Headlights (cars up to 08.2001) — Pinpoint tests (Focus 1)

A1: CHECK FUSE F61

1Enter the OFF position.

2CHECK Fuse F61 (CJB).

3CHECK FUSE F61 (7.5A)

• Is the fuse good?

→ Yes

Go to A2

→ No

Install a new fuse F61 (7.5 A). If the fuse blows again, LOCATE and REPAIR the short circuit using the wiring diagrams. Check for proper system operation.

A2: CHECK POWER SUPPLY TO FUSE F61

1Connect Fuse F61 (CJB).

2Enter the ON position.

3Measure the voltage between fuse F61 and ground.

• Is battery voltage registered?

→ Yes

Vehicles with daytime running lights: Go to A4

Vehicles without daytime running lights: Go to A3

→ No

RESTORE the power supply to fuse F61 using the wiring diagrams. Check that the system operates correctly. If the fault persists, CHECK the CJB. If necessary, INSTALL a new component. Check that the system operates correctly.

A3: CHECK POWER SUPPLY OF LOW BEAM RELAY AND HIGH BEAM RELAY

1Enter the OFF position.

2Disconnect the Headlight Low Beam Relay - C1006.

3Enter the ON position.

4Measure the voltage between pin 3 C1006 of the headlamp low beam relay socket, circuit 30-LE20 (RED) and ground.

• Is battery voltage registered?

→ Yes

Go to A4

→ No

RESTORE power to the relay between the battery and the S102 connection using the wiring diagrams. Check that the system is operating correctly.

A4: CHECK COMMON GROUND CONNECTION OF LOW BEAM RELAY AND HIGH BEAM RELAY

1Enter the OFF position.

2Measure the resistance between pin 2 C1006 of the headlamp low beam relay socket, circuit 91-LE19 (BK/BU) and ground.

• Is the resistance less than 2 ohms?

→ Yes

Go to A5

→ No

RESTORE the ground connection of the relay between connection S118 and ground G1 using the wiring diagrams. Check the correct operation of the system.

A5: CHECK THE POWER SUPPLY OF THE MULTI-FUNCTION SWITCH

1Enter the OFF position.

2Disconnect the Multifunction Switch - C459.

3Enter the ON position.

4Turn the light switch to the "LOW BEAM" position.

5Measure the voltage between pin 8 C459 of the multifunction switch, circuit 15S-LE14 (green/red), harness side and ground.

• Is battery voltage registered?

→ Yes

TEST the multifunction switch according to the component testing descriptions included with the wiring diagrams. If necessary, INSTALL a new component. Check that the system operates correctly.

→ No

Go to A6

A6: CHECK THE POWER SUPPLY TO THE LIGHT SWITCH

1Enter the OFF position.

2Disconnect Light Switch - C320.

3Enter the ON position.

4Measure the voltage between light switch pin 8 C320, circuit 15-LE29 (Green/Black), harness side and ground.

• Is battery voltage registered?

→ Yes

Go to A7

→ No

RESTORE the power supply to the light switch between fuse F61 and the light switch using the wiring diagrams. If necessary, INSTALL a new CJB. Check that the system operates correctly.

A7: CHECK LIGHT SWITCH

1CHECK the light switch according to the component testing description included with the wiring diagrams.

• Is the light switch working properly?

→ Yes

REPAIR open circuit 15S-LE14 (green/red) between light switch and multifunction switch using wiring diagrams. Check for proper system operation.

→ No

INSTALL a new light switch. Check that the system operates correctly.

B1: CHECK LOW BEAM RELAY

1Enter the OFF position.

2Disconnect the Headlight Low Beam Relay - C1006.

3CHECK the low beam headlamp relay according to the component testing description included with the wiring diagrams.

• Is the relay working properly?

→ Yes

Go to B2

→ No

INSTALL a new low beam relay. Check that the system is operating correctly.

B2: CHECK POWER SUPPLY OF THE LOW BEAM RELAY

1Measure the voltage between pin 3 C1006 of the headlamp low beam relay socket, circuit 30-LE20 (RED) and ground.

• Is battery voltage registered?

→ Yes

Go to B3

→ No

RESTORE the power supply to the low beam relay using the wiring diagrams. Check that the system is working properly.

