2003 FORD MUSTANG headlamp

DIAGNOSIS AND TESTING
Fog Lamps
Refer to Wiring Diagrams Cell
86 , Fog Lamps for schematic and connector information.
Principles of Operation
The fog lamps will only illuminate when the low beam or parking lamps are illuminated. Voltage from
the parking lamp circuit is used to activate the fog lamp relay when the fog lamp switch is ON. Voltage
from the high beam headlamp circuit will activate the fog lamp interrupt relay. When the fog lamp
interrupt relay is active, the ground path is removed from the fog lamp relay, turning off the fog lamps.
Inspection and Verification 1. Verify the customer concern by operating the fog lamps.
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)
73 III Automotive Meter or
equivalent
105-
R0057
Visual Inspection Chart Mechanical Electrical
z
Damaged headlamp switch (11654)
z Damaged fog lamp switch
z Damaged multifunction switch
(13K359) z
Blown battery junction box (BJB) Fuse 27
(20A)
z Blown central junction box (CJB) Fuse 38
(20A)
z Damaged wiring harness
z Loose or corroded connections
z Damaged fog lamp relay
z Damaged fog lamp interrupt relay
z Damaged fog lamp
Symptom Chart Klj . 1 ba
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Pinpoint Tests
PINPOINT TEST O: THE FOG LAMPS ARE INOPERATIVE Condition
Possible Sources Action
z The fog lamps are
inoperative z
BJB Fuse 27 (20A).
z CJB Fuse 38 (20A).
z Circuitry.
z Fog lamp relay.
z Fog lamp interrupt
relay.
z Headlamp switch.
z Fog lamp switch.
z Multifunction switch. z
GO to Pinpoint Test O .
z The individual fog lamp is
inoperative z
Fog lamp bulb.
z Circuitry. z
GO to Pinpoint Test P .
z The fog lamps are on
continuously z
Fog lamp relay.
z Circuitry.
z Fog lamp switch. z
GO to Pinpoint Test Q .
Test Step Result / Action
to Take O1 CHECK THE PARK LAMPS
z
Place the headlamp switch in the PARK position.
z Place the multifunction switch in low beam position.
z Do the park lamps illuminate? Yes
Turn off the
headlamp switch.
GO to
O2 .
No
GO to Pinpoint Test L .
O2 CHECK THE FOG LAMP RELAYS
z
Disconnect: Fog Lamp Relay.
z Disconnect: Fog Lamp Interrupt Relay.
z Check the fog lamp relay and fog lamp interrupt relay; refer to Wiring
Diagrams Cell 149.
z Are the relays OK? Yes
GO to
O3 .
No
INSTALL new
relay(s). TEST
the system for
normal
operation. O3 CHECK THE CIRCUIT 12 (LG/BK)
z
Measure the voltage between fog lamp interrupt relay connector Pin 1,
Circuit 12 (LG/BK), harness side and ground. Yes
GO to
O4 .
No
REPAIR the
circuit. TEST the
system for
normal
operation. Klj . 2 ba
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GENERAL PROCEDURES
Headlamp Adjustment
Headlamp Aiming
1. The headlamp aiming procedure depends on the type of beam pattern the headlamp is equipped with. Vehicles may come equipped with visual optical right (VOR), visual optical left
(VOL), or SAE only (includes sealed beam type) headlamps. To identify the headlamp beam
pattern, look on the headlamp lens. Molded in small letters on the headlamp lens is one of the
following:
zSAE
z VOR or SAE
z VOL or SAE
2. Once the headlamp beam pattern is identified, aim the headlamps using one of the following methods as applicable.
zPhotometric aimers can aim SAE, VOR and VOL type headlamps. This is the preferred
method of headlamp aiming.
z Visual or screen method aiming can be used to aim SAE, VOR and VOL type
headlamps.
z Mechanical aimers can be used only with SAE type headlamps. Lamps that can be
aimed mechanically will have three nibs molded into the lens of the lamp.
Photometric Aiming 1. For the photometric aiming procedure, refer to the appropriate photometric headlamp aimer instruction manual.
Screen Method Aiming
All headlamp types
NOTE: Horizontal aim is not necessary for VOR or VOL headlamps.
