Content .. 495 496 497 498 ..

Chrysler PT Cruiser. Manual - part 497

REMOVAL

REMOVAL - 1.6L

Failure to route the cables properly could cause the

radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.

Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping

the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.

REMOVAL - 2.0/2.4L

Failure to route the cables properly could cause the

radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.

Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping

the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.

INSTALLATION

INSTALLATION - 1.6L

Failure to route the cables properly could cause the

radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube, then connect the
other end to coil pack.

INSTALLATION - 2.0/2.4L

Failure to route the cables properly could cause the

8I - 16

IGNITION CONTROL

SPARK PLUG CABLE (Continued)

INSTRUMENT CLUSTER

TABLE OF CONTENTS

page

INSTRUMENT CLUSTER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 1

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - INSTRUMENT

CLUSTER WARNING/INDICATOR LAMPS . . . . 3

DIAGNOSIS AND TESTING - MULTIPLE/

INDIVIDUAL GAUGES INOPERATIVE . . . . . . . 3

STANDARD PROCEDURE - SELF-

DIAGNOSTICS

. . . . . . . . . . . . . . . . . . . . . . . . . 4

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 5

CLUSTER MASK/LENS

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTRUMENT CLUSTER

DESCRIPTION

The instrument cluster electronically drives the

speedometer, odometer, fuel/temperature gauges, and
tachometer. On the back of the cluster are two self-
docking connectors, a 26-way and a 10-way.

All the indicators are located within the three

gauges:

• Speedometer

• Tachometer

• Fuel/Temperature Gauge
This is a smart cluster and used to control many

Body Control Module (BCM) functions.

The purpose of the instrument cluster gauges and

indicator lamps is to keep the driver informed about
the operating condition of the vehicle. If an abnormal
condition occurs, the driver is informed by indicator
lamp and a chime. The driver can seek service before
damage occurs.

The instrument cluster has warning lamps and

indicators for the following systems:

• Airbag

• Anti-lock Brakes (ABS) if equipped

• Brake Warning

• Charging System

• Electronic Throttle Control (ETC) (1.6L only)

• Engine Temperature

• Front Fog Lamps (if equipped)

• High Beam

• Liftgate Ajar

• Low Fuel

• Low Oil Pressure

• Malfunction Indicator Lamp (MIL) (Service

Engine Soon)

• Rear Fog Lamps (Export)

• Seat Belt Warning

• Security System

• Trac-Off (if equipped)

• Wait To Start (Diesel Export Only)
The instrument cluster has a Vacuum Fluorescent

(VF) display for the following systems:

• Cruise

• Door (ajar)

• Odometer

• Trac (if equipped)

• Trip

• PRNDL (Autostick Only)

CHIME

The functions previously performed by the chime

module are now part of the smart cluster. There is no
serviceable part of the instrument cluster chime
function. Replacement of the instrument cluster is
necessary.

KEY IN IGNITION SWITCH

The Key-in switch is built into the ignition switch

assembly. Should the Key-in switch require service,
the ignition switch assembly must be replaced.

INSTRUMENT CLUSTER - EXPORT

Fig. 1 INSTRUMENT CLUSTER - EXPORT

INSTRUMENT CLUSTER

8J - 1

The instrument cluster (Fig. 1) is referred to as an

Electro-Mechanical

Instrument

Cluster

(EMIC).

Some of the features it controls are the gauges, cour-
tesy lamps, chime control, Daytime Running Lamps
(DRL) and cluster self diagnostics. The cluster sends
and receives messages via the Programmable Com-
munication Interface (PCI) data bus circuit (J1850).
All instrument cluster indicators (Airbag, Seat belt,
etc.) are LED’s and are not replaceable, with the
exception of the high beam indicator which is a bulb.
The gauges are not serviced individually, thereby
requiring complete replacement of the cluster if one
indicator or gauge becomes defective.

OPERATION

The

instrument

cluster

controls

the

courtesy

lamps. It receives and sends messages to other mod-
ules via the PCI (J1850) bus circuit. It controls all
the instrument illumination and the chime is also an
integral part of the cluster.

All gauges are the analog type. When the ignition

switch is moved to the OFF position, the cluster
drives each gauge to its lowest position. The individ-
ual gauges are not serviceable and require complete
replacement of the cluster if one or more gauges are
inoperable.

The gauges are the magnetic air-core type. When

the ignition switch is OFF, the gauge pointers should
rest at or below the lowest graduation. The instru-
ment cluster may be checked quickly by using the
cluster self-diagnostics (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - STANDARD PROCE-
DURE). After bulb check, (with the key in the RUN
position and engine running) all MODULE warning
indicators (if so equipped: Airbag, ABS, MIL, Charg-
ing System, ETC - Export only) should be extin-
guished. If any of these indicators stay ON, use the
DRB III

t scan tool to determine module faults. Also

refer to the proper Body Diagnostic Procedures man-
ual for cluster self-diagnostic results.

NOTE: If any of the gauge pointers are stuck on the
wrong side of the pointer stop, perform one of the
following:

•

Pull the M1 fuse in the fuseblock (refer to Wir-

ing Diagrams for fuse locations) and key on. The
gauge pointer will “sweep” the gauges and return
all pointers to the correct side of the stop. Key OFF,
reinsert the M1 fuse. The cluster will “sweep” the
gauges

one

additional

time.

The

cluster

will

“sweep” the gauges anytime there was a change in
the state of the M1 fuse.

•

Perform the instrument self-diagnostic check

(Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER -
STANDARD PROCEDURE). This will “sweep” all the
pointers to the correct side of the pointer stop.

