Contents Wiring diagrams Section: Warning System All sections

Warning Devices: Diagnosis Ford Explorer IV

Warning System 2 illustrations ~2126 words

Inspection and Verification

  1. Verify the customer concern.
  2. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Circuitry Key-in-ignition warning switch (part of the ignition switch) Instrument cluster
  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, connect the scan tool to the data link connector (DLC).
  5. If the scan tool does not communicate with the VCM: Check the connection to the vehicle. Refer to «MODULE COMMUNICATIONS NETWORK»(ref-270934) to diagnose no communication with the scan tool.
  6. If the scan tool does not communicate with the vehicle: Verify the ignition key is in the ON position. Verify the scan tool operation with a known good vehicle. Refer to «MODULE COMMUNICATIONS NETWORK»(ref-270934) to diagnose no response from the powertrain control module (PCM).
  7. Carry out the network test: If the scan tool responds with no communication for multiple modules, refer to «MODULE COMMUNICATIONS NETWORK»(ref-270934) . If the scan tool responds with no communication with the instrument cluster, refer to «INSTRUMENT CLUSTER»(ref-270940) . If the network test passes, retrieve and record the continuous memory DTCs.
  8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster.
  9. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(ref-270935) .
  10. If no DTCs related to the concern are retrieved, go to «Symptom Chart»(ref-270941-S13602602862007111500000) .
DTCDescriptionAction
B1868Lamp Air Bag Warning Indicator Circuit FailureINSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation.
B1915Air Bag Driver Circuit FailureINSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation.
All other DTCsREFER to INSTRUMENT CLUSTER .

INSTRUMENT CLUSTER DIAGNOSTIC TROUBLE CODE (DTC) CHART

Symptom Chart

ConditionPossible SourcesAction
No communication with the instrument clusterFuse(s) Circuitry Instrument clusterREFER to MODULE COMMUNICATIONS NETWORK .
The key-in-ignition warning chime is inoperativeCircuitry Key-in-ignition warning switch (part of the ignition switch) Instrument clusterGo to Pinpoint Test A .
The headlamps on warning chime is inoperativeInstrument clusterGo to Pinpoint Test B .
All the chimes are inoperativeInstrument clusterINSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER .
The turn signal on warning chime is inoperativeTurn signal indication Vehicle speed input Instrument clusterGo to Pinpoint Test C .
The door ajar warning chime is inoperativeInstrument clusterVERIFY the door ajar warning indicator operates correctly. If the door ajar warning indicator operates correctly, INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation. If the door ajar warning indicator does not operate correctly, REFER to INSTRUMENT CLUSTER .
The chime sounds when the driver door is ajar (no key in ignition and headlamps off)Circuitry Key-in-ignition warning switch (part of the ignition switch) Instrument clusterGo to Pinpoint Test D .
The safety belt warning chime does not operate correctlyRestraints control module (RCM) Instrument clusterGo to Pinpoint Test E .
The safety belt minder feature does not operate correctlyInstrument cluster configurationACTIVATE the safety belt minder. To activate using a scan tool, REFER to MODULE CONFIGURATION . To activate without using a scan tool, REFER to Belt-Minder® Deactivating/Activating .
RCM Instrument clusterGo to Pinpoint Test F .
The parking brake warning chime is inoperativeBrake warning indication Vehicle speed input Instrument clusterGo to Pinpoint Test G .
The air bag secondary warning chime is inoperativeInstrument clusterRETRIEVE the recorded instrument cluster DTCs from the continuous and on-demand self-tests. If the instrument cluster DTC B1868 or B1915 is present, INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation. If the instrument cluster DTC B1868 or B1915 is not present, the system is operating correctly. The air bag secondary warning chime sounds only when a fault in the air bag warning indicator is present and DTC B1868 or B1915 is recorded.
The message center warning chime is inoperativeInstrument clusterCHECK the operation of the message center. If the door ajar message, any tire pressure monitoring system (TPMS) messages, or the LOW FUEL LEVEL message is present, and no chime is heard, INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER .

Symptom Chart

Pinpoint Test A: The Key-In-Ignition Warning Chime Is Inoperative

Refer to SYSTEM WIRING DIAGRAMS , Instrument Cluster for schematic and connector information.

