| Diagnosis and Testing Refer to Wiring Diagrams Section 417-01, for schematic and connector information. Special Tool(s) | | Terminal Probe Kit 29-011A | Inspection and Checking NOTE:The generic electronic module (GEM) forms part of the central junction box (CJB). NOTE:If the powertrain control module (PCM) is changed, the new one must be programmed. For this purpose, the vehicle-specific data is read out of the module to be replaced using WDS and is transferred to the new module. u260.3REFER to: Module Configuration (418-01 Module Configuration, General Procedures). NOTE:Before reading out the vehicle-specific data, remake all the electrical connections which were separated in the vehicle, so that communication between the module and WDS is ensured. - Verify the customer concern.
- Visually check the following electrical or mechanical causes for the concern.
Visual Inspection | Mechanical | Electrical | - Stop lamp switch adjustment
| - Fuse(s)
- Lamp(s)
- Connector(s)
- Switches
- Wiring harness
| - Resolve any obvious causes or concerns found during the visual inspection before carrying out any further tests.
- If the concern is not visually evident, refer to the Symptom Chart.
Symptom Chart Symptom Chart | Symptom | Possible Sources | Action | | All stop lamps are inoperative | * Fuse * Circuit(s) * Stop lamp switch * Central junction box (CJB) | * | | One or more stoplamps inoperative | * Circuit(s) * Left/right-hand rear lamp assembly * Additional high-mounted stop lamp | * | | Stoplamps permanently on | * Circuit(s) * Stop lamp switch * Transmission selector lever assembly * Central junction box (CJB) * Powertrain control module (PCM) | * | System Checks NOTE:Use a digital multimeter for all electrical measurements. | PINPOINT TEST A : ALL STOP LAMPS ARE INOPERATIVE | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | A1: DETERMINE THE EQUIPMENT LEVEL OF THE CENTRAL JUNCTION BOX (CJB). | | | 1 Unfasten the CJB and fold it down. | | | Is the location for connector C100 on the top of the CJB? Yes No | | A2: CHECK FUSE F74 (15 A) (CJB). | | | 1 Ignition switch in position 0. | | | 2 Disconnect fuse F74 (15 A) (CJB). | | | 3 CHECK fuse F74 (15 A) (CJB). | | | Is the fuse OK? Yes No RENEW fuse F74 (15 A) (CJB) and CHECK the operation of the system. If the fuse blows again, LOCATE and RECTIFY the short to ground using the Wiring Diagrams. CHECK the operation of the system. | | A3: CHECK THE VOLTAGE AT FUSE F74 (15 A) (CJB) | | | 1 Connect fuse F74 (15 A) (CJB). | | | 2 Ignition switch in position II. | | | 3 Measure the voltage between fuse F74 (15 A) (CJB) and ground. | | | Does the meter display battery voltage? Yes No LOCATE and RECTIFY the break in the voltage supply of fuse F74 (15 A) (CJB) using the Wiring Diagrams, if necessary RENEW the CJB. CHECK the operation of the system. | | A4: CHECK FUSE F132 (15 A) (CJB) | | | 1 Ignition switch in position 0. | | | 2 Disconnect Fuse F132 (15 A) (CJB). | | | 3 CHECK Fuse F132 (15 A) (CJB). | | | Is the fuse OK? Yes No RENEW fuse F132 (15 A) (CJB) and CHECK the operation of the system. If the fuse blows again, LOCATE and RECTIFY the short to ground using the Wiring Diagrams. CHECK the operation of the system. | | A5: CHECK VOLTAGE AT FUSE F132 (15 A) (CJB) | | | 1 Connect Fuse F132 (15 A) (CJB). | | | 2 Ignition switch in position II. | | | 3 Measure the voltage between fuse F132 (15 A) (CJB) and ground. | | | Does the meter display battery voltage? Yes No LOCATE and RECTIFY the break in the voltage supply from fuse F132 (15 A) (CJB) using the Wiring Diagrams, if necessary RENEW the CJB. CHECK the operation of the system. | | A6: CHECK VOLTAGE AT STOP LAMP SWITCH | | | 1 Ignition