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Home >> Mercury >> 1993 >> Villager LS >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Instrument Panels - Electronic >> System Tests >> Test A: Instrument Cluster & Panel Lighting

Test A: Instrument Cluster & Panel Lighting

NOTE: Do NOT start this test unless directed by a symptom diagnosis in INSTRUMENT PANEL CLUSTER & LIGHTING  under TROUBLE SHOOTING.
  1. Turn key to OFF position. Check the 15A Tail Lamp fuse located in the interior fuse panel. See COMPONENT LOCATIONS  . Is the fuse OK? If yes, go to next step. If no, go to step  4 .
  2. Turn key to OFF position. Replace the 15A Tail Lamp fuse. Does the fuse fail again? If yes, go to next step. If no, go to step  4 .
  3. Turn key to OFF position. Remove the 15A Tail Lamp fuse. Disconnect the headlamp switch connector located on the instrument panel. Measure the resistance of the Orange/Blue wire between the right terminal of the 15A Tail Lamp fuse holder and ground. Is the resistance less than 5 ohms? If yes, service the Orange/Blue wire and retest system. If no, replace the 15A Tail Lamp fuse.
  4. Turn key to OFF position. Disconnect the headlamp switch connector located on the instrument panel. Measure the voltage of the Orange/Blue wire at the headlamp switch connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Orange/Blue wire.
  5. Turn key to OFF position. Disconnect the headlamp switch connector located on the instrument panel. Turn headlamp switch to the OFF position. Measure the resistance between the Orange/Blue wire terminal and the Pink wire terminals on the headlamp switch. Place headlamp switch in the parking lamp position or the headlamp position. Measure the resistance between the Orange/Blue wire terminal and the Pink wire terminal on the headlamp switch. Is the resistance less than 5 ohms with the headlamp switch in the parking lamp position or the headlamp position, and greater than 10,000 ohms with the headlamp switch in the OFF position? If yes, go to next step. If no, replace headlamp switch. See HEADLAMP SWITCH  under REMOVAL & INSTALLATION.
  6. Turn key to OFF position. Reconnect the headlamp switch connector. Disconnect the instrument panel dimmer switch connector located on the instrument panel. Disconnect the timer module connector. See COMPONENT LOCATIONS  . Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the instrument panel dimmer switch connector. Measure the voltage of the Pink wire at the timer module connector. Is the voltage greater than 10 volts? If yes and the instrument panel dimmer switch lamp does not work, go to step  13 . If yes and all instrument panel lamps do not work, go to next step. If no, service the Pink wire.
  7. Turn key to OFF position. Disconnect the instrument panel dimmer switch connector located on the instrument panel. Measure the resistance of the Black wire between the instrument panel dimmer switch connector and ground. Is the resistance less than 5 ohms? If yes, go to step  10 . If no, go to next step.
  8. Turn key to OFF position. Disconnect the instrument panel dimmer switch connector. Remove the instrument cluster. Disconnect the Green diode strip from the diode junction box located behind the instrument cluster. See COMPONENT LOCATIONS  . Measure the resistance of the Black wire between the instrument panel dimmer switch connector and Terminal No. 25 of the diode junction box. See Fig 1 . Is the resistance less than 5 ohms? If yes, go to next step. If no, service Black wire.
    Fig 1: Diode Junction Box Connector Identification
    G00101228Courtesy of FORD MOTOR CO.
  9. Turn key to OFF position. Disconnect the Green diode strip from the diode junction box. Measure the resistance of the Black/Red wire between Terminal No. 28 of the diode junction box and ground. See Fig 1 . Is the resistance less than 5 ohms? If yes, replace Green diode strip. See DIODE STRIPS  under REMOVAL & INSTALLATION. If no, service Black/Red and Black wire.