CAUTIONUse the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Scheme 3

Scheme 3

Scheme 4

Scheme 4
  1. A1 CHECK THE DOOR AJAR INDICATOR Make sure all the doors are closed. While observing the door ajar warning indicator, open the driver door. Is the door ajar warning indicator illuminated with the driver door open? YES : Go to A2 . NO : REFER to «INSTRUMENT CLUSTER»(ref-270940) .
  2. A2 CHECK CIRCUIT CDC30 (BU/GY) FOR VOLTAGE Key in OFF position. Disconnect: Instrument Cluster C220 Place the key into the ignition cylinder. Measure the voltage between the instrument cluster C220-14, circuit CDC30 (BU/GY), harness side and ground. Is the voltage greater than 10 volts? YES : Go to A4 . NO : Go to A3 .
  3. A3 CHECK CIRCUIT CDC30 (BU/GY) FOR AN OPEN OR A SHORT TO GROUND Disconnect: Ignition Switch C250 Measure the resistance between the instrument cluster C220-14, circuit CDC30 (BU/GY), harness side and the ignition switch C250-5, circuit CDC30 (BU/GY), harness side; and between the instrument cluster C220-14, circuit CDC30 (BU/GY), harness side and ground. Is the resistance less than 5 ohms between the instrument cluster and the ignition switch, and greater than 10,000 ohms between the instrument cluster and ground? YES : INSTALL a new ignition switch. REFER to «STEERING COLUMN SWITCHES»(ref-270945) . CLEAR the DTCs. REPEAT the self-test. NO : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  4. A4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect the instrument cluster connector. Check for: corrosion damaged pins pushed-out pins Connect the instrument cluster connector and make sure it seats 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-270940) . 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.

PINPOINT TEST B: THE HEADLAMPS ON WARNING CHIME IS INOPERATIVE

  1. B1 CHECK THE EXTERIOR LAMPS FOR OPERATION Turn the headlamp switch to the headlamp or parking lamp ON position. Do the headlamps or parking lamps illuminate with the headlamp switch in the ON position? YES : Go to B2 . NO : REFER to «EXTERIOR LIGHTING»(ref-270923) .
  2. B2 CHECK THE DOOR AJAR INDICATOR Key in ON position. While observing the door ajar warning indicator, open the driver door. Is the door ajar warning indicator illuminated with the driver door open? YES : Go to B3 . NO : REFER to «INSTRUMENT CLUSTER»(ref-270940) .
  3. B3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect the instrument cluster connector. Check for: corrosion damaged pins pushed-out pins Connect the instrument cluster connector and make sure it seats 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-270940) . 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.

PINPOINT TEST C: THE TURN SIGNAL ON WARNING CHIME IS INOPERATIVE

  1. C1 CHECK THE TURN SIGNAL INDICATORS OPERATION Key in ON position. Verify the turn signal indicators operation. Do the turn signal indicators operate correctly? YES : Go to C2 . NO : REFER to «INSTRUMENT CLUSTER»(ref-270940) .
  2. C2 CHECK THE ODOMETER FOR CORRECT OPERATION Drive the vehicle and observe the odometer for correct operation. Does the odometer operate correctly? YES : Go to C3 . NO : REFER to «INSTRUMENT CLUSTER»(ref-270940) .
  3. C3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect the instrument cluster connector. Check for: corrosion damaged pins pushed-out pins Connect the instrument cluster connector and make sure it seats 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-270940) . 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.

Pinpoint Test D: The Chime Sounds When The Driver Door Is Ajar (No Key In Ignition And Headlamps Off)

Refer to SYSTEM WIRING DIAGRAMS , Instrument Cluster for schematic and connector information.

CAUTIONUse the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.
  1. D1 CHECK THE EXTERIOR LIGHTS FOR OPERATION Turn the headlamp switch to the headlamp or parking lamp ON position. Do the headlamps or parking lamps illuminate with the headlamp switch in the ON position? YES : Go to D2 . NO : REFER to «EXTERIOR LIGHTING»(ref-270923) .
  2. D2 CHECK CIRCUIT CDC30 (BU/GY) FOR A SHORT TO VOLTAGE Key in OFF position. Remove the key from the ignition lock cylinder. Disconnect: Instrument Cluster C220 Measure the voltage between the instrument cluster C220-14, circuit CDC30 (BU/GY), harness side and ground. Is any voltage present? YES : Go to D3 . NO : Go to D4 .
  3. D3 CHECK THE IGNITION SWITCH Disconnect: Ignition Switch C250 Measure the voltage between the instrument cluster C220-14, circuit CDC30 (BU/GY), harness side and ground. Is any voltage present? YES : REPAIR the circuit. TEST the system for normal operation. NO : INSTALL a new ignition switch. REFER to «STEERING COLUMN SWITCHES»(ref-270945) . TEST the system for normal operation.
  4. D4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect the instrument cluster connector. Check for: corrosion damaged pins pushed-out pins Connect the instrument cluster connector and make sure it seats 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-270940) . 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.

