ELECTRONIC DASHBOARD INSTRUMENTS

Introduction
A dashboard (also called dash, instrument panel (IP), or fascia) is a control panel set
within central console of a vehicle or small aircraft. Usually located directly ahead of
the driver (or pilot), it displays instrumentation and controls for the vehicle's
operation.
The car dashboard is a bridge for information exchange between the driver and the
vehicle. Owing to the high contrast and glaring colors of the thin-film transistor (TFT)
liquid crystal display (LCD), the digital dashboard will become the information and
control center of future vehicles. So far, the dashboard of a passenger car mainly
consists of the main dashboard facing the driver and the auxiliary dashboard beside
the driver. In particular, the main dashboard contains all instruments on the car that
monitor the rotating speed, speed per hour, oil mass and water temperature.
The purpose of the dashboard and indicator lamps is to keep the driver informed about
the operating condition of the vehicle. If an abnormal condition occurs, the driver can
seek service before damage occurs. Indicator lamps use ON/OFF switch functions for
operation. The instrument panel can be removed as an assembly after a few part are
removed to allow access to the retaining bolts. There's one self-aligning bulkhead
connector on the left underside of the instrument panel replacing most of the main
harness connectors. Once removed, the instrument panel can be serviced for
replacement. Most of the parts of the instrument panel can be replaced individually
without removing the complete instrument panel assembly.

Operation

Figure 1: Digital instrumentation system

Standard sensors provide information to the ECU, which in turn will drive suitable
displays. The ECU contains a ROM section, which allows it to be programmed to a
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specific vehicle. The gauges used are as described in the above sections. Some of the
extra functions available with this system are described briefly as follows.

 Low fuel warning light – can be made to illuminate at a particular

resistance reading from the fuel tank sender unit.
 High engine temperature warning light – can be made to operate at a set
resistance of the thermistor.
 Steady reading of the temperature gauge – to prevent the gauge fluctuating
as the cooling system thermostat operates the gauge can be made to read
only at, say, five set figures. For example, if the input resistance varies
from 240 to 200 Ω as the thermostat operates, the ECU will output just one
reading, corresponding to ‘normal’ on the gauge. If the resistance is much
higher or lower the gauge will read to one of the five higher or lower
positions. This gives a low resolution but high readability for the driver.
 Oil pressure or other warning lights can be made to flash – this is more
likely to catch the driver’s attention.
 Service or inspection interval warning lights can be used – the warning
lights are operated broadly as a function of time but, for example, the
service interval is reduced if the engine experiences high speeds and/or
high temperatures. Oil condition sensors are also used to help determine
service intervals.
 Alternator warning light – works as normal but the same or an extra light
can be made to operate if the output is reduced or if the drive belt slips.
This is achieved by a wire from one phase of the alternator providing a
pulsed signal, which is compared to a pulsed signal from the ignition. If
the ratio of the pulses changed this would indicate a slipping belt.
As an example of how some of this system works consider the high
temperature and low fuel warning lights as examples. Figure 12.16 shows a
block diagram of just this part of the overall system.

Figure 2: Block diagram of high temperature and low fuel warning lights
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The analogue-to-digital converter (ADC) is time division multiplexed to various

sensors. The signals from the temperature and fuel level sensors will produce a certain
digital representation of a numerical value when they reach say 180 (about 105°C)
and 200 (10 liters left), respectively. These figures (assigned to variables ‘temp_input’
and ‘fuel_input’) can then be compared with those pre-programmed into memory,
variables ‘high_temp’ and ‘low_fuel’. The following simplified lines of computer
program indicate the logical result.
IF temp_input > high_temp THEN high_temp_light = on
IF fuel-input > low_fuel THEN low_fuel_light = on
A whole program is built up which can be made suitable for any particular
manufacturer’s requirements.
The function of any visual display is to communicate information to the desired
level of accuracy. Most displays used in the vehicle must provide instant data but the
accuracy is not always important. Analogue displays can provide almost instant
feedback from one short glance. For example, if the needle of the temperature gauge
is about in the middle then the driver can assume that the engine temperature is within
suitable limits. A digital read-out of temperature such as 98°C would not be as easy to
interpret. This is a good example as to why even when digital processing and display
techniques are used, the actual read-out will still be in analogue form. Figure 3 shows
a display using analogue gauges.
Figure 4 shows an instrument display using digital representation.
Numerical and other forms of display are, however, used for many applications.
Some of these are as follows:
• Vehicle map.
• Trip computer.
• Clock.

Figure 3: Analogue display

• Radio displays.
• Route finding displays.
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• General instruments.
These displays can be created in a number of ways; the following sections
examine each of these in more detail. To drive individual segments or parts of
a complete display, a technique called time division multiplexing is often used.