  10. Turn key to OFF position. Disconnect the instrument panel dimmer switch connector. Depress and hold the brightening side of the instrument panel dimmer switch. Measure the resistance between the Blue/Red wire terminal and the Black wire terminal on the instrument panel dimmer switch. Depress and hold the dimming side of the instrument panel dimmer switch. Measure the resistance between the Blue/Black wire terminal and the Black wire terminal on the instrument panel dimmer switch. Release the instrument panel dimmer switch. Measure the resistance between the Blue/Red wire terminal, the Blue/Black wire terminal and the Black wire terminal on the instrument panel dimmer switch. Is the resistance less than 5 ohms between the wire terminals with either side of the instrument panel dimmer switch depressed, and greater than 10,000 ohms with the instrument panel dimmer switch released? If yes, go to next step. If no, replace dimmer switch.
  11. Turn key to OFF position. Disconnect the instrument panel dimmer switch connector and the timer module connector. Measure the resistance of the Blue/Red wire and the Blue/Black wire between the timer module connector and the instrument panel dimmer switch connector. Measure the resistance of the Blue/Red wire and the Blue/Black wire between the timer module connector and ground. Are the resistances less than 5 ohms between the timer module connector and the instrument panel dimmer switch connector, and greater than 10,000 ohms between the timer module connector and ground? If yes, go to next step. If no, service the wires in question.
  12. Turn key to OFF position. Reconnect the timer module connector and the instrument panel dimmer switch connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the timer module connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, service Pink/Black wire. If no, replace the timer module. See TIMER MODULE  under REMOVAL & INSTALLATION.
  13. Turn key to OFF position. Reconnect the instrument panel dimmer switch connector. Remove the instrument panel dimmer switch bulb. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage on the instrument panel dimmer switch bulb connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, replace instrument panel dimmer switch. See AUTOLAMP/INSTRUMENT PANEL DIMMER SWITCH ASSEMBLY  under REMOVAL & INSTALLATION.
  14. Turn key to OFF position. Remove the instrument panel dimmer switch bulb. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage on the instrument panel dimmer switch bulb connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace instrument panel dimmer switch bulb. See AUTOLAMP/INSTRUMENT PANEL DIMMER SWITCH ASSEMBLY ILLUMINATION LAMP  under REMOVAL & INSTALLATION. If no, go to next step.
  15. Turn key to OFF position. Disconnect the instrument panel dimmer switch connector. Remove the instrument panel dimmer switch bulb. Measure the resistance between the Pink/Black wire terminal and the instrument panel dimmer switch bulb connector on the instrument panel dimmer switch. Is the resistance less than 5 ohms? If yes, service the Pink/Black wire between the instrument panel dimmer switch and the timer module. If no, replace the instrument panel dimmer switch. See AUTOLAMP/INSTRUMENT PANEL DIMMER SWITCH ASSEMBLY  under REMOVAL & INSTALLATION.
  16. Turn key to OFF position. Remove the instrument cluster. Disconnect the 20-pin instrument cluster connector. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the 20-pin instrument cluster connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  17. Turn key to OFF position. Disconnect the 20-pin instrument cluster connector and the 12-pin instrument cluster connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wires at the 20-pin instrument cluster connector and 12-pin instrument cluster connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the instrument cluster. See ELECTRONIC INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. If no, service the Pink/Black wire(s) between the instrument cluster and the timer module.
  18. Turn key to OFF position. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the headlamp switch connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  19. Turn key to OFF position. Remove the headlamp switch bulb. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage at the headlamp switch bulb connector on the headlamp switch. Is the voltage greater than 10 volts? If yes, go to next step. If no, replace headlamp switch. See HEADLAMP SWITCH  under REMOVAL & INSTALLATION.
  20. Turn key to OFF position. Remove the headlamp switch bulb. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage on the headlamp switch bulb connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace headlamp switch bulb. If no, go to next step.
  21. Turn key to OFF position. Disconnect the headlamp switch connector located on the instrument panel. Remove the headlamp switch bulb. Measure the resistance between the headlamp switch bulb connector and the Pink/Black wire terminal on the headlamp switch. Is the resistance less than 5 ohms? If yes, service the Pink/Black wire between the headlamp switch and the timer module. If no, replace headlamp switch. See HEADLAMP SWITCH  under REMOVAL & INSTALLATION.
