ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

General Procedures > < Trailer Lamps
Exterior Lighting - Headlamp Leveling Mondeo 2001 (10/2000-02/2007)
Diagnosis and Testing

Refer to Wiring Diagrams Section 417-01, for schematic and connector information.

Special Tool(s)

Terminal probe kit

29-011 A

Diagnosis and testing

  1. Verify the customer concern.
  1. Visually inspect for the following electrical sources of fault:

Visual inspection

Electrical
  • Fuse(s).
  • Wiring harness
  • Electrical connector(s).
  • Switch(es).
  • Sensors
  • Headlamps
  1. Resolve any obvious causes or concerns found during the visual inspection before carrying out any further tests.
  1. If the cause is not visually evident, verify the symptom and referto the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
Headlamp levelling system is inoperative, vehicles with conventional headlamps
*
Fuse(s).
*
Circuit(s).
*
Light switch
*
Headlamp levelling switch.
*
Headlamp levelling motor.
*
GO to Pinpoint Test A.
Headlamp levelling system is inoperative, vehicles with gas discharge lamps
*
Fuse(s).
*
Circuit(s).
*
Headlamp levelling motor.
*
Headlamp levelling sensor front/rear
*
Gas discharge lamps
*
GO to Pinpoint Test B.

Pinpoint Tests

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

PINPOINT TEST A : HEADLAMP LEVELLING SYSTEM IS INOPERATIVE, VEHICLES WITH CONVENTIONAL HEADLAMPS

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE HEADLAMP LEVELLING SWITCH
1
Ignition switch in position II.
2
Switch on the dipped beam.
3
Move the headlamp levelling switch from position "0" to "max" and back.
4
Check the adjustment of the headlamps.

Is the headlamp levelling system inoperative on both sides?
Yes
No
Headlamp levelling system inoperative on the left-hand side: GO to A4.
Headlamp levelling system inoperative on the right-hand side: GO to A11.
A2: CHECK THE LIGHT SWITCH.
1
Ignition switch in position 0.
2
Disconnect Light switch from connector C478 .
3
CHECK the light switch in accordance with the component checks in the wiring diagrams.
  • Test light switch connector C478 at pins 1, 6, 8 and 10.

Is the light switch OK?
Yes
No
RENEW the light switch. CHECK the operation of the system.
A3: CHECK GROUND CONNECTION OF LIGHT SWITCH FOR OPEN CIRCUIT

1
Measure the resistance between the light switch, connector C478, pin 10, circuit 31-LE29 (BK), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
LOCATE and RECTIFY break in circuit 64-LE45 (BU) between light switch and intermediate connector C30 with the aid of the wiring diagrams. CHECK the operation of the system.
No
LOCATE and RECTIFY break in circuit(s) between light switch and ground point G204 with the aid of the wiring diagrams. CHECK the operation of the system.
A4: CHECK VOLTAGE SUPPLY OF LEFT-HAND HEADLAMP
1
Switch on the dipped beam.
2
CHECK left-hand parking lamp.

Does left-hand parking lamp operate?
Yes
No
A5: CHECK FUSE F64 (CJB)
1
Ignition switch in position 0.
2
Disconnect Fuse F64 (CJB) .
3
CHECK Fuse F64 (7.5 A) .

Is the fuse OK.?
Yes
No
INSTALL a new fuse F64 (7.5 A). If fuse blows again, LOCATE and RECTIFY the short to ground with the aid of the wiring diagrams. CHECK the operation of the system.
A6: CHECK THE VOLTAGE AT FUSE F64 (CJB)
1
Connect Fuse F64 (CJB) .
2
Ignition switch in position II.
3
Switch on the dipped beam.
4
Measure the voltage between fuse F64 (CJB) and ground.

Is battery voltage displayed?
Yes
No
REFER to: Parkleuchten, R�ckleuchten, Kennzeichenleuchten.
A7: CHECK VOLTAGE SUPPLY OF LEFT-HAND HEADLAMP
1
Ignition switch in position 0.
2
Disconnect Left-hand headlamp from connector C146 .
3
Ignition switch in position II.
4
Switch on the dipped beam.

