Ford Falcon. Manual - part 331

413-01-7 Instrument 

Cluster 413-01-7

DESCRIPTION AND OPERATION (Continued)

to hold that TRIP button for an additional second, all

Security Indicator

resettable functions will be reset and the cluster will

The security indicator is activated for 3 seconds when emit 2 beeps.

the ignition is first turned to the ON position. The

security indicator is continually flashed when the

HI Series

ignition is turned to the OFF position. This warning is

HI Series clusters send this trip data information to the

attached by either PCM or BEM in the occurrence of a ICC unit, control of displayed data is conducted with

security event.

the use of ICC mounted trip buttons.

Fog Lights Indication (where fitted)

Average Speed

The fog lamp indicator is activated by a hard-wired

The average speed display indicates the average

connection to the fog lamp switch. The fog lamp

speed since the last time that the average speed

indicator is activated if the input is connected to

function was reset. It is calculated based on distance

supply.

information received from the PCM via the CAN

communication interface and time calculated internally

Cruise Indication (where fitted)

in the instrument cluster.

The cruise control information is displayed on the LCD

when requested by the PCM. If the cruise control is

Travel Time

on, CRUISE is displayed. If the cruise control is active The travel time is the time in minutes since the last

CRUISE SET is displayed.

travel time function was reset. It is calculated internal

to the instrument cluster.

PRND + 1234 Indication

Range

The PRND information is displayed in the LCD. In

addition, Adaptive and Performance modes are

The range displays the estimated distance before the

indicated. For the high series vehicles, PERF is

vehicle runs out of fuel. This estimation is based on

continually displayed when performance mode is

the resistive fuel tank sender input, fuel usage

activated, with no display when in adaptive mode. For received from the PCM and the calculated fuel

other variants, the numbers of the board trip computer consumption based on recent driving style.

display on the LCD are replaced with AdP or PEF to

When the range reaches 80, 40, 20 or 0, an audible

indicate adaptive and performance mode respectively.

warning is sounded.

General Operation

Average Economy

Dimming Operation

The average economy, uses data since the last

average economy function was reset. The calculation

The dimming for the vehicle interior is controlled

is based on fuel usage and distance information, both

through the switches on the instrument cluster.

received from the PCM.

For the high series variants, there are dim up and dim

down button, for LOW/XR variants, there is a single

When car is stationary L/hr is displayed. When car is

dimming button that cycles through 4 fixed dimming

detected to be moving, L/100km is displayed.

levels.

NOTE: Trip Computer functions are only updated

The instrument cluster has 2 dimming outputs to

whilst engine is running.

control the illumination levels in other parts of the

vehicle. These outputs are switched to ground with a

Audible Warnings

pulsed signal. The pulse width modulation for the

Buzzer Sounds

signal determines the illumination level.

On Board Trip Computer

Function

Tone

Duration

sequence

LOW/XR Series

Mode

One beep

50 ms

The on board computer supplies the driver with

Overspeed

Three running 300ms for each

information for average speed, travel time, range,

tones

frequency

average economy and instantaneous economy trip

Airbag

1 beep per

500ms on, 200ms off

data.

pulse train

time @ 5Hz air bag

The information is displayed on the LH cluster LCD.

detection

signal

The trip computer display mode is cycled by pressing

Seatbelt

6 beeps,

250ms on, pause for

the TRIP button on the instrument cluster. Single

repeated at

750ms between

beep is also emitted. It is possible to reset the

30s intervals

beeps

average speed, travel time and average economy

functions by pressing and holding the TRIP button for

1 second while in the appropriate mode. By continuing

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413-01-8 Instrument 

Cluster 413-01-8

DESCRIPTION AND OPERATION (Continued)

