ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Trailer Lamps - Vehicles Built Up To: 12-2001 > < Headlamp Leveling - Vehicles Built Up To: 12-2001

Galaxy 2000.75 (04.2000-02.2006)

Exterior Lighting - Headlamp Leveling—Vehicles Built From: 01/2002 Galaxy 2000.75 (04/2000-02/2006)
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 Verification

NOTE:
NOTE:The generic electronic module (GEM) is part of the central junction box (CJB).
NOTE:
NOTE:If a new GEM module is being installed, the new module must be configured following installation. For this purpose, the vehicle-specific data is read out of the module to be changed using WDS and is transferred to the new module.REFER to:
Module Configuration (418-01 Module Configuration, General Procedures),
Generic Electronic Module (GEM) (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
NOTE:
NOTE:Before reading out the vehicle-specific data make sure that all electrical connections in the vehicle are reconnected so that the module and WDS can communicate correctly.
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of electrical damage.

Visual Inspection Chart

Electrical
  • Fuse(s)
  • Bulb(s)
  • Electrical connector(s)
  • Switch(es)
  • Wiring harness
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
The headlamp leveling is inoperative/does not operate correctly (vehicles with conventional headlamps)
*
Fuse(s)
*
Circuit(s)
*
Illumination dimmer/headlamp leveling switch
*
Headlamp leveling unit
*
Headlamp
*
Central Junction Box (CJB)
*
GO to Pinpoint Test A.
The headlamp leveling is inoperative/does not operate correctly (vehicles with high intensity discharge headlamps)
*
Fuse(s)
*
Circuit(s)
*
Headlamp leveling unit
*
High intensity discharge headlamps
*
Headlamp leveling front sensor
*
Headlamp leveling rear sensor
*
Central Junction Box (CJB)
*
GO to Pinpoint Test B.

Pinpoint Tests

NOTE:
NOTE:Use a digital multimeter for all electrical measurements.

PINPOINT TEST A : THE HEADLAMP LEVELING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY (VEHICLES WITH CONVENTIONAL HEADLAMPS)
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: DETERMINE THE FAULT CONDITION
1
Ignition switch in position II.
2
SWITCH ON the low beams.
3
Adjust the HEADLAMP leveling (UP/DOWN).
4
CHECK the headlamp leveling.

Is the headlamp leveling left-hand side and right-hand side inoperative?
Yes
GO to A2.
No
- Headlamp leveling left-hand side is inoperative: GO to A7.
- Headlamp leveling right-hand side is inoperative: GO to A10.
A2: CHECK FUSE F58 (10 A) (CJB)
1
Ignition switch in position 0.
2
Disconnect fuse F58 (10 A) (CJB) .
3
CHECK fuse F58 (10 A) (CJB) .

Is the fuse OK?
Yes
GO to A3.
No
INSTALL a new fuse F58 (10 A) and TEST the system for normal operation. If the fuse blows again, LOCATE and REPAIR the short to ground by using the wiring diagrams. TEST the system for normal operation.
A3: CHECK THE VOLTAGE AT FUSE F58 (10 A ) (CJB)
1
Connect fuse F58 (10 A) (CJB).
2
Ignition switch in position II.
3
SWITCH ON the low beams.
4
Measure the voltage between fuse F58 (10 A) (CJB) and ground.

Is battery voltage indicated?
Yes
GO to A4.
No
INSTALL a new CJB. TEST the system for normal operation.
A4: CHECK THE VOLTAGE AT THE ILLUMINATION DIMMER/HEADLAMP LEVELING SWITCH
1
Ignition switch in position 0.
2
Disconnect illumination dimmer/headlamp leveling switch from connector C167.
3
Ignition switch in position II.
4
SWITCH ON the low beams.

5
Measure the voltage between illumination dimmer/headlamp leveling switch, connector C167, pin 4, circuit (YE), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to A5.
No
LOCATE and REPAIR the open circuit between fuse F58 (CJB) and illumination dimmer/headlamp leveling switch, by using the wiring diagrams. If necessary INSTALL a new CJB. TEST the system for normal operation.
A5: CHECK THE GROUND CONNECTION OF THE ILLUMINATION DIMMER/HEADLAMP LEVELING SWITCH
1
Ignition switch in position 0.