  22. Turn key to OFF position. Disconnect the Cruise Control ON/OFF switch connector located on the instrument panel. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the Cruise Control ON/OFF switch connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service the Pink wire.
  23. Turn key to OFF position. Disconnect the Cruise Control ON/OFF switch connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the Cruise Control ON/OFF switch connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the Cruise Control ON/OFF switch bulb. If no, service the Pink/Black wire between the Cruise Control ON/OFF switch and the timer module.
  24. Turn key to OFF position. Disconnect the radio connector located in the center console. Place headlamp switch in the parking lamp or headlamp position. Measure the voltage of the Pink wire at the radio connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  25. Turn key to OFF position. Disconnect the radio connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage on the Pink/Black wire at the radio connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, service the radio. If no, service the Pink/Black wire between the radio and the timer module.
  26. Turn key to OFF position. Disconnect the rear seat remote control panel connector located on the left rear trim panel. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the rear seat remote control panel connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  27. Turn key to OFF position. Disconnect the rear seat remote control panel connector. Measure the resistance of the Black/White wire between the rear seat remote control panel connector and ground. Is the resistance less than 5 ohms? If yes, replace/service the rear seat remote control panel. If no, service Black/White wire.
  28. Turn key to OFF position. Disconnect the compact disc player connector located in the center console. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the compact disc player connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  29. Turn key to OFF position. Disconnect the compact disc player connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the compact disc player connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, service the compact disc player. If no, service the Pink/Black wire between the compact disc player and the timer module.
  30. Turn key to OFF position. Disconnect the front climate control panel connector located in the center console. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the front climate control panel connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  31. Turn key to OFF position. Reconnect the front climate control panel connector. Remove the front climate control panel lamp(s) that are not working. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage at the front climate control panel lamp connector(s) on the front climate control panel. Is the voltage greater than 10 volts each time? If yes, go to next step. If no, replace the front climate control panel.
  32. Turn key to OFF position. Remove the front climate control panel bulb(s) that are not working. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage at the front climate control panel bulb connectors on the front climate control panel while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the front climate control panel bulb(s). If no, go to next step.
  33. Turn key to OFF position. Disconnect the front climate control panel connector. Remove the front climate control panel bulb(s) that are not working. Measure the resistance between the front climate control panel bulb connector(s) and the Pink/Black wire terminal on the front climate control panel connector. Are the resistances less than 5 ohms? If yes, service the Pink/Black wire between the front climate control panel and the timer module. If no, replace the front climate control panel.
  34. Turn key to OFF position. Disconnect the rear climate control panel connector located on the left rear trim panel. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the rear climate control panel connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  35. Turn key to OFF position. Reconnect the rear climate control panel connector. Remove the rear climate control panel lamp(s) that are not working. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage at the rear climate control panel bulb connector(s). Is the voltage greater than 10 volts? If yes, go to next step. If no, replace the rear climate control panel. See REAR CLIMATE CONTROL PANEL  under REMOVAL & INSTALLATION.
  36. Turn key to OFF position. Remove the rear climate control panel bulb(s) that are not working. Measure the resistance between the rear climate control panel bulb connector(s) and ground. Is the resistance less than 5 ohms? If yes, replace the rear climate control panel bulb(s). If no, go to next step.
  37. Turn key to OFF position. Disconnect the rear climate control panel connector. Measure the resistance of the Black wire between the rear climate control panel and ground. Is the resistance less than 5 ohms? If yes, replace the rear climate control panel. See REAR CLIMATE CONTROL PANEL  under REMOVAL & INSTALLATION. If no, service the Black wire.