switch in position 0. | | | 2 Disconnect stop lamp switch from connector C444. | | | 3 Ignition switch in position II. | | | 4 Measure the voltage between the stoplamp switch, connector C444, pin 2, circuit 15-LG23 (GN/WH), wiring harness side and ground. | | | Does the meter display battery voltage? Yes No | | A7: CHECK VOLTAGE SUPPLY TO THE STOP LAMP SWITCH FOR OPEN CIRCUIT | | | 1 Ignition switch in position 0. | | | 2 Disconnect CJB from connector C444. | | | 3 Measure the resistance between the CJB, connector C100, pin 13, circuit 15-LG23 (GN/WH), wiring harness side and the stoplamp switch, connector C444, pin 2, circuit 15-LG23 (GN/WH), wiring harness side. | | | Is a resistance of less than 2 Ohms registered? Yes INSTALL a new CJB. CHECK the operation of the system. No LOCATE and RECTIFY the break in the circuit between the CJB and the stoplamp switch with the aid of the Wiring Diagrams. CHECK the operation of the system. | | A8: CHECK THE STOP LAMP SWITCH | | | 1 Ignition switch in position 0. | | | 2 Connect a fused jumper wire (15 A) to the stop lamp switch, connector C444, between pin 2, circuit 15-LG23 (GN/WH) and pin 1, circuit 15S-LG23 (GN/WH), wiring harness side. | | | 3 Ignition switch in position II. | | | 4 CHECK the operation of the stoplamps. | | | Do the stop lamps illuminate? Yes INSTALL A NEW stop lamp switch. CHECK the operation of the system. No LOCATE and RECTIFY the break in the circuit between the stop lamp switch and soldered connection S112 using the Wiring Diagrams. CHECK the operation of the system. | | PINPOINT TEST B : ONE OR MORE STOPLAMPS INOPERATIVE | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | B1: DETERMINE THE FAULT CONDITION | | | 1 Ignition switch in position 0. | | | 2 Disconnect stop lamp switch from connector C444. | | | 3 Connect a fused jumper wire (15 A) to the stop lamp switch, connector C444, between pin 2, circuit 15-LG23 (GN/WH) and pin 1, circuit 15S-LG23 (GN/WH), wiring harness side. | | | 4 Ignition switch in position II. | | | 5 Determine the fault condition. | | | 6 CHECK the stop lamps. | | | Is only the additional high-mounted stoplamp inoperative? Yes No - Left-hand stop lamp is inoperative: GO to B2. - Right-hand stop lamp is inoperative: GO to B4. | | B2: CHECK THE VOLTAGE SUPPLY OF THE LEFT-HAND STOP LAMP | NOTE:The fused jumper lead used in the previous step is still connected to the stop lamp switch. | | | 1 Ignition switch in position 0. | | | 2 Disconnect Left-hand rear lamp assembly from connector. - 3-door and 5-door versions, without trailer hitch: C472
- 3-door and 5-door versions, with trailer hitch: C2004
- 4-door and estate versions, without trailer hitch: C476
- 4-door and estate versions, with trailer hitch: C2035
| | | 3 Ignition switch in position II. | | | 4 Measure voltage between left-hand rear lamp assembly: - 3-door and 5-door versions, without trailer hitch: connector C472, pin 2, circuit 15S-LG14B (GN/RD), wiring harness side and ground.
- 3-door and 5-door versions, with trailer hitch: connector C2004, pin 2, circuit (BK/RD), wiring harness side and ground.
- Cabriolet: Connector C3928, pin 2, circuit 15S-LG14A (GN/RD), wiring harness side and ground.
| | | 5 Measure voltage between left-hand rear lamp assembly: - 4-door versions, without trailer hitch: connector C476, pin 1, circuit 15S-LG14C (GN/RD), wiring harness side and ground.
- 4-door versions, with trailer hitch: connector C2035, pin 1, circuit 15S-LG14 (BK/RD), wiring harness side and ground.
| | | 6 Measure voltage between left-hand rear lamp assembly: - Estate versions, without trailer hitch: connector C476, pin 5, circuit 15S-LG14A (GN/RD), wiring harness side and ground.