B3: CHECK BJB

1Enter the OFF position.

2Connect the jumper wire to connector C1006 of the low beam headlamp relay socket, between pin 3, circuit 30-LE20 (red), and pin 5, circuit 15S-LE20 (green/red).

3Enter the ON position.

4Check the low beam headlights.

• Are the low beam headlights on?

→ Yes

Go to B4

→ No

Check BJB If necessary, INSTALL a new element. Check that the system is working properly.

B4: CHECK GROUND CONNECTION OF LOW BEAM RELAY

1Enter the OFF position.

2Measure the resistance between pin 2 C1006 of the headlamp low beam relay socket, circuit 91-LE19 (BK/BU) and ground.

• Is the resistance less than 2 ohms?

→ Yes

Go to B5

→ No

RESTORE the ground between the low beam relay and the S118 connection using the wiring diagrams. Check that the system is operating correctly.

B5: CHECK LOW BEAM RELAY CONTROL CIRCUIT

1Disconnect the Turn Signal Switch - C459.

2Measure the resistance between pin 9 C459 of the turn signal switch, circuit 15S-LE19 (GN/BL), harness side and pin 1 C1006 of the headlamp low beam relay socket, circuit 15S-LE19 (GN/BL).

• Is the resistance less than 2 ohms?

→ Yes

CHECK the turn signal switch according to the component testing descriptions included with the wiring diagrams. If necessary, INSTALL a new component. Check the system for proper operation.

→ No

REPAIR open circuit 15S-LE19 (Green/Blue) between turn signal switch and low beam relay using the wiring diagrams. Check for proper system operation.

C1: CHECK HIGH BEAM RELAY

1Enter the OFF position.

2Disconnect the Headlight High Beam Relay - C1005.

3CHECK the high beam relay according to the component testing description included with the wiring diagrams.

• Is the relay working properly?

→ Yes

Go to C2

→ No

INSTALL a new high beam relay. Check that the system is operating correctly.

C2: CHECK POWER SUPPLY OF THE HEADLIGHT HIGH BEAM RELAY

1Measure the voltage between pin 3 C1005 of the headlamp high beam relay socket, circuit 30-LE12 (RED) and ground.

• Is battery voltage registered?

→ Yes

Go to C3

→ No

RESTORE the power supply to the high beam relay using the wiring diagrams. Check that the system is working properly.

C3: CHECK BJB

1Enter the OFF position.

2Connect the jumper wire to connector C1005 of the headlamp high beam relay socket, between pin 3, circuit 30-LE12 (red), and pin 5, circuit(s) 15S-DC26 (green/blue), 15S-DC27 (green/blue).

3Enter the ON position.

4Check the high beam headlights.

• Are the high beam headlights on?

→ Yes

Go to C4

→ No

Check BJB If necessary, INSTALL a new element. Check that the system is working properly.

C4: CHECK GROUND CONNECTION OF HIGH BEAM RELAY

1Enter the OFF position.

2Measure the resistance between pin 2 of the headlamp high beam relay socket C1005, circuit 91-LE12 (BK/YE) and ground.

• Is the resistance less than 2 ohms?

→ Yes

Go to C5

→ No

RESTORE the ground between the high beam relay and the S118 connection using the wiring diagrams. Check for proper system operation.

C5: CHECK HEADLAMP HIGH BEAM RELAY CONTROL CIRCUIT

1Disconnect the Turn Signal Switch - C459.

2Measure the resistance between pin 7 of the turn signal switch C459, circuit 15S-LE12 (green/yellow), harness side and pin 1 of the headlamp high beam relay socket, circuit 15S-LE12 (green/yellow).

• Is the resistance less than 2 ohms?

→ Yes

CHECK the turn signal switch according to the component testing descriptions included with the wiring diagrams. If necessary, INSTALL a new component. Check the system for proper operation.

→ No

REPAIR open circuit 15S-LE12 (Green/Yellow) between turn signal switch and high beam relay using the wiring diagrams. Check for proper system operation.

D1: IDENTIFY THE HEADLIGHT THAT DOESN'T WORK IN LOW BEAM MODE

1Enter the ON position.

