A. Cluster Tests and Wiring Harness Modification
1. Use the following procedure to verify that the vehicle's dome lights are operating properly:a. Place the instrument cluster panel dimming control in the midpoint of its travel.
b. Close all the doors on the vehicle.
c. Open the driver's door and the dome light should come on.
d. Close the driver's door and the dome light should go out within approximately 45 seconds.
> If the dome operates normally continue with Step 2 of this procedure.
> If the dome light does not come on when the door is opened, troubleshoot and repair the dome light circuit as required and repeat Step 1 of this procedure.
NOTE:
Also check the vehicle warranty history to determine if the cluster has been replaced recently with a current level part number cluster. Replacing the cluster without modifying the wiring will result in an inoperative dome lamp.
> If the dome light remains on continuously after the door is closed, the cluster must be replaced. Record the mileage, order a new instrument cluster and store the vehicle with the battery disconnected. When the new cluster arrives, continue with Step 3, but skip Step 14 (cluster test with an ohmmeter).
CAUTION:
Do not return the vehicle to the customer until the new cluster is installed and wiring modifications have been performed.
2. Record the odometer reading shown on the instrument cluster.
3. Disconnect and isolate the negative battery cable.
WARNING:
To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting this repair. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
4. Remove the instrument panel knee blocker and knee blocker reinforcement.
5. Remove the brake light switch to prevent losing the adjustment setting.
6. Remove the steering column mounting nuts and lower the steering column.
7. Partially remove the center stack bezel and instrument panel end cap.
8. Remove the cluster bezel retaining screws and using a trim stick or equivalent, separate the cluster bezel from the instrument panel (Figure 1)
9. Disconnect the electrical connectors on the back of the cluster bezel and remove the instrument cluster bezel from the instrument panel.
10. Remove the four retaining screws that secure the instrument cluster to the instrument panel structural support (Figure 2).
11. Pull the instrument cluster away from the instrument panel to access and disconnect the instrument panel wire harness connectors from the instrument cluster housing (Figure 3).
12. Remove the instrument cluster from the instrument panel.
CAUTION:
Do not leave the instrument cluster in the face-down position for more than 20 minutes as gauge damage may occur.
13. Use the following procedure to relocate the yellow (w/orange tracer) wire in cavity number C11 of the white instrument panel cluster connector to the open cavity number C2 of the same connector:
NOTE:
The new cluster software will reassign the control circuit for the dome lamp to a different pin on the cluster connector. Therefore, the dome lamp wire must be relocated so that the dome lamp will function after this repair is performed.
a. Lift the secondary wire lock located on the side of the white instrument cluster electrical connector (Figure 4).
NOTE:
The secondary wire lock only needs to be lifted approximately 1/8" to release.
b. Using Special Tool 6932 (part of Special Tool kit 8197A), probe the white instrument cluster electrical connector cavity from the terminal side to release the yellow (w/orange tracer) wire terminal lock (Figure 5 and 6).
c. With Special tool 6932 inserted into the connector, remove the yellow (w/orange tracer) wire from the white instrument cluster connector (Figure 5 and 6).
d. Install the yellow (w/orange tracer) wire into cavity C2 of the white instrument panel electrical connector (Figure 6). Pull back slightly on the wire to ensure the primary lock is engaged.
e. Press the secondary wire lock down on the white instrument panel electrical connector until it is flush with the connector body. This will lock the wires into position.
14. If the cluster was not replaced in Step 1 test the cluster using the following procedure:
NOTE:
If the instrument cluster has been replaced in Step 1 of this procedure, Step 14 is not required. Continue with Step 15.
a. Place the instrument cluster face down on a clean work surface.
CAUTION:
Make sure when the instrument cluster is laying face down on the lens that it is not being damaged or scratched and that it does not remain in this position for more than 20 minutes.
b. Connect the white connector of Special Tool CH10090 to the white instrument cluster connector (Figure 7).
NOTE:
Make sure the connector is seated properly in the cluster connector.
c. Connect the wires of Special Tool CH10090 to the ohmmeter terminals (Figure 7).
NOTE:
The polarity of the leads must be red to positive and black to common.
d. Read the ohmmeter resistance measurement:
NOTE:
Place ohmmeter in the "Auto" range setting if available or in the 10k range if the ohmmeter requires a manual setting.
> If the resistance reading is more than 2000 Ohms, the cluster is good.
Continue with Step 15 of this procedure.
NOTE:
An open circuit Ohmmeter reading is considered a good cluster.
> If the resistance reading is less than 2000 Ohms, the cluster must be replaced.
Follow the procedure below to replace the instrument cluster:
1. Take the VIN and odometer reading information to the parts department and order a replacement instrument cluster.
CAUTION:
The vehicle cannot be returned to the customer until the new cluster is installed. DO NOT reinstall the old cluster into the vehicle.
2. Temporarily install the steering column and brake switch.
3. Connect the battery and park the vehicle until the new cluster arrives
4. When the replacement cluster arrives, place the original cluster in the replacement cluster box and return the original cluster to the parts department.
5. Continue with Step 15 of this procedure.
15. Position the instrument cluster close enough to the instrument panel to connect the instrument cluster wire harness connectors to the connector receptacles on the back of the cluster (Figure 3). Position the instrument cluster into the instrument panel (Figure 2).
16. Connect the negative battery cable.
17. For vehicles that did not have the cluster replaced, reprogram (flash) the CCN module using either the StarSCAN scan tool (Section B) or the StarMOBILE scan tool (Section C) before reassembling the vehicle. For vehicles that had the cluster replaced, continue with Section D. Install Instrument Cluster
NOTE:
Replacement instrument clusters will already contain the latest software and do not require reprogramming.
NOTE:
The CCN module reprogramming procedure has an additional cluster test procedure that must be performed as well as a procedure to reset the overhead temperature display.