Ford Ranger EV (2001 year). Manual - part 93

413-01-16

413-01-16

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E: ECONOMY GAUGE DOES NOT OPERATE PROPERLY OR ALWAYS INDICATES +
(POSITIVE)

TEST STEP

ACTION TO TAKE

E7 CHECK GROUND TO INSTRUMENT CLUSTER

•

With key OFF, measure the resistance between pin 6 (BK/W wire) on

Yes =

REPAIR circuit 584 (Y

instrument cluster C215 and ground. 

wire).

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK/W wire.

E8 CHECK IAA MODULE

•

With key OFF, disconnect IAA module C1945. 

Yes =

GO to E9.

•

With key ON, check the economy gauge. 

No =

REPLACE the IAA module.

•

Does the economy gauge indicate + (positive)?

E9 CHECK CIRCUIT 3408 (DB/O) FOR SHORT TO POWER

•

Connect 104-Pin Breakout Box (BOB) to the IAA module C1945; leave

Yes =

REPAIR the DB/O wire.

IAA module disconnected. 

•

With key ON, measure the voltage between BOB pin 22 and ground

No =

REPLACE the instrument

(BOB pin 80). 

cluster.

•

Is the voltage greater than 0 volts?

PINPOINT TEST F: DISTANCE TO EMPTY (DTE) GAUGE DOES NOT OPERATE OR INDICATES
INCORRECT DISTANCE TO EMPTY

TEST STEP

ACTION TO TAKE

F1 IDENTIFY SYMPTOM

•

Enter the interface adapter assembly (IAA) module active command

Yes =

GO to F2.

mode DISTANCE TO EMPTY GAUGE and set the active command

DTE G to 30%. 

•

Does the distance to empty (DTE) gauge indicate greater than 0

No =

GO to F3.

miles to empty?

F2 CHECK DTE GAUGE FOR CORRECT DTE

•

Set the active command DTE G to the following percentages and verify Yes =

System OK. CHECK wiring

the DTE gauge operation: 

for intermittent connections.

Percentage/DTE

No =

REPLACE the instrument

cluster.

— 12% = 0-3.2 km (0-2 miles)
— 20% = 13-16 km (8-10 miles)
— 28% = 27-34 km/h (17-21 miles)
— 40% = 40-47 km (25-29 miles)
— 48% = 64-71 km (40-44 miles)
— 56% = 81-87 km (50-54 miles)
— 64% = 97-103 km (60-64 miles)

•

Is the DTE gauge OK?

F3 CHECK INTERFACE ADAPTER ASSEMBLY (IAA) MODULE

•

Connect 104-Pin Breakout Box (BOB) to the IAA module and IAA

Yes =

GO to F4.

module C1945. 

• 

Enter the IAA module active command mode DISTANCE TO EMPTY No = REPLACE the IAA module.

GAUGE and set the active command DTE G to 30%. REFER to 

Section 412-04.

•

Set the multimeter to the frequency setting and measure the frequency

between BOB pin 98 and ground (BOB pin 80). 

•

Is the frequency greater than 70 Hz?

F4 CHECK CIRCUIT 3047 (Y/W) FOR OPEN

•

With key OFF, disconnect instrument cluster C214. 

Yes =

GO to F5.

(Continued)

413-01-17

413-01-17

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST F: DISTANCE TO EMPTY (DTE) GAUGE DOES NOT OPERATE OR INDICATES
INCORRECT DISTANCE TO EMPTY

TEST STEP

ACTION TO TAKE

•

Enter the active command mode DISTANCE TO EMPTY GAUGE and

No =

REPAIR the Y/W wire

set the active command DTE G to 30%. 

between instrument cluster

•

Set the multimeter to the frequency setting and measure the frequency

C214 and IAA module

between pin 10 (Y/W wire) on instrument cluster C214 and ground. 

C1945.

•

Is the frequency greater than 70 Hz?

F5 CHECK CIRCUIT 3047 (Y/W) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 98 and ground

Yes =

GO to F6.

(BOB pin 80). 

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the Y/W wire

between instrument cluster

C214 and IAA module

C1945.

F6 CHECK CIRCUIT 3047 (Y/W) FOR SHORT TO POWER

•

With key ON, measure the resistance between BOB pin 98 and ground

Yes =

REPAIR the Y/W wire

(BOB pin 80). 

between instrument cluster

C214 and IAA module

C1945.

•

Is the voltage greater than 0 volts?

