Warning System - Warning Devices Ford Cutaway E350

The following warnings are utilized

1. park brake warning
2. safety belt warning
3. key-in-ignition warning
4. headlamps on warning
5. safety belt minder warning
6. air bag warning
7. fail safe cooling warning

The chime function is contained within the instrument cluster and is not serviceable separately.

Refer to SYSTEM WIRING DIAGRAMS for schematic and connector information.

Special Tool(s)

SPECIAL TOOL 73III Automotive Meter 105-R0057 or equivalent

Scheme 1

Chime

The instrument cluster produces a repetitive chime for either a predetermined amount of time or continuously, under the following conditions

1. the driver safety belt is unbuckled and the ignition switch is in the RUN position
2. the key is in the ignition switch and the driver door is open
3. the headlamp switch is in the HEAD or PARK position, the driver door is open, and the key is not in the ignition switch
4. the Safety Belt Minder feature is enabled and the appropriate parameters have been met

Air Bag Warning Chime

The air bag warning chime warns the driver that the air bag warning indicator lamp is not working and a fault occurred by sounding a chime when the ignition switch is in the RUN position for more than 20 seconds. When these conditions exist, the retraint control module (RCM) sends a chime request through the communication network to the instrument cluster. The instrument cluster then activates the warning chime. The warning consists of 5 sets of 1-second tone bursts. Each set is separated by 5 seconds of silence.

Safety Belt Warning

The safety belt warning chime reminds the driver to fasten the safety belt. This occurs when the ignition switch is turned to the RUN position and the driver safety belt remains unbuckled. The chime is terminated by buckling the driver safety belt at any time during the 4-8 second chime warning.

The chime works in conjunction with the safety belt warning indicator in the instrument cluster.

Key-in-Ignition Warning

The key-in-ignition warning chime sounds continuously when the ignition key is in the ignition lock cylinder with the key OFF and the driver door open. The chime continues to sound until the key is removed from the ignition lock cylinder or the driver door is closed.

Headlamps On Warning

The headlamps on warning chime sounds continuously when the headlamp switch is in the PARK or HEAD position, the driver door is open, and the key is not in the ignition lock cylinder.

The chime continues to sound until the headlamp switch is turned OFF or the driver door is closed.

Park Brake Warning

The park brake warning chime provides an audible indication to the driver that the park brake is engaged while the vehicle is in motion.

Safety Belt Minder

Note. The Safety Belt Minder can be configured with or without using a diagnostic tool. For additional information on configuring this feature with a diagnostic tool, refer to MODULE CONFIGURATION . To configure this feature without using a diagnostic tool, refer to BELT MINDER DEACTIVATING/ACTIVATING .

The Safety Belt Minder feature supplements the safety belt warning function. The Safety Belt Minder feature is enabled after the current safety belt warning is complete. The Safety Belt Minder reminds the driver that the safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster once the vehicle speed has exceeded 3 mph. While activated, the Safety Belt Minder activates the chime and warning indicator for 6 seconds, with a 30 second interval between activations.

The Safety Belt Minder stops when

1. the driver seat belt is buckled.
2. the ignition switch is turned to OFF or ACC.
3. minutes have elapsed since the belt minder started.

Fail Safe Cooling Warning Chime

When the engine coolant temperature reaches an over temperature condition, the powertrain control module (PCM) provides an over temperature signal to the instrument cluster. The instrument cluster positions the temperature gauge in the HOT range and flashes the CHECK GAGE indicator. The instrument cluster also provides an intermittent chime, consisting of 3 tones within a 5 second interval for level one fail safe cooling mode or 5 tones within a 9 second interval for level two fail safe cooling mode.

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Loose or corroded connections Circuits
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/warning-system/#warning-system-warning-devices__symptom-chart) .

