6.11.3 - Gauge / Warning Light Pack ( John Ping,
October 20, 2001
A word of caution, the gauges are precision devices and are easily damaged if handled in a careless manner. Ensure that your work area is clean … including your hands. To access the Instrument Panel gauges, it is necessary to remove the Instrument Panel clear bezel. This step is accomplished by releasing the ten (five top and five bottom) plastic clips located on the gauge pack. With the ten clips removed, carefully separate the two housings.
Support the gauge pack in a manner such that the instruments are not touching any surfaces. With the gauge pack vertically supported, it is now necessary to remove the wood veneer panel. It is attached to the gauge pack with seven No. 1 Phillips head self-tapping screws. Fastener access is from the rear (printed circuit side) with two screws along the top, three screws in the middle section and two screws along the bottom. The Vehicle Condition Monitor (odometer) will release with the veneer panel. Ensure the four-pin black connector is released (pull upward) and the two odometer light bulbs are removed. Carefully separate the veneer panel from the gauge pack. Keep the gauge pack positioned vertically to ensure no instrument damage.
Remove any instrument as desired by first locating the mounting tabs for the affected instrument on the rear of the gauge pack. Press the small tabs to the right and left side of each pin to release the pin. This is precision work … be careful! Each instrument has three pins. The ancillary gauges can be replaced independently, but the speedometer / tachometer is replaced as a single module.
Install the new gauge as desired by pressing the three pins into their circuit board female receivers. Carefully position and re-install the veneer panel using the seven small self-tapping screws. Carefully position and join the clear bezel housing to the gauge pack. It is wise to clean the inside and outside of the clear bezel using a glass cleaning solution prior to re-attachment with the gauge pack.
A quick check for electrical circuit continuity can be performed using a conventional digital multi-meter. Trace out the circuit path from each instrument pin to the printed circuit ribbon strip end. Each circuit should have minimal resistance. Mount the electronic pack to the rear of the gauge pack (hinge and clip mechanism). Carefully mount the three printed circuit ribbon strips to the connectors on the electronic pack. Ensure the ribbon strips are fully seated and the connector locks are properly positioned. Mount the electronic pack rear cover plate and you are finished.
Follow the directions for re-installing the instrument pack into the dash.
Note: If the tachometer fails for no apparent reason, it its possible the inline buffer resistor (approx. 6.8k ohms) between the negative side of the ignition coil and the Instrument Panel has failed (open circuit). All models may not incorporate this design, but absolutely check the wiring schematics to determine if it applies to your vehicle. If this problem occurs on your vehicle, just bypass the original failed resistor and install a new one in the circuit to restore tachometer operation. It's a very simple matter to splice the new resistor circuit into the existing wiring harness near the ignition coil.
Note: The warning lights (tan holders) used on the Instrument Panel are the "long-life type". They will rarely need replacement as they are seldom illuminated. The illumination lights (white holders) on the Instrument Panel (center of the electronic pack) should be inspected (slight twist to the left and pull out) for deterioration (smoking / graying of the inside of the bulb). Replace any suspect bulb prior to re-assembly. The two odometer (VCM) lights at the bottom of the electronic pack (tan holders) are always illuminated and it is prudent to replace these bulbs (or swap with other low priority warning bulbs if replacements are unavailable) prior to re-assembly.