5
Test voltage between left-hand headlamp connector C146, pin 4, circuit 29S-LF7 (OG/BU), wiring harness side and ground.

Is battery voltage displayed?
Yes
No
LOCATE and RECTIFY break in circuit between fuse F64 (CJB) and headlamp with the aid of the wiring diagrams, if necessary CHECK and RENEW CJB. CHECK the operation of the system.
A8: CHECK GROUND CONNECTION OF HEADLAMP
1
Ignition switch in position 0.

2
Measure the resistance between left-hand headlamp, connector C146, pin 7, circuit 31-LE31 (BK), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
No
LOCATE and RECTIFY break in circuit between headlamp and ground connection G104 with the aid of the wiring diagrams. CHECK the operation of the system.
A9: CHECK LEFT-HAND HEADLAMP CONTROL CIRCUIT FOR OPEN CIRCUIT
1
Disconnect Light switch from connector C478 .

2
Measure resistance between left-hand headlamp, connector C146, pin 5, circuit 64-LE45 (BU), wiring harness side and light switch, connector C478, pin 1, circuit 64-LE45 (BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
No
LOCATE and RECTIFY break in circuit between headlamp and intermediate connection C30 with the aid of the wiring diagrams. CHECK the operation of the system.
A10: CHECK THE LEFT-HAND HEADLAMP LEVELLING MOTOR
1
Remove the left-hand headlamp.
2
Disconnect Left-hand headlamp levelling motor .

3
Measure resistance at left-hand headlamp between connector C146, pin 5, circuit (BU), component side and headlamp levelling motor, circuit (BU), wiring harness side.

4
Measure resistance between left-hand headlamp, connector C146, pin 7, circuit (BK), component side and left-hand headlamp levelling motor, circuit (BK), wiring harness side.

5
Measure resistance at left-hand headlamp between connector C146, pin 4, circuit (VT/YE), component side and headlamp levelling motor, circuit (VT/YE), wiring harness side.

Is the resistance in all three measurements less than 2 ohms?
Yes
CHECK left-hand headlamp levelling motor and RENEW if necessary. CHECK the operation of the system.
No
LOCATE and RECTIFY break in circuit between headlamp levelling motor and headlamp connector. CHECK the operation of the system.
A11: CHECK VOLTAGE SUPPLY OF RIGHT-HAND HEADLAMP
1
Switch on the dipped beam.
2
Check right-hand parking lamp.

Does right-hand parking lamp operate?
Yes
No
A12: CHECK FUSE F63 (CJB)
1
Ignition switch in position 0.
2
Disconnect Fuse F63 (CJB) .
3
CHECK Fuse F63 (7.5 A) (CJB) .

Is the fuse OK.?
Yes
No
INSTALL a new fuse F63 (7.5 A). If fuse blows again, LOCATE and RECTIFY the short to ground with the aid of the wiring diagrams. CHECK the operation of the system.
A13: CHECK THE VOLTAGE AT FUSE F63 (CJB)
1
Connect Fuse F63 (CJB) .
2
Ignition switch in position II.
3
Switch on the dipped beam.
4
Measure the voltage between fuse F63 (CJB) and ground.

Is battery voltage displayed?
Yes
No
REFER to: Parkleuchten, R�ckleuchten, Kennzeichenleuchten.
A14: CHECK VOLTAGE SUPPLY OF RIGHT-HAND HEADLAMP
1
Ignition switch in position 0.
2
Disconnect Right-hand headlamp from connector C147 .
3
Ignition switch in position II.
4
Switch on the dipped beam.

5
Test voltage between right-hand headlamp connector C147, pin 4, circuit 29S-LF16 (OG/GN), wiring harness side and ground.

Is battery voltage displayed?
Yes
No
LOCATE and RECTIFY break in circuit between fuse F63 (CJB) and headlamp with the aid of the wiring diagrams. CHECK the operation of the system.
A15: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
1
Ignition switch in position 0.