- Estate versions, with trailer hitch: connector C2035, pin 5, circuit 15S-LG14 (BK/RD), wiring harness side and ground.
| | | Does the meter display battery voltage? Yes No LOCATE and RECTIFY the break in the circuit between soldered connection S112 and the rear lamp assembly using the Wiring Diagrams. CHECK the operation of the system. | | B3: CHECK THE GROUND CONNECTION TO THE LEFT-HAND REAR LAMP ASSEMBLY | | | 1 Ignition switch in position 0. | | | 2 Measure resistance between left-hand rear lamp assembly: - 3-door and 5-door versions, without trailer hitch: connector C472, pin 3, circuit 31-LF23(A/B) (BK), wiring harness side and ground.
- 3-door and 5-door versions, with trailer hitch: connector C2004, pin 3, circuit (BK), wiring harness side and ground.
- Cabriolet: Connector C3928, pin 3, circuit 31-LF23A (BK), wiring harness side and ground.
| | | 3 Measure resistance between left-hand rear lamp assembly: - 4-door versions, without trailer hitch: connector C476, pin 4, circuit 31-LF23C (BK), wiring harness side and ground.
- 4-door versions, with trailer hitch: connector C2035, pin 4, circuit 31-LF23 (GN), wiring harness side and ground.
| | | 4 Measure resistance between left-hand rear lamp assembly: - Estate versions, without trailer hitch: connector C476, pin 3, circuit 31-LF23 (BK), wiring harness side and ground.
- Estate versions, with trailer hitch: connector C2035, pin 3, circuit 31-LF23 (GN), wiring harness side and ground.
| | | Is a resistance of less than 2 Ohms registered? Yes CHECK and if necessary RENEW the rear lamp assembly. CHECK the operation of the system. No LOCATE and RECTIFY the break in the circuit(s) between the rear lamp assembly and ground connection G77 using the Wiring Diagrams. CHECK the operation of the system. | | B4: CHECK THE VOLTAGE SUPPLY OF THE RIGHT-HAND STOP LAMP | NOTE:The fused jumper lead used in the first step is still connected to the stop lamp switch. | | | 1 Ignition switch in position 0. | | | 2 Disconnect Right-hand rear lamp assembly from connector. - 3-door and 5-door versions, without trailer hitch: C473
- 3-door and 5-door versions, with trailer hitch: C2007
- 4-door and estate versions, without trailer hitch: C477
- 4-door and estate versions, with trailer hitch: C2037
| | | 3 Ignition switch in position II. | | | 4 Measure voltage between right-hand rear lamp assembly: - 3-door and 5-door versions, without trailer hitch: connector C473, pin 2, circuit 15S-LG21A (GN/BK), wiring harness side and ground.
- 3-door and 5-door versions, with trailer hitch: connector C2007, pin 2, circuit (GN), wiring harness side and ground.
- Cabriolet: Connector C3929, pin 2, circuit 15S-LG21 (GN/BK), wiring harness side and ground.
| | | 5 Measure voltage between right-hand rear lamp assembly: - 4-door versions, without trailer hitch: connector C477, pin 7, circuit 15S-LG21B (GN/BK), wiring harness side and ground.
- 4-door versions, with trailer hitch: connector C2037, pin 7, circuit 15S-LG14 (GN), wiring harness side and ground.
| | | 6 Measure voltage between right-hand rear lamp assembly: - Estate versions, without trailer hitch: connector C477, pin 5, circuit 15S-LG21 (GN/BK), wiring harness side and ground.
- Estate versions, with trailer hitch: connector C2037, pin 5, circuit 15S-LG21 (GN), wiring harness side and ground.
| | | Does the meter display battery voltage? Yes No LOCATE and RECTIFY the break in the circuit(s) between soldered connection S112 and the rear lamp assembly using the Wiring Diagrams. CHECK the operation of the system. | | B5: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY | | | 1 Ignition switch in position 0. | | | 2 Measure the resistance between the right-hand rear lamp assembly: - 3-door and 5-door versions, without trailer hitch: connector C473, pin 3, circuit 31-LF24 (BK), wiring harness side and ground.
