illuminates.

A1e17,Wiring,A1.

Values OK:D.M., Chassis and Drivetrain,Vol. 2 – 6.3

16.0 ASD MIL (A1e24, Figure 3)Wiring and contacts

W16/6 uN30/2

2(1.2)

Ignition: OFFDisconnect ASD controlmodule (N30/2) fromconnector ( 21, Figure 6).Engine: at Idle A1e24

illuminates.

A1e24,Wiring,A1






17.0 ASR MIL (A1e22, Figure 3)Wiring and contacts

W16/6 uN30/1

10(1.10)

Ignition: OFFDisconnect connector fromASR control module(N30/1) ( 21 Figure 4).

Engine: at Idle A1e22illuminates.

A1e22,Wiring,A1


18.0 ASD warning lamp (A1e25)Wiring and contacts

W16/6 uN30/2

4(1.4)

Ignition: OFFDisconnect ASD controlmodule (N30/2) fromconnector ( 21, Figure 6).Engine: at Idle

A1e25illuminates.

A1e25,Wiring,A1


19.0 ASR warning lamp (A1e21)Wiring and contacts

W16/6 uN30/1

12(1.12)

Ignition: OFFDisconnect connector fromASR control module(N30/1) ( 21, Figure 4).Engine: at Idle A1e21

illuminates.

A1e21,Wiring,A1

Values OK: D.M., Chassis and Drivetrain,Vol. 2 – 5.3





20.0 “CHECK ENGINE” MIL(A1e26, Figure 2)Wiring and contacts

Ignition: OFFDisconnect connector fromdiagnostic module (N59/1) ( 21, Figure 6).Engine: at Idle A1e26 does not

illuminate.

Wiring,O 20.1

20.1 Wiring and contacts

2N59/1

u 9

Ignition: OFFDisconnect connector fromN59/1 (Install bridge, Figure 5).Engine: at Idle A1e26

illuminates.

Wiring,A1,Diagnostic module (N59/1).

Values OK: D.M., Engines, Vol. 3 – 8.5




P54-6556-13

Figure 1

A1 Instrument cluster

P54-6506-13

Figure 3Indicator/warning lamps (right)1 Exterior lamp failure indicator lamp2 ASD or ASR MIL3 Generator charge indicator lamp4 SRS MIL5 Safety belt reminder lamp6 ABS MIL

P54-6505-13

Figure 2Indicator/warning lamps (left)1 Low ECL indicator lamp2 High beam indicator lamp3 Low brake fluid level and parking brake indicator lamp4 Brake pad wear indicator lamp5 Low engine oil level indicator lamp6 Low windshield washer fluid level indicator lamp7 “CHECK ENGINE ” MIL




P54-6089-13

Figure 4

A1 Instrument cluster1 Connector (24-pole)2 Connector (21-pole)

P54-6553-13

Figure 5

N59/1 Diagnostic module (OBD S)




P54-6692-57

Figure 6

5a ABS control module connector, socket 517 Data link connector, 38-pole (X11/4), socket 1718 ASR control module connector, socket 1830 Data link connector, 38-pole (X11/4), socket 30


1.6 instrument cluster (ic) contentsmanual.startekinfo.com/volumes/ic1/1_6/content.pdf · oil level...

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