2
Measure the resistance between illumination dimmer/headlamp leveling switch, connector C167, pin 1, circuit (BN/BU), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
GO to A6.
No
LOCATE and REPAIR the open circuit (BN/BU), between illumination dimmer/headlamp leveling switch and splice S14 by using the wiring diagrams. TEST the system for normal operation.
A6: CHECK THE COMMON CONTROL CIRCUIT TO THE HEADLAMP LEVELING UNITS
1
Disconnect headlamp left-hand side from connector C194.

2
Measure the resistance between illumination dimmer/headlamp leveling switch, connector C167, pin 2, circuit (RD/BU), wiring harness side and headlamp left-hand side, connector C194, pin 5, circuit (RD/BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
INSTALL a new illumination dimmer/headlamp leveling switch. TEST the system for normal operation.
No
LOCATE and REPAIR the open circuit between illumination dimmer/headlamp leveling switch and splice S13, by using the wiring diagrams. TEST the system for normal operation.
A7: CHECK THE VOLTAGE AT THE HEADLAMP LEFT-HAND SIDE
1
Ignition switch in position 0.
2
Disconnect headlamp left-hand side from connector C194.
3
Ignition switch in position II.
4
SWITCH ON the low beams.

5
Measure the voltage between headlamp left-hand side, connector C194, pin 1, circuit (YE/BK), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to A8.
No
LOCATE and REPAIR the open circuit between splice S15 and headlamp, by using the wiring diagrams. TEST the system for normal operation.
A8: CHECK THE CONTROL VOLTAGE AT THE HEADLAMP LEFT-HAND SIDE
1
SWITCH ON the low beams.
2
ADJUST the headlamp leveling during the measurement.

3
Measure the voltage between headlamp left-hand side, connector C194, pin 5, circuit (RD/BU), wiring harness side and ground.

Is the voltage varying analog to the adjustment of the headlamp leveling?
Yes
GO to A9.
No
LOCATE and REPAIR open circuit, between splice S13 and headlamp, by using the wiring diagrams. TEST the system for normal operation.
A9: CHECK THE GROUND CONNECTION OF THE HEADLAMP LEFT-HAND SIDE
1
Ignition switch in position 0.

2
Measure the resistance between headlamp left-hand side, connector C194, pin 3, circuit (BN/BU), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
CHECK the headlamp leveling unit, if necessary INSTALL a new headlamp. TEST the system for normal operation.
No
LOCATE and REPAIR the open circuit between headlamp and splice S14 by using the wiring diagrams. TEST the system for normal operation.
A10: CHECK THE VOLTAGE AT THE HEADLAMP RIGHT-HAND SIDE
1
Ignition switch in position 0.
2
Disconnect headlamp right-hand side from connector C195.
3
Ignition switch in position II.
4
SWITCH ON the low beams.

5
Measure the voltage between headlamp right-hand side, connector C195, pin 1, circuit (YE), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to A11.
No
LOCATE and REPAIR open circuit, between splice S18 and headlamp, by using the wiring diagrams. TEST the system for normal operation.
A11: CHECK THE CONTROL VOLTAGE AT THE HEADLAMP RIGHT-HAND SIDE
1
SWITCH ON the low beams.
2
ADJUST the headlamp leveling during the measurement.

3
Measure the voltage between headlamp right-hand side, connector C195, pin 5, circuit (RD/BU), wiring harness side and ground.

Is the voltage varying analog to the adjustment of the headlamp leveling?
Yes
GO to A12.
No
LOCATE and REPAIR open circuit between splice S13 and headlamp, by using the wiring diagrams. TEST the system for normal operation.
A12: CHECK THE GROUND CONNECTION OF THE HEADLAMP RIGHT-HAND SIDE
1
Ignition switch in position 0.

2
Measure the resistance between headlamp right-hand side, connector C195, pin 3, circuit (BN/BU), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
CHECK the headlamp leveling unit, if necessary INSTALL a new headlamp. TEST the system for normal operation.
No
LOCATE and REPAIR open circuit between headlamp and splice S14 by using the wiring diagrams. TEST the system for normal operation.

PINPOINT TEST B : THE HEADLAMP LEVELING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY (VEHICLES WITH HIGH INTENSITY DISCHARGE HEADLAMPS)
NOTE:
NOTE:It is not possible to adjust the headlamps manually.
NOTE:
NOTE:For testing the basic function of the automatic headlamp leveling system, switch on the low beams and change the load (rear axle) of the vehicle. Check if the headlamp leveling system adjusts the headlamps correctly.
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: DETERMINE THE FAULT CONDITION
1
Ignition switch in position II.
2
SWITCH ON the low beams.
3
CHECK the headlamp leveling.