2Turn the light switch to the "LOW BEAM" position.

3Check the low beam headlights

• Is the left headlight on in low beam mode?

→ Yes

Go to D5

→ No

Go to D2

D2: CHECK FUSE F16

1Enter the OFF position.

2CHECK Fuse F16 (BJB).

3CHECK FUSE F16 (10A)

• Is the fuse good?

→ Yes

Go to D3

→ No

Install a new fuse F16 (10 A). If the fuse blows again, LOCATE and REPAIR the short circuit using the wiring diagrams. Check for proper system operation.

D3: CHECK POWER SUPPLY TO FUSE F16

1Connect Fuse F16 (BJB).

2Enter the ON position.

3Turn the light switch to the "LOW BEAM" position.

4Measure the voltage between fuse F16 and ground.

• Is battery voltage registered?

→ Yes

Go to D4

→ No

RESTORE power to fuse F16 using the wiring diagrams. Check that the system is working properly.

D4: CHECK THE POWER SUPPLY OF THE LEFT HEADLIGHT

1Enter the OFF position.

2Disconnect Headlight, Left Side - C835.

3Enter the ON position.

4Turn the light switch to the "LOW BEAM" position.

5Measure the voltage between pin 7 C835 headlamp, left side, circuit 15S-LE16 (green/orange), harness side and ground.

• Is battery voltage registered?

→ Yes

CHECK headlight, left side. If necessary, INSTALL a new element. Check that the system is operating correctly.

→ No

REPAIR open circuit 15S-LE16 (green/orange) between fuse F16 and headlamp, left side using the wiring diagrams. Check for proper system operation.

D5: CHECK FUSE F17

1Enter the OFF position.

2CHECK Fuse F17 (BJB).

3CHECK FUSE F17 (10A)

• Is the fuse good?

→ Yes

Go to D6

→ No

Install a new fuse F17 (10 A). If the fuse blows again, LOCATE and REPAIR the short circuit using the wiring diagrams. Check for proper system operation.

D6: CHECK POWER SUPPLY TO FUSE F17

1Connect Fuse F17 (BJB).

2Enter the ON position.

3Turn the light switch to the "LOW BEAM" position.

4Measure the voltage between fuse F17 and ground.

• Is battery voltage registered?

→ Yes

Go to D7

→ No

RESTORE the power supply to fuse F17 using the wiring diagrams. Check that the system is working properly.

D7: CHECK THE POWER SUPPLY OF THE RIGHT HEADLIGHT

1Enter the OFF position.

2Disconnect Headlight, Right Side - C834.

3Enter the ON position.

4Turn the light switch to the "LOW BEAM" position.

5Measure the voltage between pin 7 C834 headlamp, right side, circuit 15S-LE23 (green/white), harness side and ground.

• Is battery voltage registered?

→ Yes

CHECK headlight, right side. If necessary, INSTALL a new element. Check that the system is working properly.

→ No

REPAIR open circuit 15S-LE23 (Green/White) between fuse F17 and headlamp, right side using the wiring diagrams. Check for proper system operation.

E1: IDENTIFY THE HEADLIGHT THAT DOES NOT WORK IN HIGH BEAM MODE

1Enter the ON position.

2Turn the light switch to the "LOW BEAM" position.

3Turn the turn signal switch to the HIGH BEAM position.

4Check the high beam headlights.

• Is the left headlight on high beam?

→ Yes

Go to E5

→ No

Go to E2

E2: CHECK FUSE F26

1Enter the OFF position.

2CHECK Fuse F26 (BJB).

3CHECK FUSE F26 (10A)

• Is the fuse good?

→ Yes

Go to E3

→ No

Install a new fuse F26 (10 A). If the fuse blows again, LOCATE and REPAIR the short circuit using the wiring diagrams. Check the system for proper operation.

E3: CHECK POWER SUPPLY TO FUSE F26

1Connect Fuse F26 (BJB).

2Enter the ON position.

3Turn the light switch to the "LOW BEAM" position.

4Turn the turn signal switch to the HIGH BEAM position.

5Measure the voltage between fuse F26 and ground.

• Is battery voltage registered?

