GM Service Manual Online
For 1990-2009 cars only

Cluster Assembly

The Instrument Panel (IP) Cluster Assembly receives power from either one or two IP Fuse Block sources. If Automatic Transmission, power runs from the TRANS fuse 20, through CKT 1020 (PNK) to pin 7 of the IP Cluster connector. If Manual Transmission, power runs from the GAUGES fuse 4, through CKT 39 (PNK) to pin 7 of the IP Cluster connector. In both cases, the GAUGES fuse 4 supplies power to pin 22 of the IP Cluster connector.

Power coming in through pin 7 of the IP Cluster supplies voltage to the Tachometer, Electric Speedometer, PRNDL Indicator, and the Check Gauges Lamp Driver. Pin 22 of the IP Cluster carries power to the remaining components within the IP Cluster Assembly:

Ground for the IP Cluster Assembly goes through two pins. One is pin 4, the other is pin 31. Both run to splice S215 and onto ground G104 and G103 (Gas Only).

Fuel Gauge

Magnetic fields of two coils moves the pointer of the fuel gauge. The coils are at right angles to each other. Battery voltage is applied to the E-coil (empty) and the circuit divides at the opposite end of the coil. One path continues to ground through the F-coil (full). Another path goes through CKT 30 (PPL) to ground on single tanks using the variable resistance of the level sensor in the fuel pump and sender (Gasoline) or the fuel gauge sender (Diesel). On dual tank vehicles, CKT 30 (PPL) passes resistance from either the Vehicle Control Module (VCM) (Gas) or the Fuel Pump Balance Module (Diesel).

On gasoline vehicles with dual tanks, the VCM sends a 5 volt reference through CKT 474 (GRY) to the Fuel Pump Balance Module. The Fuel Pump Balance Module sends out a fuel level signal to the senders through either CKT 970 (DK BLU/WHT) for the Primary Sender and CKT 975 (LT BLU) for the Secondary Sender. Ground for both senders runs through CKT 900 (BLK) to the VCM. The Fuel Pump Balance Module will send the return voltage to the VCM through CKT 1589 (PPL/WHT) and the VCM will send the signal onto the Fuel Gauge through CKT 30 (PPL). The fuel pump balance module averages the resistance for vehicles with two fuel tanks. When the tank is low, the resistance of the level sensor is low. A large current flow passes through the E-coil and the pointer moves toward E on the fuel gauge. When the tank is full, the level sensor resistance is high, and less current passes through the E-coil, and the pointer moves toward F on the scale. With two coils operating the pointer, the fuel gauge is not affected by changes in the system's battery voltage.

On diesel vehicles with dual tanks, CKT 30 (PPL) runs directly to the Fuel Pump Balance Module. Grounds for the two fuel tank senders run directly to G104. The remainder of the operation is the same as gasoline.

For single fuel tank vehicles, the fuel gauge includes the following functions:

    • The level sensor in the fuel gauge sender produces a resistance of about 40 ohms (Gas)/0 ohms (Diesel) empty and about 250 ohms (Gas)/90 ohms (Diesel) full.
    • A short to ground in the sender or the wiring provides a fully empty indication.
    • An open in the circuit provides completely full indication.

For dual fuel tank vehicles, the fuel pump balance module does the following functions:

    • Measures the resistance for both of the fuel senders. Resistance is the same as single tank units.
    • Averages the resistance and produces an equivalent resistance that reflects the average level of both fuel tanks.
    • Power to the module, and a change in the input resistance, produces a change in the output resistance to the fuel gauge.
    • The fuel pump balance module responds to a very low resistance (short to ground) in one or both fuel sender circuits by considering the affected tank(s) to be empty.
    • A very high resistance (open circuit) in either fuel sender circuit causes the fuel pump balance module to produce a zero output (both tanks empty) signal to the fuel gauge.
    • Equalizes the level in both of the fuel tanks. Fuel is fed to the engine from the front (primary) fuel tank.
    • Energizes the fuel pump balance relay when the level in the front tank decreases to about two gallons less than the level in the rear (secondary) fuel tank. This starts the secondary fuel pump which transfers fuel from the rear tank to the front tank.

When the level in the front tank increases to about two gallons greater than the rear tank, the secondary fuel pump stops. This then empties the rear tank first.

Oil Pressure Gauge

The oil pressure gauge displays the engine oil pressure. Current flow through two coils moves the pointer of the gauge and is similar in operation to the fuel gauge. The oil pressure sender senses engine oil pressure sending resistance through CKT 31 (TAN) to pin 15 of the I/P Cluster.

The oil sender has a low resistance (approximately 0 ohms) when the oil pressure is low (0 psi), and a high resistance (approximately 90 ohms) when the oil pressure is high (80 psi).

Temperature Gauge

The temperature gauge displays the engine coolant temperature. Current flow through two coils moves the pointer of the gauge and is similar in operation to the fuel gauge. The engine coolant temperature sender sends resistance through CKT 35 (DK GRN) to pin 13 of the IP Cluster.

The engine coolant temperature sender has low resistance at higher temperatures. The sender has a resistance of approximately 49.5 ohms at 123°C (260°F). The sender resistance increases at lower temperatures and is approximately 1305 ohms at 47°C (100°F). This causes the current through the sensor to increase as the coolant temperature increases and the temperature gauge pointer then moves toward the hot end of the gauge.

Voltmeter

The voltmeter measures the electrical system's voltage when the ignition switch is in the RUN or START position. The voltmeter measures battery voltage when supplied to the instrument cluster.

With the engine running, the normal reading is between 12-16 volts. The indication may decrease to 9.5 volts in cold weather with the engine stopped and ignition in the RUN position.

Speedometer and Odometer

The Speedometer, grounded through the I/P Cluster ground circuit, receives its speed signal from either the VCM (Gas) or PCM (Diesel) through CKT 389 (DK GRN), which connects to the IP Cluster at pin 14.

Tachometer

The tachometer, also utilizing the IP Clusters ground, displays the engine speed in revolutions per minute (RPM). Voltage pulses are taken from the ignition control (Gasoline) or the generator (Diesel) through CKT 121 (WHT) and sent to the tachometer through pin 6 of the I/P Cluster. Solid state circuits convert the pulse frequency in order to move the pointer of the tachometer.