Figure 4: Digital display

Description and Operation

Headlamp Switch
The headlamp switch is part of the Multi-Function Switch.
Instrument Cluster
There are two conventional instrument cluster assemblies available. The clusters
electronically drive the speedometer, odometer, gauges, and tachometer (if equipped).
The instrument cluster controls the courtesy lamps, it receives and sends messages to
other modules via the PCI bus circuit, it controls all the instrument illumination and
the chime is also an integral part of the cluster. The front turn signals are wired
through the cluster and then go to the front lamps. The reason being that the DRL
module is built into the cluster (if equipped).
All gauges in the electronic clusters are the analog type gauges. When the ignition
switch is moved to the OFF position, the cluster drives each gauge to its lowest
position. The individual gauges are not serviceable and require complete replacement
of the cluster if one or more gauges are inoperable. One button is used to switch the
display from trip to total mileage. Holding the button when the display is in the trip
mode will reset the trip mileage. This button is also used to put the cluster in self-
diagnostic mode. Refer to Service Procedures, Cluster Self Diagnostics in this section.
Most of the indicators will come on briefly for a bulb heck when the ignition is turned
from OFF to ON. All of the LED’s are replaceable. In the event that the instrument
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cluster loses communication with all other modules on the PCI bus, the cluster will
display “nobus” in the VF display. The VF display also displays “Door”, “Cruise”,
“Trac”, and odometer trip or total.
If the cluster does not detect voltage on the courtesy lamp circuit, the message
“FUSE” will alternate with the odometer/trip odometer for 30 seconds after the
ignition is turned on and for 15 seconds after the vehicle is first moved. The lack of
voltage can be due to the M1 Fused B (+) (IOD) fuse being open, a bad or missing
courtesy lamp bulb, or a circuit problem.
Warning and Indicator Lamps
 The instrument cluster has warning lamps and indicators for the following
systems:
• Airbag
• Anti-lock Brakes (ABS) if equipped
• Brake warning
• Charging System
• Front fog lamps (if equipped)
• High beam indicator
• Low fuel (premium cluster only)
• Low oil pressure
• Malfunction indicator (service engine soon) lamp
• Right and left turn signals
• Seat belt warning
• Security system
• Trac-Off (ABS equipped vehicles only)
 The instrument cluster has a Vacuum Fluorescent (VF) display for the
following systems:
• Cruise
• Door (ajar)
• Odometer
• Set (cruise)
• Trac
• Trip
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Diagnosis and Testing

Brake System Warning Lamp Test
The brake warning lamp illuminates when the parking brake is applied with ignition
switch turned to the ON position. The same lamp will also illuminate if one of the two
service brake systems fail the when brake pedal is applied.
To test the system:
• As the ignition switch is turned to the start position the lamp should light.
• Turn ignition switch to the ON position and apply the parking brake. The lamp
should light.
If lamp fails to light inspect for:
• A burned out lamp
• Loose, corroded or damaged socket
• A damaged circuit board
• A broken or disconnected wire at the switch
• Defective switch
Instrument Cluster Lamps
Every time the vehicle is switched to the START/ RUN position, the cluster goes
through a bulb check. This tests most of the indicator lamps and Vacuum Fluorescent
(VF) displays. If only one lamp is out, remove the instrument cluster and replace the
defective bulb or Light Emitting Diode (LED). If some or all of the lamps fail to light,
refer to the proper Body Diagnostics Procedures Manual. To diagnose the cluster
lamps first place the cluster in self-diagnostic mode. With the ignition switch in the
off position, press the trip odometer reset button down. Simultaneously turn the
ignition key to the ON position and release the trip reset button. All the indicator
lamps and VF displays should illuminate except for the fog lamp, turn signal, and
high beam select indicators.
Low Oil Pressure Warning Lamp Test
The low oil pressure warning lamp will illuminate when the ignition switch is turned
to the ON position without engine running. The lamp also illuminates if the engine oil
pressure drops below a safe oil pressure level. To test the system, turn the ignition
switch to the ON position. If the lamp fails to light, inspect for a broken or
disconnected wire at the oil pressure switch, located at the front of the engine. If the
wire at the connector checks good, pull the connector loose from the switch and with
a jumper wire, ground the connector to the engine. With the ignition switch turned to
the ON position, check the warning lamp. If the lamp still fails to light, inspect for a
burned out lamp or disconnected socket in the cluster.
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Instrumentation System Faults

Table 1 lists some common symptoms of an instrumentation system malfunction
together with suggestions for the possible fault. The faults are very generic but will
serve as a good reminder.

Symptoms Possible fault

Fuel and temperature gauges
both read high or low (thermal
type gauges)
Gauges read full/hot or empty/
cold all the time
Individual instruments do not
work
Voltage stabilizer
Short/open circuit sensors
Short or open circuit wiring
Loose or broken
wiring/connections/fuse
Sender units (sensor) faulty
Gauge unit fault (not very common)

Table 1: Common symptoms and possible faults of an instrumentation

system malfunction

The process of checking a thermal gauge fuel or temperature instrument

system is broadly as follows.

1. Hand and eye checks (loose wires, loose switches and other obvious
faults) – all connections clean and tight.
2. Either fit a known good 200 resistors in place of the temperature sender –
gauge should read full.
3. Or short fuel tank sender wires to earth – gauge should read full.
4. Check continuity of wire from gauge to sender – 0 to 0.5 Ω.
5. Check supply voltage to gauge (pulsed 0–12 V on old systems) – 10 V
stabilized on most.
6. If all above tests are OK the gauge head is at fault.