2
Measure the resistance between right-hand headlamp, connector C147, pin 7, circuit 31-LE30 (BK), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
No
LOCATE and RECTIFY break in circuit between headlamp and ground connection G105 with the aid of the wiring diagrams. CHECK the operation of the system.
A16: CHECK RIGHT-HAND HEADLAMP CONTROL CIRCUIT FOR OPEN CIRCUIT
1
Disconnect Light switch from connector C478 .

2
Measure the resistance between right-hand headlamp, connector C147, pin 5, circuit 64-LE46 (BU/RD), wiring harness side and the light switch, connector C478, pin 1, circuit 64-LE45 (BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
No
LOCATE and RECTIFY break in circuit 64-LE46 (BU/RD) between headlamp and intermediate connector C30 with the aid of the wiring diagrams. CHECK the operation of the system.
A17: CHECK RIGHT-HAND HEADLAMP LEVELLING MOTOR
1
Remove the right-hand headlamp.
2
Disconnect Right-hand headlamp levelling motor .

3
Measure the resistance at right-hand headlamp between connector C147, pin 5, circuit (BU/RD), component side and the headlamp levelling motor, circuit (BU/RD), wiring harness side.

4
Measure the resistance at right-hand headlamp between connector C147, pin 7, circuit (BK), component side and the headlamp levelling motor, circuit (BK), wiring harness side.

5
Measure the resistance at right-hand headlamp between connector C147, pin 4, circuit (VT/YE), component side and the headlamp levelling motor, circuit (VT/YE), wiring harness side.

Is the resistance in all three measurements less than 2 ohms?
Yes
CHECK right-hand headlamp levelling motor and RENEW if necessary. CHECK the operation of the system.
No
LOCATE and RECTIFY break in circuit between headlamp levelling motor and headlamp connector. CHECK the operation of the system.

PINPOINT TEST B : HEADLAMP LEVELLING SYSTEM IS INOPERATIVE, VEHICLES WITH GAS DISCHARGE LAMPS

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: READ OUT THE FAULT MEMORY
1
Ignition switch in position 0.
2
Connect the diagnostic tool.
3
Check the system using WDS.

Are any trouble codes (DTCs) displayed?
Yes
RESOLVE the faults according to the WDS instructions. CLEAR the fault memory and CHECK the operation of the system.
No
B2: ESTABLISH FAULT CONDITION
NOTE:
NOTE: On vehicles with gas discharge lamps the headlamp levelling takes place automatically according to the loading of the vehicle. The basic settings should be performed once on an unladen vehicle with the aid of WDS.
1
Ignition switch in position II.
2
Switch on the dipped beam.
3
Simulate an unladen vehicle.
4
Simulate a laden vehicle.
5
Check the operation of the headlamp levelling system.

Is the headlamp levelling system inoperative on both sides?
Yes
No
Headlamp levelling system inoperative on the left-hand side: GO to B3.
Headlamp levelling system inoperative on the right-hand side: GO to B24.
B3: CHECK FUSE F93 (CJB)
1
Ignition switch in position 0.
2
Disconnect Fuse F93 (CJB) .
3
CHECK Fuse F93 (10 A) .

Is the fuse OK.?
Yes
No
INSTALL a new fuse F93 (10 A). If fuse blows again, LOCATE and REMEDY the short to ground with the aid of the wiring diagrams. CHECK the operation of the system.
B4: CHECK THE VOLTAGE AT FUSE F93 (CJB)
1
Connect Fuse F93 (CJB) .
2
Ignition switch in position II.
3
Switch on the dipped beam.
4
Measure the voltage between fuse F93 (CJB) and ground.

Is battery voltage displayed?
Yes
No
LOCATE AND RECTIFY the break in the voltage supply of fuse F93 (CJB) with the aid of the wiring diagrams, if necessary CHECK AND RENEW CJB. CHECK the operation of the system.
B5: CHECK CIRCUIT 15-LE2(A) (GN/BU) FOR OPEN CIRCUIT
1
Ignition switch in position 0.
2
Disconnect Left-hand gas discharge lamps from connector C1146 .
3
Ignition switch in position II.
4
Switch on the dipped beam.