Is the headlamp leveling left-hand side and right-hand side inoperative?
Yes
GO to B2.
No
- Headlamp leveling left-hand side is inoperative: GO to B16.
- Headlamp leveling right-hand side is inoperative: GO to B19.
B2: CHECK FUSE F19 (5 A) (CJB)
1
Ignition switch in position 0.
2
Disconnect fuse F19 (5 A) (CJB).
3
CHECK fuse F19 (5 A) (CJB) .

Is the fuse OK?
Yes
GO to B3.
No
INSTALL a new fuse F19 (5 A) and TEST the system for normal operation. If the fuse blows again, LOCATE and REPAIR the short to ground by using the wiring diagrams. TEST the system for normal operation.
B3: CHECK THE VOLTAGE AT FUSE F19 (5 A) (CJB)
1
Connect fuse F19 (5 A) (CJB) .
2
Ignition switch in position II.
3
Measure the voltage between fuse F19 (5 A) and ground.

Is battery voltage indicated?
Yes
GO to B4.
No
INSTALL a new CJB. TEST the system for normal operation.
B4: CHECK THE VOLTAGE AT THE HEADLAMP LEFT-HAND SIDE
1
Ignition switch in position 0.
2
Disconnect headlamp left-hand side from connector C271.
3
Ignition switch in position II.

4
Measure the voltage between headlamp left-hand side, connector C271, pin 11, circuit (BK/GY), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to B5.
No
LOCATE and REPAIR the open circuit between fuse F19 (CJB) and splice S25, by using the wiring diagrams. If necessary INSTALL a new CJB. TEST the system for normal operation.
B5: CHECK THE GROUND CONNECTION OF THE HEADLAMP LEFT-HAND SIDE
1
Ignition switch in position 0.

2
Measure the resistance between headlamp left-hand side, connector C271, pin 8, circuit (BN), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
GO to B6.
No
LOCATE and REPAIR the open circuit between headlamp left-hand side and splice S17 by using the wiring diagrams. TEST the system for normal operation.
B6: CHECK THE VOLTAGE AT THE HEADLAMP LEVELING FRONT SENSOR
1
Connect headlamp left-hand side to connector C271.
2
Disconnect headlamp leveling front sensor from connector C278.
3
Ignition switch in position II.
4
SWITCH ON the low beams.

5
Measure the voltage at the headlamp leveling front sensor, connector C278, between:
  • Vehicles before 05/2004: pin 5, circuit (BU/BK) and pin 1, circuit (BN/BU), wiring harness side.
  • Vehicles as of 05/2004: pin 5, circuit (BK/BU) and pin 1, circuit (BN/BU), wiring harness side.

Is a voltage of 5 volts indicated?
Yes
GO to B9.
No
GO to B7.
B7: CHECK THE CIRCUIT (BK/BU) OR (BU/BK) BETWEEN HEADLAMP LEFT-HAND SIDE AND HEADLAMP LEVELING FRONT SENSOR FOR OPEN
1
Ignition switch in position 0.
2
Disconnect headlamp left-hand side from connector C277.

3
Measure the resistance between headlamp left-hand side, connector C277, pin 4, circuit (BK/BU), wiring harness side and:
  • Vehicles before 05/2004: headlamp leveling front sensor, connector C278, pin 5, circuit (BU/BK), wiring harness side.
  • Vehicles as of 05/2004: headlamp leveling front sensor, connector C278, pin 5, circuit (BK/BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
GO to B8.
No
LOCATE and REPAIR the open circuit between headlamp and headlamp leveling front sensor, by using the wiring diagrams. TEST the system for normal operation.
B8: CHECK THE CIRCUIT (BN/BU) BETWEEN HEADLAMP LEFT-HAND SIDE AND HEADLAMP LEVELING FRONT SENSOR FOR OPEN

1
Measure the resistance between headlamp left-hand side, connector C277, pin 3, circuit (BN/BU), wiring harness side and headlamp leveling front sensor, connector C278, pin 1, circuit (BN/BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
CHECK the headlamp left-hand side by using the WDS and if necessary INSTALL a new headlamp. TEST the system for normal operation.
No
LOCATE and REPAIR the open circuit between headlamp and headlamp leveling front sensor, by using the wiring diagrams. TEST the system for normal operation.
B9: CHECK THE VOLTAGE AT THE HEADLAMP LEVELING REAR SENSOR
1
Ignition switch in position 0.
2
Disconnect headlamp leveling rear sensor from connector C279.
3
Ignition switch in position II.
4
SWITCH ON the low beams.