NOTE: Consult your state vehicle inspection manual for recommended tolerance ranges for visual
aiming.
NOTE: The sight shield may need to be positioned or removed for access to the adjusters.
1. Before starting headlamp adjustment: zCheck the tire inflation.
z Check that no other load is in the vehicle other than a half tank of fuel.
z Check that the headlamps are clean.
z Check for correct headlamp operation.
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z
Check that the vehicle is on level ground.
z If the vehicle is equipped with air suspension, make sure that the switch is on.
2. NOTE: The vertical wall or screen must be a minimum of 2.4 meters (8 feet) wide.
Park the vehicle on a level surface approximately 7.6 meters (25 feet) from the vertical wall or
screen directly in front of it.
3. NOTE: The center of the lamp is marked by a 3 mm (0.12 in) circle on the headlamp lens.
Mark a horizontal reference line on the vertical wall or screen. 1. Measure the center of the headlamp height to ground and record.
2. Make a 2.4 meter (8 foot) horizontal mark (masking tape) on the vertical wall or screen at the same distance from the ground as previously recorded.
4. NOTE: This procedure should be done in a dark environment to effectively see the headlamp
beam pattern.
Turn on the low beam headlamps to illuminate the wall or screen and open the hood.
5. NOTE: For SAE type headlamps, the appearance of the beam pattern may vary between
vehicles.
On the wall or screen, locate the high intensity area of the beam pattern. Place the top edge of
the high intensity zone even with the horizontal reference line.
VOR type headlamps 6. NOTE: The appearance of the VOR beam pattern may vary between vehicles.
Identify at the top edge of this high intensity area a distinct horizontal cutoff in the beam pattern.
If the top edge of this cutoff is not even with the horizontal reference line, the headlamp beam will need to be adjusted. Klj . 2 ba
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VOL type headlamps
7. For VOL type headlamps, there will be a distinct cutoff in the left portion of the beam pattern. The edge of this cutoff should be positioned 50.2 mm (2 in) below the horizontal reference line.
1. Horizontal reference line.
2. Top edge of the beam pattern.
3. High intensity zone.
Mechanical Aiming 1. For the mechanical aiming procedure, refer to the appropriate mechanical headlamp aimer instruction manual. Klj . 3 ba
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REMOVAL AND INSTALLATION
Bulb —
Headlamp
Removal
WARNING: The halogen bulb contains gas under pressure. The bulb may shatter if the
glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Grasp
the bulb only by its base. Avoid touching the glass envelope.
NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement
bulb is installed. Removing the bulb for an extended period of time may effect headlamp bulb
performance. Contaminants may enter the headlamp where they can settle on the lens and reflector.
Never turn on the headlamps with the bulb removed.
1. Remove the headlamp assembly. For additional information, refer to Lamp Assembly —
Headlamp .
2. Rotate the headlamp bulb retainer counterclockwise.
3. Remove the headlamp bulb and retainer. zGrasp the headlamp bulb by its base and remove the bulb.
Installation 1. WARNING: The halogen bulb contains gas under pressure. The bulb may shatter if
the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its
base. Grasp the bulb only by its base. Avoid touching the glass envelope.
To install, reverse the removal procedure.
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REMOVAL AND INSTALLATION
Lamp Assembly —
Headlamp
Removal 1. NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position.
Raise the headlamp retainers.
2. Remove the headlamp assembly. zDisconnect the electrical connectors and replace the lamp if necessary.
Installation 1. To install, reverse the removal procedure. zIf necessary, adjust the headlamps. For additional information, refer to Headlamp Adjustment in this section.
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REMOVAL AND INSTALLATION
Lamp Switch —
Headlamp
Removal 1. Disconnect the battery ground cable.
2. Remove the headlamp switch knob. 1. Pull the headlamp switch knob out.
2. Insert a thin tool into the slot, pull and remove the headlamp switch knob.
3. Remove the instrument panel cluster finish panel. zRemove the screws and remove the finish panel.
4. Remove the headlamp switch. 1. Remove the screws.
2. Remove the switch.
3. Disconnect the electrical connectors.
SECTION 417-
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22003 Mustang Workshop Manual
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