5
Measure the voltage between left-hand gas discharge lamp, connector C1146, pin 5, circuit 15-LE2A (GN/BU), wiring harness side and ground.

Is battery voltage displayed ?
Yes
No
LOCATE and REPAIR break in circuit 15-LE2(A) (GN/BU) between fuse F93 (CJB) and the gas discharge lamp using the wiring diagrams. CHECK the operation of the system.
B6: CHECK FUSE F16 (BJB)
1
Ignition switch in position 0.
2
Disconnect Fuse F16 (BJB) .
3
CHECK Fuse F16 (20 A) (BJB) .

Is the fuse OK.?
Yes
No
INSTALL a new fuse F16 (20 A). If fuse blows again, LOCATE and REMEDY the short to ground with the aid of the wiring diagrams. CHECK the operation of the system.
B7: CHECK THE VOLTAGE AT FUSE F16 (BJB)
1
Connect Fuse F16 (BJB) .
2
Ignition switch in position II.
3
Measure the voltage between fuse F16 (20 A) and ground.

Is battery voltage displayed?
Yes
No
LOCATE AND RECTIFY the break in the voltage supply of fuse F16 (BJB) with the aid of the wiring diagrams, if necessary TEST and RENEW the BJB. CHECK the operation of the system.
B8: CHECK VOLTAGE SUPPLY OF LEFT-HAND HEADLAMP FOR OPEN CIRCUIT

1
Measure the voltage between left-hand gas discharge lamp, connector C1146, pin 14, circuit 15S-LE16 (GN/OG), wiring harness side and ground.

Is battery voltage displayed?
Yes
No
LOCATE and RECTIFY break in circuit between fuse F16 (BJB) and gas discharge lamp with the aid of the wiring diagrams. CHECK the operation of the system.
B9: CHECK THE GROUND CONNECTION OF LEFT-HAND HEADLAMP
1
Ignition switch in position 0.

2
Measure the resistance between left-hand gas discharge lamp, connector C1146, pin 11, circuit 31-LE31 (BK), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
- Headlamp levelling system inoperative on both sides: GO to B10.
Headlamp levelling system inoperative on the left-hand side: GO to B23.
No
LOCATE and RECTIFY break in circuit between gas discharge lamp and soldered connection S315 with the aid of the wiring diagrams. CHECK the operation of the system.
B10: CHECK VOLTAGE SUPPLY OF REAR HEADLAMP LEVELLING SENSOR FOR OPEN CIRCUIT
1
Connect Left-hand gas discharge lamp with connector C1146 .
2
Disconnect Rear headlamp levelling sensor from connector C94 .
3
Ignition switch in position II.
4
Switch on the dipped beam.

5
Measure the voltage between rear headlamp levelling sensor, connector C94, pin 3:
  • Vehicles built before 10/2001: circuit 7-XL9 (YE/VT), wiring harness side and ground.
  • Vehicles built from 10/2001: circuit 7-LE54 (YE/BK), wiring harness side and ground.

Is a constant voltage of 5 V displayed?
Yes
No
- No voltage is displayed, vehicles built before 10/2001: LOCATE and RECTIFY the break in circuit 7-XL9 (YE/VT) (before 10/2001) between the gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- No voltage is displayed, vehicles built from 10/2001: LOCATE and RECTIFY the break in circuit 7-LE54 (YE/BK) between gas discharge lamp and headlamp levelling sensor with the aid of wiring diagrams. CHECK the operation of the system.
- Battery voltage is displayed: LOCATE and RECTIFY short to battery voltage in the circuits connected to gas discharge lamp, connector C1146, pin 9 with the aid of the wiring diagrams. CHECK the operation of the system. If the concern persists, CHECK and if necessary RENEW the gas discharge lamp. CHECK the operation of the system.
B11: CHECK VOLTAGE SUPPLY OF FRONT HEADLAMP LEVELLING SENSOR FOR OPEN CIRCUIT
1
Ignition switch in position 0.
2
Disconnect Front headlamp levelling sensor from connector C195 .
3
Ignition switch in position II.
4
Switch on the dipped beam.