No =

GO to F7.

F7 CHECK POWER TO INSTRUMENT CLUSTER

•

With key OFF, disconnect instrument cluster C215. 

Yes =

REPLACE the instrument

cluster.

•

With key ON, measure the voltage between pin 12 (BK/LG wire) on

No =

GO to F8.

instrument cluster C214 and pin 6 (BK/W wire) on instrument cluster

C215. 

•

Is the voltage greater than 10 volts?

F8 CHECK GROUND TO INSTRUMENT CLUSTER

•

With key OFF, measure the resistance between pin 6 (BK/W wire) on

Yes =

REPAIR circuit 3049

instrument cluster C215 and ground. 

(BK/LG wire).

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK/W wire.

PINPOINT TEST G: MOTOR ENABLED GAUGE DOES NOT OPERATE OR INDICATES WAY ABOVE THE
ON MARK

TEST STEP

ACTION TO TAKE

G1 IDENTIFY SYMPTOM

•

Turn the ignition key to the START position and identify the symptom. 

Yes =

GO to G2.

•

Does the motor enabled gauge indicate OFF?

No =

GO to G8.

G2 CHECK MOTOR ENABLED GAUGE

•

Enter the interface adapter assembly (IAA) module active command

Yes =

System OK. CHECK wiring

mode INSTRUMENTATION CONTROL and set the active commands

for intermittent connections.

GAUGE PWR to ON and MOTOR ENA to ON. 

•

Does the motor enabled gauge indicate ON?

No =

GO to G3.

G3 CHECK GAUGE DRIVE SIGNAL FROM INTERFACE ADAPTER

ASSEMBLY (IAA) MODULE

•

Connect 104-Pin Breakout Box (BOB) to the IAA module and IAA

Yes =

GO to G5.

module C1945. 

•

With key ON, measure the voltage between BOB pin 15 and ground

No =

GO to G4.

(BOB pin 80). 

•

Is the voltage greater than 10 volts?

G4 CHECK CIRCUIT 3405 (GY/R) FOR SHORT TO GROUND

(Continued)

413-01-18

413-01-18

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST G: MOTOR ENABLED GAUGE DOES NOT OPERATE OR INDICATES WAY ABOVE THE
ON MARK

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect the IAA module from the BOB; leave BOB

Yes =

REPLACE the IAA module.

connected to IAA module C1945. REFER to 

Section 412-04.

•

With key OFF, measure the resistance between BOB pin 15 and ground

No =

REPAIR the GY/R wire.

(BOB pin 80). 

•

Is the resistance greater than 10,000 ohms?

G5 CHECK CIRCUIT 3405 (GY/R) FOR OPEN

•

With key OFF, disconnect instrument cluster C214 and measure the

Yes =

GO to G6.

resistance of the GY/R wire between pin 13 on instrument cluster C214

and BOB pin 15. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the GY/R wire.

G6 CHECK POWER TO INSTRUMENT CLUSTER

•

With key ON, measure the voltage between pin 4 (BK/LG wire) on

Yes =

REPLACE the instrument

instrument cluster C214 and pin 6 (BK/W wire) on instrument cluster

cluster.

C215. 

•

Is the voltage greater than 10 volts?

No =

GO to G7.

G7 CHECK GROUND TO INSTRUMENT CLUSTER

•

With key OFF, measure the resistance between pin 6 (BK/W wire) on

Yes =

REPAIR circuit 3049

instrument cluster C215 and ground. 

(BK/LG wire).

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK/W wire.

G8 CHECK CIRCUIT 3405 (GY/R) FOR SHORT TO POWER

•

Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =

REPAIR the GY/R wire.

module disconnected. 

•

With key OFF, disconnect instrument cluster C214. 

No =

REPLACE the instrument

•

With key ON, measure the voltage between BOB pin 15 and ground

cluster.

(BOB pin 80). 

•

Is the voltage greater than 0 volts?

PINPOINT TEST H: MALFUNCTION INDICATOR LAMP (MIL) DOES NOT OPERATE OR STAYS ON
CONTINUOUSLY

TEST STEP

ACTION TO TAKE

H1 IDENTIFY SYMPTOM

NOTE: If the malfunction indicator lamp (MIL) illuminates continuously,

Yes =

GO to H8.

retrieve diagnostic trouble codes (DTCs) before carrying out the following

test steps. If DTCs exist, refer to the appropriate DTC Index in Section

100-07. If no DTCs exist and  the vehicle exhibits abnormal symptoms,

refer to the Powertrain Diagnostic Routines Index in Section 100-09.