→ Yes

Go to E4

→ No

RESTORE the power supply to fuse F26 using the wiring diagrams. Check that the system is working properly.

E4: CHECK THE POWER SUPPLY OF THE LEFT HEADLIGHT

1Enter the OFF position.

2Disconnect Headlight, Left Side - C835.

3Enter the ON position.

4Turn the light switch to the "LOW BEAM" position.

5Turn the turn signal switch to the HIGH BEAM position.

6Measure the voltage between pin 6 C835 headlamp, left side, circuit 15S-LE15 (GN/BLK), harness side and ground.

• Is battery voltage registered?

→ Yes

CHECK headlight, left side. If necessary, INSTALL a new element. Check that the system is operating correctly.

→ No

REPAIR open circuit 15S-LE15 (Green/Black) between fuse F26 and headlamp, left side using the wiring diagrams. Check for proper system operation.

E5: CHECK FUSE F27

1Enter the OFF position.

2CHECK Fuse F27 (BJB).

3CHECK FUSE F27 (10A)

• Is the fuse good?

→ Yes

Go to E6

→ No

Install a new fuse F27 (10 A). If the fuse blows again, LOCATE and REPAIR the short circuit using the wiring diagrams. Check the system for proper operation.

E6: CHECK POWER SUPPLY TO FUSE F27 (BJB)

1Connect Fuse F27 (BJB).

2Enter the ON position.

3Turn the light switch to the "LOW BEAM" position.

4Turn the turn signal switch to the HIGH BEAM position.

5Measure the voltage between fuse F27 and ground.

• Is battery voltage registered?

→ Yes

Go to E7

→ No

RESTORE the power supply to fuse F27 using the wiring diagrams. Check that the system is working properly.

E7: CHECK THE POWER SUPPLY OF THE RIGHT HEADLIGHT

1Enter the OFF position.

2Disconnect Headlight, Right Side - C834.

3Enter the ON position.

4Turn the light switch to the "LOW BEAM" position.

5Turn the turn signal switch to the HIGH BEAM position.

6Measure the voltage between pin 6 C834 headlamp, right side, circuit 15S-LE22 (green/orange), harness side and ground.

• Is battery voltage registered?

→ Yes

CHECK headlight, right side. If necessary, INSTALL a new element. Check that the system is working properly.

→ No

REPAIR open circuit 15S-LE22 (green/orange) between fuse F27 and headlamp, right side using the wiring diagrams. Check for proper system operation.

F1: DETERMINE THE STATE IN WHICH THE MALFUNCTION OCCURS.

1Enter the ON position.

2Turn the light switch to the "OFF" position.

3Check the high beam headlights.

• Are the high beam headlights on?

→ Yes

Go to F7

→ No

Low beam headlights on: Go to F2

F2: LOCATE THE LOCATION OF THE POWER SUPPLY SHORT CIRCUIT

1Enter the OFF position.

2Disconnect the Headlight Low Beam Relay - C1006.

3Enter the ON position.

4Turn the light switch to the "OFF" position.

5Check the low beam headlights.

• Are the low beam headlights on?

→ Yes

Go to F3

→ No

Go to F4

F3: LOCATE THE LOCATION OF THE POWER SUPPLY SHORT CIRCUIT

1Enter the OFF position.

2Disconnect Fuse F16 (BJB).

3Disconnect Fuse F17 (BJB).

4Enter the ON position.

5Check the low beam headlights.

• Is one of the headlights on low beam?

→ Yes

Left headlight illuminates in low beam mode: REPAIR short to power in circuit 15S-LE16 (green/orange) between fuse F16 and headlight, left side using the wiring diagrams. Check for proper system operation.

Right headlight illuminates in low beam mode: REPAIR short to power in circuit 15S-LE15 (Green/Black) between fuse F17 and headlight, right side using the Wiring Diagrams. CHECK for proper system operation.

→ No

Check BJB If necessary, INSTALL a new element. CHECK the system is working properly.

F4: CHECK LOW BEAM RELAY

1CHECK the low beam headlamp relay according to the component testing description included with the wiring diagrams.

• Is the relay working properly?

→ Yes

Go to F5

→ No

INSTALL a new low beam relay. CHECK the system for proper operation.