Symptom Chart

WARNING DEVICES SYMPTOM CHART

Scheme 2

Scheme 3

Scheme 4

1. A1 CHECK THE SAFETY BELT CHIME OPERATION NOTE: Verify the Safety Belt Minder is activated before beginning diagnosis. Depower the supplemental restraint system (SRS). For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(/ford/cutaway-e350/2004-2007/remont/airbag/#supplemental-restraint-system) . Key in OFF position. Disconnect: Driver Safety Belt Pretensioner C323. Connect a fused (10A) jumper wire between the driver safety belt pretensioner C323-4, circuit 85 (BN/LB), harness side and ground. Key in ON position. Does the Safety Belt Minder warning chime sound? Yes : GO to A3 . No : GO to A2.
2. A2 CHECK CIRCUIT 85 (BN/LB) FOR AN OPEN Key in OFF position. Disconnect: Instrument Cluster C220b. Measure the resistance between the instrument cluster C220b-25, circuit 85 (BN/LB), harness side and the driver safety belt pretensioner C323-4, circuit 85 (BN/LB), harness side. Is the resistance less than 5 ohms? Yes : GO to A4 . No : REPAIR the circuit. TEST the system for normal operation.
3. A3 CHECK CIRCUIT 57 (BK) FOR AN OPEN Measure the resistance between the driver safety belt pretensioner C323-3, circuit 57 (BK), harness side and ground. Is the resistance less than 5 ohms? Yes : INSTALL a new driver safety belt pretensioner. REFER to «SAFETY BELT SYSTEM»(/ford/cutaway-e350/2004-2007/remont/restraints-control-systems/#safety-belt-system) . TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.
4. A4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all the instrument cluster connectors. Check for: corrosion pushed out pins Connect all the instrument cluster connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new instrument cluster. REFER to «INSTRUMENT CLUSTER»(ref-231355) . TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Scheme 5

Scheme 6

1. B1 CHECK THE COURTESY LAMPS Key in OFF position. Open the driver door. Do the courtesy lamps illuminate? Yes : GO to B2. No : REFER to «INTERIOR LIGHTING»(/ford/cutaway-e350/2004-2007/remont/interiorillumination-lights/#interior-lighting) .
2. B2 CHECK THE KEY-IN-IGNITION SWITCH OPERATION Disconnect: Instrument Cluster C220b. Measure the resistance between the instrument cluster C220b-18, circuit 159 (BK/PK), harness side and ground, while inserting and removing the key. Is the resistance less than 5 ohms with the key in, and greater than 10,000 ohms with the key out? Yes : GO to B4 . No : GO to B3.
3. B3 CHECK CIRCUIT 159 (RD/PK) FOR AN OPEN Disconnect: Clockspring C218b. Measure the resistance between the instrument cluster C220b-18, circuit 158 (BK/PK), harness side and the clockspring C218b-3, circuit 158 (BK/PK), harness side. Is the resistance less than 5 ohms? Yes : INSTALL a ignition lock cylinder. REFER to «HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS»(/ford/cutaway-e350/2004-2007/remont/door-locks-anti-theft-systems/#door-system-handles-locks-latches-and-entry-systems) . TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.
4. B4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all the instrument cluster connectors. Check for: corrosion pushed out pins Connect all the instrument cluster connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new instrument cluster. REFER to «INSTRUMENT CLUSTER»(ref-231355) . TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Scheme 7

Scheme 8

1. C1 CHECK CIRCUIT 14 (BN) FOR AN OPEN Key in OFF position. Disconnect: Instrument Cluster C220a. Pull the headlamp switch to the PARK position. Measure the voltage between the instrument cluster C220a-7, circuit 14 (BN), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to C2. No : REPAIR the circuit. TEST the system for normal operation.
2. C2 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all the instrument cluster connectors. Check for: corrosion pushed out pins Connect all the instrument cluster connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new instrument cluster. REFER to «INSTRUMENT CLUSTER»(ref-231355) . TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

Preparation

1. Before deactivating/activating the safety belt minder, set the parking brake.
2. Place the transmission in PARK.
3. Turn the key to the OFF position.
4. Close all the vehicle doors.
5. Unbuckle the driver safety belt.
6. Place the headlamp switch in the OFF position.

Deactivating/Activating

1. Turn the key to the ON position. (Do not start the engine.)
2. Wait until the safety belt warning indicator turns off (approximately 1 minute).
3. Buckle then unbuckle the safety belt 9 times, ending with the safety belt unbuckled. The air bag warning indicator then illuminates for 3 seconds.
4. Within 10 seconds of the air bag warning indicator illuminating, buckle then unbuckle the safety belt. This enables the safety belt minder if disabled, or disables the safety belt minder if enabled.
5. The following sequence of events confirms the safety belt minder is enabled: flashing of the air bag warning indicator 4 times per second for 3 seconds seconds with the air bag warning indicator off flashing of the air bag warning indicator 4 times per second for 3 seconds again
6. The air bag warning indicator flashing 4 times per second for 3 seconds provides confirmation that the safety belt minder is disabled.
7. After confirmation, the deactivation/activation procedure is complete.

See also:
• MODULE CONFIGURATION
• EXTERIOR LIGHTING
• SUPPLEMENTAL RESTRAINT SYSTEM
• SAFETY BELT SYSTEM
• INTERIOR LIGHTING
• HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS
• BELT MINDER DEACTIVATING/ACTIVATING
• SYMPTOM CHART