•

With key ON, identify the symptom. 

•

Does the MIL stay on continuously?

No =

GO to H2.

H2 CHECK OPERATION OF MALFUNCTION INDICATOR LAMP

(MIL)

•

Enter the interface adapter assembly (IAA) module active command

Yes =

System OK. CHECK wiring

mode INDICATOR LAMP CONTROL III and set the active command

for intermittent connections.

MIL to ON. 

•

Does the MIL illuminate?

No =

GO to H3.

H3 CHECK MIL CONTROL CIRCUIT

•

Connect 104-Pin Breakout Box (BOB) to interface adapter assembly

Yes =

REPLACE the IAA module.

(IAA) module C1945; leave IAA module disconnected. REFER to 

Section 412-04.

•

With key OFF, connect a jumper wire between BOB pin 31 and ground

No =

GO to H4.

(BOB pin 80). 

•

Does the MIL illuminate?

(Continued)

413-01-19

413-01-19

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H: MALFUNCTION INDICATOR LAMP (MIL) DOES NOT OPERATE OR STAYS ON
CONTINUOUSLY

TEST STEP

ACTION TO TAKE

H4 CHECK MIL BULB

•

With key OFF, remove and check the MIL bulb. 

Yes =

GO to H5.

•

Is the bulb OK?

No =

REPLACE the bulb.

H5 CHECK CIRCUIT 3045 (T) FOR OPEN

•

With key OFF, disconnect instrument cluster C215 and measure the

Yes =

GO to H6.

resistance of the T wire between pin 8 on instrument cluster C215 and

BOB pin 31. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the T wire.

H6 CHECK CIRCUIT 3045 (T) FOR SHORT TO POWER

•

With key ON, measure the voltage between BOB pin 31 and ground

Yes =

REPAIR the T wire.

(BOB pin 80). 

•

Is the voltage greater than 0 volts?

No =

GO to H7.

H7 CHECK POWER TO INSTRUMENT CLUSTER

•

With key OFF, measure the voltage between pin 10 (LB wire) on

Yes =

REPLACE the instrument

instrument cluster C215 and ground. 

cluster.

•

Is the voltage greater than 10 volts?

No =

REPAIR circuit 742 (LB

wire).

H8 CHECK INSTRUMENT CLUSTER

NOTE: Carry out the following test steps only if the MIL illuminates

Yes =

REPLACE the instrument

continuously with the ignition key in the OFF position and the vehicle not

cluster.

connected to a power control station (PCS).

•

Connect 104-Pin Breakout Box (BOB) to the IAA module and IAA

module C1945. 

•

With key OFF, disconnect instrument cluster C215 and measure the

No =

GO to H9.

resistance between BOB pin 31 and ground (BOB pin 80). 

•

Is the resistance greater than 10,000 ohms?

H9 CHECK CIRCUIT 3045 (T) FOR SHORT TO GROUND

•

With key OFF, disconnect the IAA module from the BOB; leave BOB

Yes =

REPLACE the IAA module.

connected to IAA module C1945. REFER to 

Section 412-04.

•

With key OFF, measure the resistance between BOB pin 31 and ground

No =

REPAIR the T wire.

(BOB pin 80). 

•

Is the resistance greater than 10,000 ohms?

PINPOINT TEST J: POWER RESET INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY

TEST STEP

ACTION TO TAKE

J1 IDENTIFY SYMPTOM

NOTE: If the power reset indicator illuminates and the vehicle will not

Yes =

GO to J8.

start, refer to Emergency Power Off (EPO)/Interlock System in

 Section

414-03A 

or 

Section 414-03B.

•

With key ON, identify the symptom. 

•

Does the power reset indicator stay on continuously?

No =

GO to J2.

J2 CHECK OPERATION OF POWER RESET INDICATOR

•

Enter the interface adapter assembly (IAA) module active command

Yes =

System OK. CHECK wiring

mode INDICATOR LAMP CONTROL III and set the active command

for intermittent connections.

ENG RESET to ON. 

•

Does the power reset indicator illuminate?

No =

GO to J3.

J3 CHECK POWER RESET INDICATOR CONTROL CIRCUIT

•

Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =

REPLACE the IAA module.

module disconnected. REFER to 

Section 412-04.

(Continued)