5
Measure the voltage between front headlamp levelling sensor, connector C195, pin 3:
  • Vehicles built before 10/2001: circuit 7-XL9A (YE/VT), wiring harness side and ground.
  • Vehicles built from 10/2001: circuit 7-LE53 (YE/BU), wiring harness side and ground.

Is a constant voltage of 5 V displayed?
Yes
No
- No voltage is displayed, vehicles built before 10/2001: LOCATE and RECTIFY break in circuit 7-XL9A (YE/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- No voltage is displayed, vehicles built from 10/2001: LOCATE and RECTIFY break in circuit 7-LE53 (YE/BU) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Battery voltage is displayed: LOCATE and RECTIFY short to battery voltage in the circuits connected to gas discharge lamp, connector C1146, pin 9 with the aid of the wiring diagrams. CHECK the operation of the system. If the concern persists, CHECK and if necessary RENEW the gas discharge lamp. CHECK the operation of the system.
B12: CHECK CONTROL CIRCUIT OF REAR HEADLAMP LEVELLING SENSOR FOR SHORT TO BATTERY VOLTAGE
1
Ignition switch in position 0.
2
Disconnect Left-hand gas discharge lamp from connector C1146 .
3
Ignition switch in position II.

4
Measure the voltage between rear headlamp levelling sensor, connector C94, pin 2:
  • Vehicles built before 10/2001: circuit 8-XL9 (WH/VT), wiring harness side and ground.
  • Vehicles built from 10/2001: 8-LE54 (WH/BK), wiring harness side and ground.

Is battery voltage displayed?
Yes
- Vehicles built before 10/2001: LOCATE and RECTIFY short to battery voltage in circuit 8-XL9 (WH/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY short to battery voltage in circuit 8-LE54 (WH/BK) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
No
B13: CHECK CONTROL CIRCUIT OF REAR HEADLAMP LEVELLING SENSOR FOR SHORT TO GROUND
1
Ignition switch in position 0.

2
Measure resistance between rear headlamp levelling sensor, connector C94, pin 2:
  • Vehicles built before 10/2001: circuit 8-XL9 (WH/VT), wiring harness side and ground.
  • Vehicles built from 10/2001: circuit 8-LE54 (WH/BK), wiring harness side and ground.

Is the resistance more than 10,000 Ohms?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY short to ground in circuit 8-XL9 (WH/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY short to ground in circuit 8-LE54 (WH/BK) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
B14: CHECK CONTROL CIRCUIT OF REAR HEADLAMP LEVELLING SENSOR FOR OPEN CIRCUIT

1
Measure resistance between left-hand gas discharge lamp, connector C1146 pin 10:
  • Vehicles built before 10/2001: circuit 8-XL9 (WH/VT), wiring harness side and rear headlamp levelling sensor, connector C94, pin 2, circuit 8-XL9 (WH/VT), wiring harness side.
  • Vehicles built from 10/2001: circuit 8-LE54 (WH/BK), wiring harness side and rear headlamp levelling sensor, connector C94, pin 2, circuit 8-LE54 (WH/BK), wiring harness side.

Is the resistance less than 2 ohms?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY break in circuit 8-XL9 (WH/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY the break in circuit 8-LE54 (WH/BK) between gas discharge lamp and headlamp levelling sensor with the aid of wiring diagrams. CHECK the operation of the system.
B15: CHECK CONTROL CIRCUIT OF FRONT HEADLAMP LEVELLING SENSOR FOR SHORT TO BATTERY VOLTAGE
1
Ignition switch in position II.

2
Measure the voltage between front headlamp levelling sensor, connector C195, pin 2:
  • Vehicles built before 10/2001: circuit 8-XL9A (WH/VT), wiring harness side and ground.
  • Vehicles built from 10/2001: circuit 8-LE53 (WH/BU), wiring harness side and ground.

Is battery voltage displayed?
Yes
- Vehicles built before 10/2001: LOCATE and RECTIFY short to battery voltage in circuit 8-XL9A (WH/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY short to battery voltage in circuit 8-LE53 (WH/BU) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
No
B16: CHECK CONTROL CIRCUIT OF FRONT HEADLAMP LEVELLING SENSOR FOR SHORT TO GROUND
1
Ignition switch in position 0.