5
Measure the voltage at the headlamp leveling rear sensor, connector C279, between:
  • Vehicles before 05/2004: pin 5, circuit (BU/BK) and pin 1, circuit (BN/BU), wiring harness side.
  • Vehicles as of 05/2004: pin 5, circuit (BK/BU) and pin 1, circuit (BN/BU), wiring harness side.

Is a voltage of 5 volts indicated?
Yes
GO to B12.
No
GO to B10.
B10: CHECK THE CIRCUIT (BK/BU) OR (BU/BK) BETWEEN HEADLAMP LEFT-HAND SIDE AND HEADLAMP LEVELING REAR SENSOR FOR OPEN
1
Ignition switch in position 0.
2
Disconnect headlamp left-hand side from connector C277.

3
Measure the resistance between headlamp left-hand side, connector C277, pin 4, circuit (BK/BU), wiring harness side and headlamp leveling rear sensor, connector C279:
  • Vehicles before 05/2004: pin 5, circuit (BU/BK), wiring harness side.
  • Vehicles as of 05/2004: pin 5, circuit (BK/BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
GO to B11.
No
LOCATE and REPAIR the open circuit(s) between headlamp and headlamp leveling rear sensor, by using the wiring diagrams. TEST the system for normal operation.
B11: CHECK THE CIRCUIT (BN/BU) BETWEEN HEADLAMP LEFT-HAND SIDE AND HEADLAMP LEVELING REAR SENSOR

1
Measure the resistance between headlamp left-hand side, connector C277, pin 3, circuit (BN/BU), wiring harness side and headlamp leveling rear sensor, connector C279, pin 1, circuit (BN/BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
CHECK the headlamp left-hand side by using the WDS and if necessary INSTALL a new headlamp. TEST the system for normal operation.
No
LOCATE and REPAIR the open circuit(s) (BN/BU), between headlamp and headlamp leveling rear sensor, by using the wiring diagrams. TEST the system for normal operation.
B12: CHECK THE HEADLAMP LEVELING FRONT SENSOR
1
Check the headlamp leveling front sensor, according to the Component Test attached to this procedure.

Is the headlamp leveling front sensor OK?
Yes
GO to B13.
No
INSTALL a new headlamp leveling front sensor. TEST the system for normal operation.
B13: CHECK THE HEADLAMP LEVELING REAR SENSOR
1
Check the headlamp leveling rear sensor, according to the Component Test attached to this procedure.

Is the headlamp leveling rear sensor OK?
Yes
GO to B14.
No
INSTALL a new headlamp leveling rear sensor. TEST the system for normal operation.
B14: CHECK THE CIRCUIT (BU/GY) BETWEEN HEADLAMP LEFT-HAND SIDE AND HEADLAMP LEVELING FRONT SENSOR
1
Ignition switch in position 0.
2
Disconnect headlamp left-hand side from connector C271.

3
Measure the resistance between headlamp left-hand side, connector C271, pin 1, circuit (BU/GY), wiring harness side and headlamp leveling front sensor, connector C278, pin 4, circuit (BU/GY), wiring harness side.

Is the resistance less than 2 ohms?
Yes
GO to B15.
No
LOCATE and REPAIR the open circuit between headlamp and headlamp leveling front sensor, by using the wiring diagrams. TEST the system for normal operation.
B15: CHECK THE CIRCUIT (BU/GN) BETWEEN HEADLAMP LEFT-HAND SIDE AND HEADLAMP LEVELING REAR SENSOR

1
Measure the resistance between headlamp left-hand side, connector C271, pin 2, circuit (BU/GN), wiring harness side and headlamp leveling rear sensor, connector C279, pin 4, circuit (BU/GN), wiring harness side.

Is the resistance less than 2 ohms?
Yes
CHECK the headlamp left-hand side by using the WDS and if necessary INSTALL a new headlamp. TEST the system for normal operation.
No
LOCATE and REPAIR the open circuit between headlamp and headlamp leveling rear sensor, by using the wiring diagrams. TEST the system for normal operation.
B16: CHECK THE VOLTAGE AT THE HEADLAMP LEFT-HAND SIDE
1
Ignition switch in position 0.
2
Disconnect headlamp left-hand side from connector C271.
3
Ignition switch in position II.

