2003 FORD MUSTANG headlamp

PINPOINT TEST F: THE SAFETY BELT WARNING CHIME DOES NOT
OPERATE CORRECTLY z
Is the resistance less than 5 ohms? E8 TEST CIRCUIT 14 (BN) FOR SHORT TO BATTERY
z
Key in OFF position.
z Disconnect: GEM C201c.
z Set the headlamp switch in the OFF position. Measure the
voltage between GEM C201c pin 7, circuit 14 (BN),
harness side and ground.
z Is the voltage greater than 10 volts? Yes
REPAIR the circuit. REPEAT
the self-
test. CLEAR the
DTCs.
No
GO to E9 .
E9 CHECK FOR CORRECT MODULE OPERATION
z
Check:
zfor corrosion
z for pushed- out pins
z connector seated correctly
z Connect any disconnected connectors.
z Make sure all other system connectors are fully seated.
z Operate the system and verify the concern is still present.
z Is the concern still present? Yes
INSTALL a new GEM.
REFER to
Section 419 - 10 .
CLEAR the DTCs. REPEAT
the GEM self- test.
No
The system is operating
correctly at this time.
Concern may have been
caused by a loose or
corroded connector. CLEAR
the DTCs. REPEAT the self-
test. Test Step Result / Action to Take
F1 CHECK IGNITION STATES
NOTE:
Verify the belt minder is activated before
diagnosing.
z Connect the diagnostic tool.
z Enter the following diagnostic mode on the diagnostic tool:
GEM PID. Yes
GO to
F2 .
No
Go To Pinpoint Test B . Klj . 17 ba
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GENERAL PROCEDURES
Belt Minder Deactivating/Activating
Preparation
1. Before deactivating/activating the belt minder, set the parking brake.
2. Place the gearshift in P (Park) (automatic transmission) or the neutral position (manual transmission).
3. Place the ignition switch in the OFF position.
4. Close all the vehicle doors.
5. Unbuckle the driver safety belt.
6. Place the parklamps/headlamps switch in the OFF position. (If the vehicle is equipped with Autolamps, this will not affect the procedure.)
Deactivating/Activating 1. Turn the ignition switch to the RUN position. (Do not start the engine.)
2. Wait until the safety belt warning lamp turns off. (approximately one to two minutes)
3. NOTE: Steps 3 through 5 must be completed within 60 seconds or the procedure must be
repeated.
Buckle then unbuckle the safety belt three times, ending with the safety belt unbuckled. This
portion of the procedure can be done before or during belt minder warning activation.
4. Turn the parklamps/headlamps on then off.
5. Buckle then unbuckle the safety belt three times ending with the safety belt unbuckled. After this step the safety belt warning lamp will be illuminated for three seconds.
6. Within seven seconds of the safety belt warning lamp turning off, buckle then unbuckle the safety belt. This will enable the belt minder if disabled or disable the belt minder if enabled.
7. The following sequence of events confirm the belt minder is enabled: zflashing of the safety belt warning belt lamp four times per second for three seconds
z three seconds with the safety belt lamp off
z flashing the safety belt lamp four times per second for three seconds again
8. The safety belt lamp flashing four times per second for three seconds provides confirmation that the belt minder is disabled. 9. After confirmation, the deactivation/activation procedure is complete. SECTION 413-
09: Warning Devices 2003 Mustang Workshop Manual Klj . 1 ba
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PINPOINT TEST H: RADIO INTERFERENCE
Component Tests
Battery—Load Test
1. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam.
2. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage.
zIf the voltage does not increase as specified, carry out the Generator On- Vehicle Tests.
For additional information, refer to Generator On- Vehicle Tests in this section.
z If the voltage increases as specified, the charging system is operating normally. NOISE
z
Disconnect: Generator C102c (4.6L 4V) or
C102a (3.8L or 4.6L 2V).
z Key in START position.
z With the engine running, turn the headlights
on, rear defroster on, and the blower motor to
the HI position.
z Is the noise still present? Yes
GO to
G4 .
No
INSTALL a new generator. REFER to
Section 414 - 02 . TEST the system for
normal operation. G4 CHECK GENERATOR FOR MECHANICAL
NOISE z
Key in OFF position.
z Connect: Generator C102c (4.6L 4V) or C102a
(3.8L or 4.6L 2V).
z Key in START position.
z Turn all accessories off. With the engine
running, use a stethoscope or equivalent
listening device to probe the generator for
unusual mechanical noise.
z Is the generator the noise source? Yes
INSTALL a new generator. REFER to
Section 414
- 02 . TEST the system for
normal operation.
No
REFER to Section 303 - 00 to diagnose
the source of engine noise. Test Step Result / Action to Take
H1 VERIFY GENERATOR IS SOURCE OF
RADIO INTERFERENCE z
Key in START position.
z With the engine running, tune the radio to
a station where the interference is present.
z Key in OFF position.
z Disconnect: Generator C102c (4.6L 4V) or
C102a (3.8L or 4.6L 2V).
z Key in START position.
z With the engine running, note any radio
interference.
z Is the interference present with the
generator disconnected? Yes
REFER to
Section 415 - 00 for diagnosis and
testing of the in- vehicle entertainment
system.
No
INSTALL a new generator. REFER to
Section 414 - 02 . TEST the system for normal
operation. Klj . 10 ba
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4. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps
on high beam.
5. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage.
zIf the voltage does not increase as specified, carry out the Generator On- Vehicle Tests—
No Load Test. For additional information, refer to Generator On- Vehicle Tests in this
section.
z If the voltage increases as specified, the charging system is operating normally.
6. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the generator. Generator output should be at least 58 amps.
Generator On- Vehicle Tests— No Load Test
1. Switch the battery tester to the voltmeter function.
2. Connect the voltmeter positive lead to the generator B+ output terminal, circuit 38 (BK/OG) and the negative lead to ground.
3. Turn all electrical accessories off.
4. With the engine running at 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts. If not, refer to the Symptom Chart. Klj . 13 ba
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Pinpoint Tests speakers
zSubwoofer
amplifier.
z Circuitry. E .
z Poor quality sound from one or
more speakers (not all
speakers) z
Speaker(s).
z Circuitry.
z Audio unit.
z Subwoofer
amplifier. z
Go To Pinpoint Test F .
z Poor quality sound from all
speakers z
Audio unit.
z Speaker(s).
z Circuitry. z
Go To Pinpoint Test G .
z The subwoofer is inoperative zSubwoofer.
z Subwoofer
amplifier.
z Circuitry. z
Go To Pinpoint Test H .
z Loud popping when cycling the
ignition switch z
Audio unit.
z Circuitry. z
Go To Pinpoint Test I .
z One or more audio control
buttons (such as volume, seek,
tune and scan) are not
functional in either radio, tape,
or CD mode or all modes z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation.
z When the headlamp switch is in
park or headlamp position and
the ignition switch is in the RUN
or ACC position, the audio unit
back lighting is inoperative — all
other I/P lighting functions are
normal z
Circuitry.
z Audio unit. z
REFER to Section 413 - 00 .
z The audio unit has two items
that can be dimmed— the audio
unit display and the control
buttons; one dims and the other
does not z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation.
z Irregular operation of display
and indicator LEDs z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation.
z Response time between
pressing any of the audio
control buttons and system
response is more than two
seconds z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation. Klj . 3 ba
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DESCRIPTION AND OPERATION
Exterior Lighting
The exterior lighting system consists of the following components:
zheadlamps (13008)
z parking lamps
z rear lamps (13404)
z high mounted stoplamp
z license lamps
z front turn lamps
z reversing lamps
z fog lamps (if equipped)
z headlamp switch (11654)
z fog lamp switch (if equipped)
z brake pedal position (BPP) switch (13480)
z multifunction switch (13K359)
z digital transmission range (DTR) sensor (A/T)
z reversing lamp switch (M/T)
z electronic flasher
z fog lamp relays (if equipped)
SECTION 417-
01: Exterior Lighting 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Headlamps
Refer to Wiring Diagrams Cell
85 , Headlamps for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the headlamps.
2. Visually inspect for the following obvious signs of mechanical and electrical damage.
3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart.
Symptom Chart SECTION 417-
01: Exterior Lighting 2003 Mustang Workshop Manual Special Tool(s)
73III Automotive Meter or
equivalent
105-
R0057
Visual Inspection Chart Mechanical Electrical
z
Damaged headlamp switch (11654)
z Damaged multifunction switch (13K359) z
Battery junction box (BJB) fuse 2 (30A)
z Central junction box (CJB) fuse(s):
„38 (20A)
„ 4 (7.5A) (RH)
„ 10 (7.5A) (LH)
z Damaged wiring harness
z Loose or corroded connections
z Headlamp bulb
Symptom Chart Condition
Possible Sources Action
z Both
headlamps are
inoperative z
Battery junction
box (BJB) fuse 2
(30A).
z Headlamp
switch.
z Circuitry.
z Multifunction
switch. z
Go To Pinpoint Test A .
z The low beams
are inoperative z
Circuitry.
z Multifunction
switch. z
Go To Pinpoint Test B . Klj . 1 ba
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Pinpoint Tests
PINPOINT TEST A: BOTH HEADLAMPS ARE INOPERATIVE z
The high beams
are inoperative z
Central junction
box (CJB) fuse
38 (20A).
z Circuitry.
z Multifunction
switch. z
Go To Pinpoint Test C .
z One low beam
headlamp is
inoperative z
Central junction
box (CJB) fuse
(s):
„10 (7.5A)
(LH).
„ 4 (7.5A)
(RH).
z Headlamp bulb.
z Circuitry. z
Go To Pinpoint Test D .
z One high beam
headlamp is
inoperative z
Headlamp bulb.
z Circuitry. z
Go To Pinpoint Test E .
z The headlamps
are on
continuously z
Headlamp
switch.
z Circuitry.
z Multifunction
switch. z
Go To Pinpoint Test F .
z The flash- to-
pass feature is
inoperative z
Circuitry.
z Multifunction
switch. z
CHECK Circuit 196 (DB/OG) for
an open. REPAIR if necessary. IF
OK, INSTALL a new multifunction
switch; REFER to Section 211 -
05 . TEST the system for normal
operation. Test Step Result / Action to Take
A1 CHECK THE VOLTAGE TO THE HEADLAMP SWITCH
z
Disconnect: Headlamp Switch C205.
z Measure the voltage between headlamp switch C205 Pin
B1, Circuit 196 (DB/OG), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
A2 .
No
REPAIR the circuit. TEST
the system for normal
operation. A2 CHECK CIRCUIT 15 (RD/YE) FOR OPEN
z
Disconnect: Multifunction Switch C202a. Yes Klj . 2 ba
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