2
Measure the resistance between front headlamp levelling sensor, connector C195, pin 2:
  • Vehicles built before 10/2001: circuit 8-XL9A (WH/VT), wiring harness side and ground.
  • Vehicles built from 10/2001: circuit 8-LE53 (WH/BU), wiring harness side and ground.

Is the resistance more than 10,000 Ohm?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY short to ground in circuit 8-XL9A (WH/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY short to ground in circuit 8-LE53 (WH/BU) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
B17: CHECK CONTROL CIRCUIT OF FRONT HEADLAMP LEVELLING SENSOR FOR OPEN CIRCUIT

1
Measure resistance between left-hand gas discharge lamp, connector C1146 pin 12:
  • Vehicles built before 10/2001: circuit 8-XL9A (WH/VT), wiring harness side and front headlamp levelling sensor, connector C195, pin 2, circuit 8-XL9A (WH/VT), wiring harness side.
  • Vehicles built from 10/2001: circuit 8-LE53 (WH/BU), wiring harness side and front headlamp levelling sensor, connector C195, pin 2, circuit 8-LE53 (WH/BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY break in circuit 8-XL9A (WH/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY break in circuit 8-LE53 (WH/BU) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
B18: CHECK POWER SUPPLY OF REAR HEADLAMP LEVELLING SENSOR FOR OPEN CIRCUIT

1
Measure the resistance between the left-hand gas discharge lamp:
  • Vehicles built before 10/2001: connector C1146, pin 9, circuit 7-XL9 (YE/VT), wiring harness side and rear headlamp levelling sensor, connector C94, pin 3, circuit 7-XL9 (YE/VT), wiring harness side.
  • Vehicles built from 10/2001: connector C1146, pin 9, circuit 7-LE54 (YE/BK), wiring harness side and rear headlamp levelling sensor, connector C94, pin 3, circuit 7-LE54 (YE/BK), wiring harness side.

Is the resistance less than 2 ohms?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY break in circuit 7-XL9 (YE/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY the break in circuit 7-LE54 (YE/BK) between gas discharge lamp and headlamp levelling sensor with the aid of wiring diagrams. CHECK the operation of the system.
B19: CHECK POWER SUPPLY OF FRONT HEADLAMP LEVELLING SENSOR FOR OPEN CIRCUIT

1
Measure resistance between left-hand gas discharge lamp, connector C1146 pin 9:
  • Vehicles built before 10/2001: circuit 7-XL9 (YE/VT), wiring harness side and front headlamp levelling sensor, connector C195, pin 3, circuit 7-XL9A (YE/VT), wiring harness side and ground.
  • Vehicles built from 10/2001: circuit 7-LE54 (YE/BK), wiring harness side and front headlamp levelling sensor, connector C195, pin 3, circuit 7-LE53 (YE/BU), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY break in circuit 7-XL9(A) (YE/VT) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY the break in circuit 7-LE53 (YE/BK)/7-LE54 (YE/BK) between gas discharge lamp and headlamp levelling sensor with the aid of wiring diagrams. CHECK the operation of the system.
B20: CHECK CIRCUIT 9-XL9 (BN/WH) OR 9-LE54 (BN/YE) FOR A SHORT TO GROUND
1
Ignition switch in position 0.

2
Measure resistance between rear headlamp levelling sensor, connector C94, pin 1:
  • Vehicles built before 10/2001: circuit 9-XL9 (BN/WH), wiring harness side and ground.
  • Vehicles built from 10/2001: circuit 9-LE54 (BN/YE) (from 10/2001), wiring harness side and ground.