- 3-door and 5-door versions, with trailer hitch: connector C2007, pin 3, circuit (BK), wiring harness side and ground.
- Cabriolet: Connector C3929, pin 3, circuit 31-LF24A (BK), wiring harness side and ground.
| | | 3 Measure the resistance between the right-hand rear lamp assembly: - 4-door versions, without trailer hitch: connector C477, pin 4, circuit 31-LF24B (BK), wiring harness side and ground.
- 4-door versions, with trailer hitch: connector C2037, pin 4, circuit 31-LF24A (GN), wiring harness side and ground.
| | | 4 Measure the resistance between the right-hand rear lamp assembly: - Estate versions, without trailer hitch: connector C477, pin 3, circuit 31-LF24A (BK), wiring harness side and ground.
- Estate versions, with trailer hitch: connector C2037, pin 3, circuit 31-LF24A (GN), wiring harness side and ground.
| | | Is a resistance of less than 2 Ohms registered? Yes CHECK and if necessary RENEW the rear lamp assembly. CHECK the operation of the system. No LOCATE and RECTIFY the break in the circuit(s) between the right-hand rear lamp assembly and ground connection G70 using the Wiring Diagrams. CHECK the operation of the system. | | B6: CHECK VOLTAGE SUPPLY OF ADDITIONAL HIGH-MOUNTED STOP LAMP | NOTE:The fused jumper lead used in the first step is still connected to the stop lamp switch. | | | 1 Ignition switch in position 0. | | | 2 Disconnect additional high-mounted stop lamp from connector C107. | | | 3 Ignition switch in position II. | | | 4 Measure the voltage between additional high-mounted stoplamp, connector C107, pin 1: - 3/5-door version: circuit 15S-LG6 (BK), wiring harness side and ground.
- 4-door: circuit 15S-LG6C (GN/YE), wiring harness side and ground.
- Estate versions: circuit 15S-LG6 (BK), wiring harness side and ground.
- Cabriolet: circuit 15S-LG6 (BK), wiring harness side and ground.
| | | Does the meter display battery voltage? Yes No - 4-door: LOCATE and RECTIFY the break in the circuit between the stoplamp switch and the additional high-mounted stop lamp using the wiring diagrams. CHECK the operation of the system. - All other models: LOCATE and RECTIFY the break in the circuit(s) between soldered connection S112 and the additional high-mounted stop lamp using the wiring diagrams. CHECK the operation of the system. | | B7: CHECK THE GROUND CONNECTION OF THE ADDITIONAL HIGH-MOUNTED STOPLAMP | | | 1 Ignition switch in position 0. | | | 2 Measure the resistance between additional high-mounted stoplamp, connector C107, pin 2: - 3/5-door version: circuit 31-LG6 (BK), wiring harness side and ground.
- 4-door: circuit 91-LG6 (BK/YE), wiring harness side and ground.
- Wagon: circuit 31-LG6 (BK), wiring harness side and ground.
- Cabriolet: circuit 31-LG6 (BK), wiring harness side and ground.
