Question about 1988 Suzuki Samurai

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Electrical issue with instrument cluster?

Just can't find what I'm missing here. I have no fuel indication or temp and an oil light. Was previously having all these issues and I'd turn on the vent fan and the fuel and Temp gauges would shoot from nothing to max. Turn off the fan and the gauges return to zero. Found an ungrounded relay under the right side dash and now the headlights, vent fan and turn signals work just fine, but I'm still getting nothing for fuel/temp and the oil light is still on. Have shot the wires and replaced the oil pressure switch. I'm getting oil pressure but the light is still on. I'm thinking I have a grounding problem somewhere in the instrument area.  What am I missing?

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  • Anonymous Sep 27, 2008

    I bought an 88 and 1/2 Samurail ast year. The temperature gauge and gas gauge have not worked. I haven't started on this problem because I'm not sure where to start.



    I also have an intermittant starting problem. It must be in the switch, because I can take a wire and touch the positive battery terminal and the wire to the starter, and it will start right up. Do I need to replace the entire switch?



    Also, the horn doesn't work. The previous own wired a seperate button for the horn, but it doesnb't work either. Any ides where to start with any of these?

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  • Master
  • 625 Answers

Check all the fuses first

Posted on Jun 01, 2008

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I have a 2005 Ford Focus and the fuel light stays on. It is very dim, even when I shut the car off.


Principles of Operation
NOTE: When installing a new instrument cluster, the new instrument cluster must be configured. Refer to Section 418-01 .
The instrument cluster is a hybrid electronic cluster (HEC) which receives and outputs information using both hardwired circuitry and the controller area network (CAN) communication circuits.
It is very important to understand:
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  • all the information necessary for a feature to operate.
  • which module(s) receive(s) the input or command message.
  • if the module that received the input controls the output of the feature, or if it sends a message over the CAN to another module.
  • which module controls the output of the feature.
The instrument cluster carries out a prove-out when the ignition switch is turned from the OFF to the RUN position to verify the integrity of the warning indicators. The charging system warning indicator, the low oil pressure warning indicator and the malfunction indicator lamp (MIL) illuminate when the key is turned to the ON position, and then turn off when the engine is started. The seat belt warning indicator proves-out for 60 seconds and then turns off, or turns off when the seat belt is fastened. The following indicators prove-out when the key is turned to the ON position:
  • door ajar warning indicator (3 seconds)
  • anti-lock brake system (ABS) warning indicator (3 seconds)
  • O/D OFF indicator (3 seconds)
  • air bag warning indicator (6 seconds)
  • brake warning indicator (3 seconds)
  • door ajar warning indicator (3 seconds)
  • shift up indicator (3 seconds)
  • low fuel warning indicator (3 seconds)
  • traction control indicator (3 seconds)
  • check fuel cap indicator (3 seconds)
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Low Fuel Warning Indicator
The instrument cluster utilizes fuel level data supplied by the hardwired fuel pump module to control the low fuel warning indicator, which illuminates when the fuel drops to a pre-determined level.
Your best bet is to take this to the Ford dealer , unless you have Ford IDS - factory scan tool to diagnose this
Your best bet

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The magnetic gauge movement consists of three primary coils, one of which is wound at a 90-degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet, to which a shaft and pointer are attached, rotates to align to this primary field, resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which has two holes for dial mounting. There is no adjustment, calibration or maintenance required for these gauges. The instrument cluster amplifier is calibrated to the fuel gauge. The instrument cluster amplifier and fuel gauge must be replaced as a system. Instrument Cluster Gauge Amplifier/Check Gauge Module
The instrument cluster gauge amplifier electrically averages fuel sender readings so the fuel gauge displays actual fuel level and not fluctuations due to sloshing in fuel tank. The instrument cluster gauge amplifier is a small printed circuit board which latches into a pocket on the back of the instrument cluster. The electrical connections for ignition, ground, input from fuel sender and output to fuel gauge are made through a spring-type connector on the instrument cluster gauge amplifier to the instrument cluster printed circuit (10K843) on the instrument cluster. There are no provisions for calibration or adjustment of the instrument cluster gauge amplifier.
Fuel Sending Unit
The fuel sending unit consists of a variable screened resistor made up of a ceramic substrate. It is controlled by the action of an attached float in the fuel tank. When the fuel level is low, resistance in the sending unit is low. When the fuel level is high, the resistance in the sending unit is high. As the float moves from empty to full, the resistance will gradually and continuously increase. f9e3b50.gif

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Hello blackbearwhi,
I have repaired many GM instrument clusters and without question your issue is a failed instrument cluster. The particular item that is giving you the bad gauge readings is the stepper motor that drives each gauge.
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Hello Mcook389,
If you have above average soldering and de-soldering skills you can perform the repair yourself.
I have repaired many GM instrument clusters and without question this issue is affecting GM instrument cluster all over the country. The particular item that is giving you the bad gauge readings is the stepper motor that drives each gauge.
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go here for villager help.

http://groups.yahoo.com/group/villagerquest/

Section 13-01B: Instrument Cluster — Conventional 1996 Villager Workshop Manual
REMOVAL AND INSTALLATION Instrument Panel Finish Panel Removal
  1. Disconnect the battery ground cable (14301).
  1. Block the wheels (1007) to prevent the vehicle from moving.
  1. Turn the ignition switch (11572) to the OFF position.
  1. Shift the transmission range (TR) selector to MANUAL LOW (1).
  1. Tilt the steering wheel (3600) to the lowest position, if equipped with a tilt wheel.
  1. Remove the two instrument panel finish panel screws.
  1. Remove the instrument panel finish panel (044D70) enough to access the switch electrical connectors.
  1. Disconnect the rear windshield wiper/washer switch electrical connector.
  1. Disconnect the heated back window and light switch electrical connector.
  1. Disconnect the emergency warning switch electrical connector.
  1. Disconnect the SECURITY indicator light electrical connector.
  1. Disconnect the speed control on/off (CRUISE CONT. ON/OFF) switch electrical connector.
  1. Disconnect the headlamp switch electrical connector.
  1. Disconnect the autolamp/light switch rheostat resistor electrical connector.
  1. Remove the instrument panel finish panel with the switches attached.
-------------------------------------------------------------------------------------------------
Instrument Cluster
Removal
  1. Disconnect the battery ground cable (14301).
  1. Block the wheels (1007) to prevent the vehicle from moving.
  1. Turn the ignition switch (11572) to the OFF position.
  1. Shift the transmission range (TR) selector to MANUAL LOW (1).
  1. Tilt the steering wheel (3600) to the lowest position, if equipped with a tilt wheel.
  1. Remove the two instrument panel finish panel screws.
  1. Remove the instrument panel finish panel (044D70) enough to access the switch electrical connectors.
  1. Disconnect the rear windshield wiper/washer switch electrical connector.
  1. Disconnect the heated back window and light switch electrical connector.
  1. Disconnect the emergency warning switch electrical connector.
  1. Disconnect the SECURITY indicator light electrical connector.
  1. Disconnect the speed control on/off (CRUISE CONT. ON/OFF) switch electrical connector.
  1. Disconnect the headlamp switch electrical connector.
  1. Disconnect the autolamp/light switch rheostat resistor electrical connector.
  1. Remove the instrument panel finish panel with the switches attached.
  1. Remove the four instrument cluster screws.
  2. Remove the transmission range indicator (7A110) from the instrument cluster (10849).

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http://www.nissanpathfinders.com/Solution2.pdf

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