Function

Tone

Duration

sequence

Door ajar

Three beeps

400ms on, pause for

300ms between

beeps

Park brake

Continuous for 500 ms on, 1 second

20 seconds

off

High

Five beeps at

300ms on, pause for

temperature 30 second

100ms between

intervals

beeps

Low oil

Four beeps

300ms on, pause for

after 5 second 100ms between

delay

beeps

Low fuel

Three beeps

300 ms on, pause for

Range

repeated at 1s 100 ms between

intervals

Park lights

Three beeps

300ms on, pause for

on

repeated at 2s 200ms between

intervals

beeps

Indicator /

One beep

5 ms for the relay on

hazard

sound and 5 ms for

the relay off sound

Buzzer Activation

Function

Activation

Indicator /

Indicator light is turned on

hazard
Mode

Increase or decrease of overspeed

threshold, change of overspeed

function status

Overspeed

Vehicle indicated speed becomes

greater than the Overspeed threshold

with the overspeed function activated

Airbag

Airbag audible request activated

Seatbelt

Refer Seatbelt and Airbag Audible

section

Door ajar

Door ajar flags set when the car is

started (Revs over 350RPM)

Park brake

Park brake input is active and vehicle

speed is more than 10 km/hr

High

High temperature request flag on

temperature

CAN is set the first time and every 1

minute

Low oil

5 seconds after low oil LED warning is

first activated

Low fuel

Range decreases to 80, 40, 20 or 0

Park lights

Park lights are on when the ignition is

on

being switched off for 20 seconds.

Headlights fail flag set with ignition on

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413-01-9 Instrument 

Cluster 413-01-9

DIAGNOSIS AND TESTING

activated and that all buttons on the cluster (Dim Up,

Instrument Cluster

Dim Down (or Trip computer Mode switch - if fitted),

Hazard and Trip reset) are not pressed. Prior to

Inspection and Verification

executing the self test, set continuous DTC’s should

A visual inspection of the vehicle cluster unit and

be checked for and cleared. See DTC list for

various electrical connections should be made prior to explanation on codes that the cluster may return.

any detailed tests are performed.

1.  To enter the instrument cluster self diagnostic

1.  Verify the customer concern by operating the

mode, Place the ignition and Parklights in the ON

system.

position and select the Self test option on the

WDS.

2.  Visually inspect for obvious signs of mechanical

or electrical damage.

2.  The self-test is deactivated after 5 seconds has

elapsed. During the self test, the ignition should

Ensure that battery terminal connection is well

be held in the ON position.

made. If loose / corroded, clean and

re-tighten.

Any returned trouble codes should then be checked

for using the WDS unit. Refer to the DTC list for

Check general condition of cluster. Look for

further actions.

any physical signs of damage, that might be

cause of cluster problem.

Tests performed during the self test (Duration 5

seconds).

Check condition of cluster related fuses.

Visual Inspection Chart

Test Performed On: Test Description

Mechanical

Electrical

Cluster LCD, dial,

All Illumination Initiates to Off.

External switch and

Illumination values are then

Damaged engine oil

Fuse(s)

LCD Illumination

progressively raised until the

filter

Central junction box

maximum value is reached.

Low engine oil level

(CJB) fuse F30 (7.5A)

Engine coolant level

CJB fuse F34 (7.5A)

NOTE: May not be noticeable

Damaged coolant

Circuit

in daylight conditions.

thermostat

LED(s)

Speedometer,

All Gauges initiate to minimum

Door adjustment

Wiring harness

Tachometer,

values. They are then swept

Loose or corroded

Temperature and

to their full scale deflection

connector(s)

Fuel gauge

and back to minimum again.

Damaged instrument

Warning LEDs

All warning LEDs are initiated

cluster

to be Off. Each warning LED

3.  If an obvious cause for an observed or reported

is then activated one at a

concern is found, correct the cause (if possible)

time, in a clockwise fashion.

before proceeding to the next step.

Buzzer

Buzzer sweep cycle is

4.  Verify the following systems are working correctly

sounded.

by operating the system.

See DTC List for further details and information

Charging

regarding DTC’s.

Fuel

Module Configuration

Cooling

All new instrument clusters are defaulted with the

Turn signals

following information:

Headlamps

Odometer set to 0km

The continuous trouble codes should then be checked

Sedan petrol fuel map

for using the WDS unit. See DTC list for explanation

on codes that the cluster may return. Upon checking

Police mode disabled

for previously set codes, the Self-diagnostic Mode

Traction control fitted

should be entered.