PINPOINT TEST E: THE SAFETY BELT WARNING CHIME DOES NOT OPERATE CORRECTLY

  1. E1 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCs) FROM BOTH THE CONTINUOUS AND ON-DEMAND RCM SELF-TESTS Check for recorded RCM DTCs from the continuous and on-demand self-tests. Are any RCM DTCs recorded? YES : REFER to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-270926) . NO : Go to E2 .
  2. E2 CHECK THE INSTRUMENT CLUSTER SAFETY BELT WARNING INDICATOR OPERATION NOTE: The safety belt warning chime stops sounding when the safety belt is fastened, when the ignition key is turned from the ON or START position to the OFF/LOCK or ACC position, or when the chime has sounded for approximately 6 seconds. Key in ON position. Following the instrument cluster prove-out, observe the safety belt warning indicator with the safety belt buckled and unbuckled. Does the safety belt warning indicator operate correctly? YES : Go to E3 . NO : REFER to «INSTRUMENT CLUSTER»(ref-270940) .
  3. E3 CHECK THE INSTRUMENT CLUSTER CHIME FOR OPERATION Enter the following diagnostic mode on the diagnostic tool: Instrument Cluster Self-Test Carry out the instrument cluster on-demand self-test while observing the instrument cluster chime. Does the instrument cluster chime operate? YES : Go to E5 . NO : Go to E4 .
  4. E4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect the instrument cluster connector. Check for: corrosion damaged pins pushed-out pins Connect the instrument cluster connector and make sure it seats 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-270940) . 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.
  5. E5 CHECK FOR CORRECT RCM OPERATION Disconnect the RCM connectors. Check for: corrosion damaged pins pushed-out pins Connect the RCM 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 RCM. REFER to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-270926) . 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.

PINPOINT TEST F: THE SAFETY BELT MINDER FEATURE DOES NOT OPERATE CORRECTLY

  1. F1 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCs) FROM BOTH THE CONTINUOUS AND ON-DEMAND RCM SELF-TESTS Check for recorded RCM DTCs from the continuous and on-demand self-tests. Are any RCM DTCs recorded? YES : REFER to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-270926) . NO : Go to F2 .
  2. F2 CHECK THE INSTRUMENT CLUSTER CHIME FOR OPERATION Enter the following diagnostic mode on the diagnostic tool: Instrument Cluster Self-Test Carry out the instrument cluster on-demand self-test while observing the instrument cluster chime. Does the instrument cluster chime operate? YES : Go to F4 . NO : Go to F3 .
  3. F3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect the instrument cluster connector. Check for: corrosion damaged pins pushed-out pins Connect the instrument cluster connector and make sure it seats 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-270940) . 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.
  4. F4 CHECK FOR CORRECT RCM OPERATION Disconnect all the RCM connectors. Check for: corrosion damaged pins pushed-out pins Connect all the RCM 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 RCM. REFER to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-270926) . 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.

PINPOINT TEST G: THE PARKING BRAKE WARNING CHIME IS INOPERATIVE

  1. G1 CHECK THE BRAKE WARNING INDICATOR OPERATION Key in ON position. Apply the parking brake. Observe the brake warning indicator. Does the brake warning indicator turn on with the parking brake applied? YES : Go to G2 . NO : REFER to «INSTRUMENT CLUSTER»(ref-270940) .
  2. G2 CHECK THE SPEEDOMETER FOR CORRECT OPERATION Drive the vehicle and observe the speedometer at different speeds. Does the speedometer operate correctly? YES : Go to G3 . NO : REFER to «INSTRUMENT CLUSTER»(ref-270940) .
  3. G3 CHECK THE PARKING BRAKE WARNING CHIME FOR OPERATION Apply the parking brake and drive the vehicle at a speed greater than 5 km/h (3 mph). Observe the parking brake warning chime. Does the parking brake warning chime operate correctly? YES : The system is operating correctly at this time. The vehicle must be moving at a speed greater than 5 km/h (3 mph) with the parking brake applied. NO : Go to G4 .
  4. G4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect the instrument cluster connector. Check for: corrosion damaged pins pushed-out pins Connect the instrument cluster connector and make sure it seats 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-270940) . 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.