F5: CHECK LOW BEAM RELAY CONTROL CIRCUIT FOR SHORT TO POWER SUPPLY

1Enter the OFF position.

2Connect the Low Beam Headlight Relay - C1006.

3Enter the ON position.

4Turn the light switch to the "OFF" position.

5Turn the turn signal switch to the HIGH BEAM position.

6Check the low beam headlights.

• Are the low beam headlights on?

→ Yes

REPAIR the short to power in circuit 15S-LE19 (GN/BU) between the low beam relay and the turn signal switch using the wiring diagrams. CHECK the system for proper operation. If the fault persists, CHECK the turn signal switch. INSTALL a new component if necessary.

→ No

Go to F6

F6: CHECK LIGHT SWITCH

1Enter the OFF position.

2Disconnect Light Switch - C320.

3Enter the ON position.

4Turn the turn signal switch to neutral position.

5Check the low beam headlights.

• Are the low beam headlights on?

→ Yes

REPAIR the short to power in circuit 15S-LE14 (Green/Red) connected to the light switch using the wiring diagrams. CHECK the system for proper operation.

→ No

TEST the light switch according to the component testing descriptions included with the wiring diagrams. If necessary, INSTALL a new component. TEST the system for proper operation.

F7: DETERMINE THE STATE IN WHICH THE HIGH BEAM HEADLIGHT FAILURE OCCURRES

1Enter the OFF position.

2Disconnect the Headlight High Beam Relay - C1005.

3Enter the ON position.

4Check the high beam headlights.

• Are the high beam headlights on?

→ Yes

Go to F8

→ No

Go to F9

F8: LOCATE THE LOCATION OF THE POWER SUPPLY SHORT CIRCUIT

1Enter the OFF position.

2Disconnect Fuse F26 (BJB).

3Disconnect Fuse F27 (BJB).

4Enter the ON position.

5Check the high beam headlights.

• Is one of the headlights on high beam?

→ Yes

Left headlight illuminates in high beam mode: REPAIR the short to power in circuit 15S-LE15 (green/black) connected to headlight, left side using the Wiring Diagrams. CHECK the system for proper operation.

Right headlight illuminates in high beam mode: REPAIR the short to power in circuit 15S-LE22 (green/orange) connected to headlight, right side using the wiring diagrams. CHECK the system for proper operation.

→ No

None of the headlights illuminate in high beam mode: CHECK the BJB. If necessary, INSTALL a new element. CHECK the system is operating correctly.

F9: CHECK HIGH BEAM RELAY

1CHECK the high beam relay according to the component testing description included with the wiring diagrams.

• Is the relay working properly?

→ Yes

Go to F10

→ No

INSTALL a new high beam relay. CHECK the system for proper operation.

F10: CHECK HEADLAMP HIGH BEAM RELAY CONTROL CIRCUIT FOR SHORT TO POWER SUPPLY

1Enter the OFF position.

2Connect the High Beam Relay - C1005.

3Disconnect the Turn Signal Switch - C459.

4Enter the ON position.

5Check the high beam headlights.

• Are the high beam headlights on?

→ Yes

REPAIR the short to power in the circuit(s) connected to pin 1 of the C1005 Headlamp High Beam Relay using the wiring diagrams. CHECK the system for proper operation.

→ No

Check the turn signal switch. If necessary, INSTALL a new component. CHECK the system for proper operation.

G1: DETERMINE THE STATE IN WHICH THE MALFUNCTION OCCURS.

1Enter the ON position.

2Check the high beam headlights.

• Are the high beam headlights on?

→ Yes

Go to G2

→ No

Proceed to PINPOINT TEST C

G2: CHECK POWER SUPPLY TO TURN SIGNAL SWITCH

1Enter the OFF position.

2Disconnect the Turn Signal Switch - C459.

3Enter the ON position.

4Measure the voltage between turn signal switch pin 6 C459, circuit 15-LE14 (green/red), harness side and ground.

• Is battery voltage registered?

→ Yes

INSTALL a new turn signal switch. Check that the system operates correctly.

→ No

REPAIR open circuit 15-LE14 (Green/Red) between fuse F61 and turn signal switch using the wiring diagrams. Check for proper system operation.