  38. Turn key to OFF position. Disconnect the rear blower motor switch connector from the front climate control panel located in the center console. Headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the rear blower motor switch connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  39. Turn key to OFF position. Disconnect the rear blower motor switch connector from the front climate control panel. Headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the rear blower motor switch connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the rear blower motor switch. See REAR BLOWER MOTOR SWITCH  under REMOVAL & INSTALLATION. If no, service the Pink/Black wire between the rear blower motor switch and the timer module.
  40. Turn key to OFF position. Disconnect the cigar lighter and ashtray bulb connector located in the center console. Headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the cigar lighter and ashtray bulb connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  41. Turn key to OFF position. Disconnect the cigar lighter and ashtray bulb connector. Headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the cigar lighter and ashtray bulb connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the cigar lighter and ashtray bulb. If no, service the Pink/Black wire between the cigar lighter and ashtray and the timer module.
  42. Turn key to OFF position. Disconnect the Rear Defogger switch connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the Rear Defogger switch connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the Rear Defogger switch. If no, service the Pink/Black wire between the rear defogger switch and the timer module.
  43. Turn key to OFF position. Disconnect the Rear Defogger switch connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the Rear Defogger switch connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the rear defogger switch. If no, service the Pink/Black wire between the rear defogger switch and the timer module.
  44. Turn key to OFF position. Disconnect the hazard switch connector located on the instrument panel. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the hazard switch connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  45. Turn key to OFF position. Disconnect the hazard switch connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the hazard switch connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace hazard switch. See HAZARD SWITCH  under REMOVAL & INSTALLATION. If no, service the Pink/Black wire between the hazard switch and the timer module.
  46. Turn key to OFF position. Disconnect the Power E-AT switch connector located on the instrument panel. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the Power E-AT switch connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  47. Turn key to OFF position. Disconnect the Power E-AT switch connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the Power E-AT switch connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the Power E-AT switch. If no, service the Pink/Black wire between the Power E-AT switch and the timer module.
  48. Turn key to OFF position. Disconnect the rear wiper/washer switch connector located on the instrument panel. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the rear wiper/washer switch connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  49. Turn key to OFF position. Disconnect the rear wiper/washer switch connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the rear wiper/washer switch connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the rear wiper/washer switch. See REAR WINDOW WIPER/WASHER SWITCH ASSEMBLY  under REMOVAL & INSTALLATION. If no, service the Pink/Black wire between the rear wiper/washer switch and the timer module.
  50. Turn key to OFF position. Disconnect the fuel computer control panel connector located on the instrument panel. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage of the Pink wire at the fuel computer control panel connector. Is the voltage greater than 10 volts? If yes, go to next step. If no, service Pink wire.
  51. Turn key to OFF position. Reconnect the fuel computer control panel connector. Remove the fuel computer control panel bulb(s) that are not working. Place headlamp switch in the parking lamp position or the headlamp position. Measure the voltage at the fuel computer control panel bulb connector on the fuel computer control panel assembly. Is the voltage greater than 10 volts? If yes, go to next step. If no, replace the fuel computer control panel assembly. See FUEL COMPUTER CONTROL PANEL  under REMOVAL & INSTALLATION.
  52. Turn key to OFF position. Remove the fuel computer control panel bulb(s) that are not working. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage at the fuel computer control panel bulb connector on the fuel computer control panel assembly while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the fuel computer control panel bulb(s). If no, go to next step.
  53. Turn key to OFF position. Disconnect the fuel computer control panel connector. Place headlamp switch in the parking lamp position or the headlamp position. Operate the instrument panel dimmer switch from the dimmest position to the brightest position. Measure the voltage of the Pink/Black wire at the fuel computer control panel connector while operating the instrument panel dimmer switch. Does the voltage vary from approximately 9 volts (dimmest position) to approximately 0.2 volts (brightest position)? If yes, replace the fuel computer control panel assembly. See FUEL COMPUTER CONTROL PANEL  under REMOVAL & INSTALLATION. If no, service the Pink/Black wire between the fuel computer control panel and the timer module.
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