4
Measure the voltage between headlamp left-hand side, connector C271, pin 11, circuit (BK/GY), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to B17.
No
LOCATE and REPAIR the open circuit between splice S25 and headlamp by using the wiring diagrams. TEST the system for normal operation.
B17: CHECK THE VOLTAGE AT THE HEADLAMP LEFT-HAND SIDE
1
SWITCH ON the LOW beams.

2
Measure the voltage between headlamp left-hand side, connector C271, pin 5, circuit (YE/BK), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to B18.
No
LOCATE and REPAIR the open circuit between fuse F59 (CJB) and headlamp, by using the wiring diagrams. If necessary INSTALL a new CJB. TEST the system for normal operation.
B18: CHECK THE GROUND CONNECTION OF THE HEADLAMP LEFT-HAND SIDE
1
Ignition switch in position 0.

2
Measure the resistance between headlamp left-hand side, connector C271, pin 8, circuit (BN), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
CHECK the headlamp leveling unit. TEST the system for normal operation. If the headlamp leveling unit is OK check the headlamp by using the WDS and if necessary INSTALL a new headlamp. TEST the system for normal operation.
No
LOCATE and REPAIR the open circuit between headlamp and splice S17 by using the wiring diagrams. TEST the system for normal operation.
B19: CHECK THE VOLTAGE AT THE HEADLAMP RIGHT-HAND SIDE
1
Ignition switch in position 0.
2
Disconnect headlamp right-hand side from connector C272.
3
Ignition switch in position II.

4
Measure the voltage between headlamp right-hand side, connector C272, pin 11, circuit (BK/GY), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to B20.
No
LOCATE and REPAIR the open circuit between splice S25 and headlamp, by using the wiring diagrams. TEST the system for normal operation.
B20: CHECK THE VOLTAGE AT THE HEADLAMP RIGHT-HAND SIDE
1
SWITCH ON the low beams.

2
Measure the voltage between headlamp right-hand side, connector C272, pin 5, circuit (YE), wiring harness side and ground.

Is battery voltage indicated?
Yes
GO to B21.
No
LOCATE and REPAIR the open circuit between fuse F60 (CJB) and headlamp, by using the wiring diagrams. If necessary INSTALL a new CJB. TEST the system for normal operation.
B21: CHECK THE GROUND CONNECTION OF THE HEADLAMP RIGHT-HAND SIDE
1
Ignition switch in position 0.

2
Measure the resistance between headlamp right-hand side, connector C272, pin 8, circuit (BN), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
GO to B22.
No
LOCATE and REPAIR the open circuit between headlamp and splice S177 by using the wiring diagrams. TEST the system for normal operation.
B22: CHECK THE CIRCUIT (RD/YE) BETWEEN HEADLAMP RIGHT-HAND SIDE AND HEADLAMP LEFT-HAND SIDE
1
Disconnect headlamp left-hand side from connector C271.

2
Measure the resistance between headlamp left-hand side, connector C271, pin 9, circuit (RD/YE), wiring harness side and headlamp right-hand side, connector C272, pin 9, circuit (RD/YE), wiring harness side.

Is the resistance less than 2 ohms?
Yes
CHECK the headlamp leveling unit. TEST the system for normal operation. If the headlamp leveling unit is OK check the headlamp by using the WDS and if necessary INSTALL a new headlamp. TEST the system for normal operation
No
LOCATE and REPAIR the open circuit between headlamp left-hand side and headlamp right-hand side by using the wiring diagrams. TEST the system for normal operation.

Component Test

HEADLAMP LEVELING SENSOR

CAUTION:
CAUTION:Electronic modules are sensitive to electrical charge. If exposed to these charges, damage may result.
CAUTION:
CAUTION:Be sure, that the headlamp leveling sensor is supplied with exactly 5 volts.
  • Switch the ignition OFF.
  • Disconnect the connector.
  • Using an external 5 volts DC supply.
  • Using a digital multimeter.
  • Using a test cable and set up the test as in the following description.
  1. Check the headlamp leveling sensor.

  • Connect the power supply positive terminal with the headlamp leveling sensor, pin 5 and the negative terminal with pin 1.
  • Connect the digital multimeter positive terminal with pin 4 and the negative terminal with pin 1.
  • Change the vehicle load while measurement.

Measure the voltage.

Is the range of values at the digital multimeter between 2.0 - 2.7 volts?

If yes, the headlamp leveling sensor is OK.

If no, INSTALL a new headlamp leveling sensor.

Trailer Lamps - Vehicles Built Up To: 12-2001 > < Headlamp Leveling - Vehicles Built Up To: 12-2001