One button is used to switch the display from trip

to total mileage. Holding the button when the display
is in the trip mode will reset the trip mileage. This
button is also used to put the cluster in self-diagnos-
tic mode (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - STANDARD PROCEDURE). Some of the
indicators will come on briefly for a bulb check when
the ignition is turned from OFF to ON. The LED’s
are non serviceable and if one or more warning indic-
tor LED’s are out, the entire cluster must be
replaced.

In the event that the instrument cluster looses

communication with all other modules on the PCI
bus, the cluster will display “nobuS” in the VF dis-
play. The VF display also displays “Door”, “Cruise”,
“Trac”, and odometer trip or total.

If the cluster does not detect voltage on the M1 cir-

cuit, the message “FUSE” will alternate with the
odometer/trip odometer. The lack of voltage can be
due to the M1 Fused B(+) (IOD) fuse being open, or a
circuit problem.

Indicator lamps use ON/OFF switch functions for

operation, while gauges use a sending unit or sensor.

The instrument cluster will learn some features of

the vehicle that it is installed in so swapping clusters
from vehicle to vehicle is not recommended.

The features that are learned are:
• ABS

• Traction Control

• SKIM

• RKE

• Air Bags

• Cruise Control

• Lowest/Highest Fuel Level

INSTRUMENT CLUSTER - EXPORT

When the ignition key is ON, the instrument clus-

ter indicator lamps will come on for a brief bulb
check. The seat belt indicator lamp will remain ON
until the (Driver) seat belt is fastened. The chime
will sound for 6 seconds if the seat belt is unbuckled
when the ignition is first turned ON. The export
instrument cluster operates in the same manner as
non-export clusters. Refer to the appropriate Body
Diagnostic Procedures manual for complete diagnosis
and testing of the instrument cluster.

8J - 2

INSTRUMENT CLUSTER

INSTRUMENT CLUSTER (Continued)

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER WARNING/INDICATOR LAMPS

Every time the vehicle is switched to the START/

RUN position, the cluster goes through a BULB
CHECK. This tests most of the indicator lamps and
Vacuum Fluorescent (VF) displays. If any of the
lamps fail to light during the bulb check, refer to the
proper Body Diagnostic Procedures manual. The
lamps are not replaceable except for the high beam
indicator and gauge illumination bulbs. None of these
though will illuminate, along with the security indi-
cator, during the bulb check at initial KEY ON.

To diagnose the cluster lamps first place the clus-

ter in self-diagnostic mode. With the ignition switch
in the OFF position, press the trip odometer reset
button down. Simultaneously turn the ignition key to
the ON position and release the trip reset button.
Depending on optional equipment, the indicator
lamps and VF displays should illuminate except for
the fog lampm liftgate ajar, and any unlearned fea-
tures.

DIAGNOSIS AND TESTING - MULTIPLE/
INDIVIDUAL GAUGES INOPERATIVE

Test speedometer, tachometer and other gauges for

malfunction using the following:

(1) First perform Cluster Self-Diagnostics (Refer to

8 - ELECTRICAL/INSTRUMENT CLUSTER - STAN-
DARD PROCEDURE). If there is a response, watch
for the effected gauge(s) for operation. Replace clus-
ter as necessary. If there is no response to the cluster
self-diagnostics, go to Step 2.

(2) Remove the cluster (Refer to 8 - ELECTRICAL/

INSTRUMENT CLUSTER - REMOVAL).

(3) Check for ignition voltage at Pin 14 of the

26-way cluster wire harness connector. Refer to Wir-
ing Diagrams for connector views. Check for battery
voltage at Pin 4 of the 26-way connector. If no volt-
age, repair as necessary.

(4) Check Pin 1 and Pin 2 of the 26-way connector

for continuity to ground. If no ground, repair as nec-
essary.

(5) If the voltage and ground are OK, and the pins

or the connectors are not distorted, replace the
instrument cluster(Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - REMOVAL).

(6) Autostick clusters only - In KEY UNLOCK/

RUN/START there is B+ battery voltage at Pin 15 of
the 26-way connector. Refer to Step 3.

26-WAY CLUSTER HARNESS CONNECTOR PIN

CALL-OUT

CAV.

FUNCTION

POWER GROUND

LOGIC GROUND

PARK LAMP ILLUMINATION FEED

BATTERY FEED - M1

DOME/MAP/CARGO LAMP

DRIVER DOOR AJAR

LEFT TURN OUTPUT (DRL)

LEFT TURN SIGNAL INPUT

RIGHT TURN OUTPUT (DRL)

RIGHT TURN SIGNAL INPUT

IGNITION RUN/START

UNLOCK/RUN/START (AUTOSTICK ONLY

SPARE OUTPUT B

LOW BEAM SENSE (CANADIAN ONLY)

HIGH BEAM

KEY-IN IGNITION

SEAT BELT

PARK BRAKE

PANEL ILLUMINATION DRIVER

PASSENGER DOOR AJAR

LIFTGATE AJAR

PROGRAM VPM

PCI BUS

10-WAY CLUSTER HARNESS CONNECTOR PIN

CALL-OUT

CAV.

FUNCTION

FRONT FOG

VEHICLE THEFT/SECURITY SYSTEM
(VTSS)

SPARE INPUT 5

SPARE INPUT 4

SPARE INPUT 3

REAR FOG

PANEL DIMMING LEVEL

REVERSE INPUT

FUEL SENSOR

SPARE INPUT 2

INSTRUMENT CLUSTER

8J - 3

INSTRUMENT CLUSTER (Continued)

Content .. 495 496 497 498 ..