Workshop Manuals Factory service & repair Fiat
Fiat Ducato Factory Service Manual (2002-2006)23 · Fault diagnosis
23 · Diagnostics

Main beam headlamps not working

Make
Fiat
Model
Ducato Factory Service Manual
Year
2002–2006
Section
Lights › Main beam headlamps not working
Fault diagnosisMain beam headlamps not working

MAIN BEAM HEADLAMPS NOT WORKING

hen the stalk switch wheel is operated with the key ON, the main beams do not work

STEPOPERATIONS TO BE CARRIED OUTTEST RESULTS
1INDIVIDUAL LIGHT CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check condition of the bulbs and associated bulb holder unitMove on to Step1. Bulbs damaged

1. Change the bulbs

Op. 5540B24 MAIN HEADLAMP BULB (1), LH OR RH - R R

2. Front light cluster fault

2. Repair or replace the front light cluster

Op. 5540B10 EXTERIOR LIGHT DIMMER RESISTOR - R+R

2MAIN BEAM ELECTRICAL CIRCUIT CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Check the following, in order:

  • Main beam fuse;
  • Connections between battery, engine bay control unit, main beam relay and bulbs;
  • Bulb earth
Move on to Step1. Component defective1. Replace defective component (in the case of a fuse, find out what caused it to blow)
2. Connections interrupted

2. Repair the connections

See E2012 MAIN BEAM HEADLAMPS

3MAIN BEAM ELECTRICAL CIRCUIT CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Check the following, in order:

  • Connections between battery, ignition switch, engine bay control unit, main beam relay, switch control unit and stalk unit
  • Stalk switch unit earth;
Move on to Step1. Component defective1. 1. Replace defective component (in the case of a fuse, find out what caused it to blow)
2. Connections interrupted

2. Repair the connections

See E2012 MAIN BEAM HEADLAMPS

4STEERING COLUMN SWITCH UNIT CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Check that the stalk unit is working properly: particularly the main beam selector

See E2012 MAIN BEAM HEADLAMPS

Move on to StepStalk unit not working properly

Replace the steering column switch unit

Op. 5550A12 COMPLETE STALK UNIT - R+R FOR VERSIONS WITH AIR BAG

5CHECK MAIN BEAM RELAYALL OKPROBLEMS ENCOUNTEREDACTION

Check the main beam relay is working properly

See E2012 MAIN BEAM HEADLAMPS

Move on to StepMain beam relay not working properly

Change the main beam relay

Op. 5550A12 COMPLETE STALK UNIT - R+R FOR VERSIONS WITH AIR BAG

6IGNITION SWITCH CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Check the ignition switch is operating correctly: particularly the main beam supply relay

See E2012 MAIN BEAM HEADLAMPS

Move on to StepIgnition switch fault

Repair or replace the ignition switch

Op. 5520A12 IGNITION SWITCH ASSEMBLY - R R FOR VERSIONS WITH AIR BAG

7SWITCH CONTROL UNIT CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Check the following, in order:

  • Correct power supply to switch control unit
  • Check that when an earth signal is activated from the stalk unit to the switch control unit, an earth signal leaves the switch control unit to control the main beam relay
Move on to Step1. Connections interrupted

1. Repair the connections

See E2012 MAIN BEAM HEADLAMPS

2. Switch control unit fault2. Change the switch control unit
8ENGINE BAY CONTROL UNIT CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Check the following, in order:

  • Correct engine bay control unit power supplies;
  • Check that when an earth signal is activated from the switch control unit to the engine bay control unit, a battery voltage output is generated to control the bulbs.
Move on to Step1. Connections interrupted

1. Repair the connections

See E2012 MAIN BEAM HEADLAMPS

2. Engine bay control unit fault

2. Change engine bay control unit

Op. 5505A13 SUPPLEMENTARY JUNCTION CONTROL UNIT IN ENGINE BAY - R R

9CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Check that the fault is no longer present

Parts & tools for this job For 2002 Fiat Ducato

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