| | | Is a resistance of less than 2 Ohms registered? Yes CHECK and if necessary INSTALL A NEW additional high-mounted stop lamp. CHECK the operation of the system. No - 4-door: LOCATE and RECTIFY the break in the circuit between the additional high-mounted stoplamp and soldered connection S203 using the Wiring Diagrams. CHECK the operation of the system. - All other models: LOCATE and RECTIFY the break in the circuit between the additional high-mounted stoplamp and ground connection G77 with the aid of the wiring diagrams. CHECK the operation of the system. | | PINPOINT TEST C : STOPLAMPS PERMANENTLY ON | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | C1: CHECK THE STOP LAMP SWITCH | | | 1 Ignition switch in position 0. | | | 2 Disconnect stop lamp switch from connector C444. | | | 3 Ignition switch in position II. | | | 4 CHECK the stop lamps. | | | Do the stop lamps illuminate continuously? Yes No INSTALL A NEW stop lamp switch. CHECK the operation of the system. | | C2: DETERMINE THE EQUIPMENT OF THE VEHICLE | | | 1 FIND OUT whether the vehicle is fitted with a trailer hitch. | | | Is the vehicle equipped with a trailer hitch? Yes No - Vehicles without automatic transmission: GO to C6. - Vehicles with automatic transmission: GO to C4. | | C3: ELIMINATE THE TRAILER CONTROL UNIT AS THE CAUSE FOR THE SHORT TO BATTERY VOLTAGE. | | | 1 Ignition switch in position 0. | | | 2 Disconnect Fuse F59 (20 A) (CJB). | | | 3 Ignition switch in position II. | | | 4 CHECK the stop lamps. | | | Do the stop lamps illuminate continuously? Yes - Vehicles without automatic transmission: GO to C6. - Vehicles with automatic transmission: GO to C4. No RENEW the trailer control unit. CHECK the operation of the system. | | C4: RULE OUT TRANSMISSION SELECTOR LEVER ASSEMBLY AS POSSIBLE CAUSE FOR A SHORT TO BATTERY VOLTAGE | | | 1 Ignition switch in position 0. | | | 2 Connect Vehicles with trailer socket only: Fuse F59 (20 A) (CJB). | | | 3 Disconnect fuse F70 (10 A) (CJB). | | | 4 Ignition switch in position II. | | | 5 CHECK the stop lamps. | | | Do the stop lamps illuminate continuously? Yes No INSTALL A NEW transmission selector lever assembly. CHECK the operation of the system. | | C5: NARROW DOWN THE CAUSE OF THE SHORT TO BATTERY VOLTAGE | | | 1 Ignition switch in position 0. | | | 2 Connect fuse F70 (10 A) (CJB). | | | 3 Disconnect CJB from connector C102. | | | 4 Ignition switch in position II. | | | 5 CHECK the stop lamps. | | | Do the stop lamps illuminate continuously? Yes No LOCATE and RECTIFY the short to battery voltage in the circuits connected to the CJB, connector C102, pin 17 using the Wiring Diagrams. CHECK the operation of the system. | | C6: RULE OUT PCM AS POSSIBLE CAUSE FOR A SHORT TO BATTERY VOLTAGE | | | 1 Ignition switch in position 0. | | | 2 Connect Vehicles with trailer socket only: Fuse F59 (20 A) (CJB). | | | 3 Disconnect fuse F36 (10 A) (BJB). | | | 4 Disconnect fuse F75 (10 A) (CJB). | | | 5 Disconnect fuse F30 (3 A) (BJB). - 2.0l Duratorq TDCi Engine
| | | 6 Ignition switch in position II. | | | 7 CHECK the stop lamps. | | | Do the stop lamps illuminate continuously? Yes No INSTALL a new PCM. CHECK the operation of the system. | | C7: NARROW DOWN THE CAUSE OF THE SHORT TO BATTERY VOLTAGE | | | 1 Ignition switch in position 0. | | | 2 Connect fuse F36 (10 A) (BJB). | | | 3 Connect fuse F75 (10 A) (CJB). | | | 4 Connect fuse F30 (3 A) (BJB). - 2.0l Duratorq TDCi Engine
| | | 5 Disconnect CJB from connector C96. | | | 6 Ignition switch in position II. | | | 7 CHECK the stop lamps. | | | Do the stop lamps illuminate continuously? Yes No LOCATE and RECTIFY the short to battery voltage in the circuits connected to the CJB, connector C96, pin 31 using the Wiring Diagrams. CHECK the operation of the system. | | C8: NARROW DOWN THE CAUSE OF THE SHORT TO BATTERY VOLTAGE | | | 1 Ignition switch in position 0. | | | 2 Disconnect CJB from connector C100. | | | 3 Ignition switch in position II. | | | 4 CHECK the stop lamps. | | | Do the stop lamps illuminate continuously? Yes LOCATE and RECTIFY short to battery voltage in the circuits connected to soldered connection S112 with the aid of the wiring diagrams. CHECK the operation of the system. Vehicles with trailer hitch, CHECK the trailer socket and RENEW if necessary. CHECK the operation of the system. No CHECK and if necessary INSTALL A NEW CJB. CHECK the operation of the system. | |