Seatbelt audible reminder enabled

Self Tests

The instrument cluster is a programmable module,

which must be configured via the WDS. The WDS is

Diagnostic Self Test Mode

used to select appropriate data for the vehicle i.e., if

The Diagnostics self test provides an automated

the cluster is replaced or any cluster options are to be

means of testing the cluster functionality, allowing the modified.

operator to check for correct operation in one easy

Data Extraction from existing Cluster:

sequence. Faults detected by the cluster will be

recorded in the form of DTC’s, as detailed in the DTC If a cluster is to be replaced with a new unit,

section. It is important that for the duration of the test, depending on the condition of the existing cluster, the

the ignition is in the ON position, the Park Lamps are

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413-01-10 Instrument 

Cluster 413-01-10

DIAGNOSIS AND TESTING (Continued)

configuration data is read from the existing cluster and

the gauge fails, the input (e.g. fuel sender) is

written to the new replacement cluster.

checked for validity and user prompted with

further tests / pinpoint tests.

Place key in the ‘ON’ position and select

‘Programmable Module Installation’ on the WDS

Button Test

Follow the text screens until successful

This test will check for mechanical button problems

Place key in OFF position and install the

within the cluster

replacement instrument cluster - See ‘Removal

1.  User will be prompted to press each button, with

and Installation’ for details

confirmation upon each press. (Stuck / non

Key in the ON position. Follow text screens until

operational buttons detected). The cluster buttons

successful.

tested are:

Once complete, verify correct operation.

 1. 

Hazard 

Button

 

2.  Trip Reset Button

Programmable Options:

 

3.  Dim Up Button

Odometer:

 

4.  Dim Down / Trip Computer Button

The odometer can be programmed using the WDS

Illumination Test

unit by selecting ‘Update Odometer Value’ The

Odometer value can be programmed to any value

This test will check for illumination problems within the

between 0km and 999,999km, providing the following

cluster

conditions have been met:

1.  Each Illumination channel driven to set levels with

user confirmation.

The replacement cluster odometer value is less

than 100km

Multifunction Output Test — LCD / Warning

The replacement cluster has had its odometer set

LED / Buzzer

less than three times

This test will check the following:

Once programmed, the replacement clusters

1.  Working LCD segments within the cluster

odometer will immediately be updated (+0/-1) and a

permanent (unerasable) DTC will be set if the

 

1.  All segments (PRND, Odometer, Cruise, Trip

odometer was set to a value greater than 100km.

Data, Overspeed and Low wash symbols)

enabled, then disabled, with user

Fuel Table:

confirmation.

The fuel table map can be programmed using the

2.  Software controllable LEDs within the cluster

WDS unit by selecting ‘Update Fuel’ options. Upon

 

1.  All software controllable warning LED’s

selection, the technician will be prompted with

enabled, then disabled, with user

questions to determine the fuel table required. The

confirmation. If a LED fails, the user will be

appropriate map is then uploaded to the cluster.

guided through test to pinpoint the failure. The

LEDs controlled are:

Variant Information:

Security Warning

The Variant Information can be programmed using the

Park Brake Reminder

WDS unit by selecting ‘Update Variant Information’

Seatbelt Reminder

option. Upon selection, the technician will be

Low Fuel Warning

prompted with a list of available options for the

High Temp Warning

replacement cluster. The technician should then

Throttle Warning

select the appropriate options and upload the data.

Traction Control Warning

The options for the cluster include:

Door Ajar Warning

Traction Control Fitted - Only selected if the

 

2.  Cluster hardwired LED’s NOT tested during

vehicle has a traction control unit fitted.

this test include:

Seatbelt Audible Reminder Enabled - Set if user

Fog Lights Reminder

requests the seatbelt audible reminder to be

High Beam Reminder

enabled by default.

Alternator Reminder

Brake Fail Warning

Functional Tests

ABS Warning

Fuel Cut Off Warning

Gauge Test

3.  Buzzer operation within the cluster

This test will check for mechanical gauge problems

 

1.  Buzzer sweep cycle engaged, with user

within the cluster

confirmation of operation.

1.  Each gauge is swept / pointed to a particular

value, with user confirmation on gauge position. If

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