Is the resistance more than 10,000 Ohms?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY short to ground in circuit 9-XL9 (BN/WH) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY short to ground in circuit 9-LE54 (BN/YE) between gas discharge lamp and headlamp leveling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
B21: CHECK CIRCUIT 9-XL9 (BN/WH) OR 9-LE54 (BN/YE) FOR OPEN CIRCUIT

1
Measure resistance between left-hand gas discharge lamp, connector C1146 pin 13:
  • Vehicles built before 10/2001: circuit 9-XL9 (BN/WH), wiring harness side and rear headlamp levelling sensor, connector C94, pin 1, circuit 9-XL9 (BN/WH), wiring harness side.
  • Vehicles built from 10/2001: circuit 9-LE54 (BN/YE), wiring harness side and rear headlamp levelling sensor, connector C94, pin 1, circuit 9-LE54 (BN/YE), wiring harness side.

Is the resistance less than 2 ohms?
Yes
No
- Vehicles built before 10/2001: LOCATE and RECTIFY break in circuit 9-XL9 (BN/WH) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY the break in circuit 9-LE54 (BN/YE) between gas discharge lamp and headlamp levelling sensor with the aid of wiring diagrams. CHECK the operation of the system.
B22: CHECK CIRCUIT 9-XL9A (BN/WH) OR 9-LE53 (BN/BU) FOR OPEN CIRCUIT

1
Measure resistance between left-hand gas discharge lamp, connector C1146 pin 13:
  • Vehicles built before 10/2001: circuit 9-XL9 (BN/WH), wiring harness side and front headlamp levelling sensor, connector C195, pin 1, circuit 9-XL9A (BN/WH), wiring harness side.
  • Vehicles built from 10/2001: circuit 9-LE54 (BN/YE), wiring harness side and front headlamp levelling sensor, connector C195, pin 1, circuit 9-LE53 (BN/BU), wiring harness side.

Is the resistance less than 2 ohms?
Yes
CHECK left-hand headlamp levelling sensors and gas discharge lamp and RENEW if necessary. CHECK the operation of the system.
No
- Vehicles built before 10/2001: LOCATE and RECTIFY break in circuit 9-XL9A (BN/WH) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
- Vehicles built from 10/2001: LOCATE and RECTIFY break in circuit 9-LE53 (BN/BU) between gas discharge lamp and headlamp levelling sensor with the aid of the wiring diagrams. CHECK the operation of the system.
B23: CHECK LEFT-HAND HEADLAMP LEVELLING MOTOR
1
Remove the left-hand gas discharge lamp.
2
Disconnect Left-hand headlamp levelling motor .

3
Measure resistance at left-hand gas discharge lamp, connector C1146, pin 5, circuit (BU), component side and the headlamp levelling motor, circuit (BU), wiring harness side.

4
Measure resistance at left-hand gas discharge lamp, connector C1146, pin 11, circuit (BK), component side and the headlamp levelling motor, circuit (BK), wiring harness side.

5
Measure resistance at left-hand headlamp between connector C1146, pin 14, circuit (VT/YE), component side and the headlamp levelling motor, circuit (VT/YE), wiring harness side.

Is the resistance in all three measurements less than 2 ohms?
Yes
CHECK left-hand headlamp levelling motor and RENEW if necessary. CHECK the operation of the system. If the concern persists, CHECK and if necessary RENEW the left-hand gas discharge lamp. CHECK the operation of the system.
No
LOCATE and RECTIFY break in circuit between headlamp levelling motor and gas discharge lamp. CHECK the operation of the system.
B24: CHECK POWER SUPPLY OF RIGHT-HAND GAS DISCHARGE LAMP FOR OPEN CIRCUIT
1
Ignition switch in position 0.
2
Disconnect Right-hand gas discharge lamp from connector C1147 .
3
Ignition switch in position II.
4
Switch on the dipped beam.

5
Measure the voltage between right-hand gas discharge lamp, connector C1147, pin 5, circuit 15-LE2B (GN/BU), wiring harness side and ground.

Is battery voltage displayed?
Yes
No
LOCATE and RECTIFY break in circuit between soldered connection S335 and gas discharge lamp with the aid of the wiring diagrams. CHECK the operation of the system.
B25: CHECK FUSE F18 (BJB)
1
Ignition switch in position 0.
2
Disconnect Fuse F18 (BJB) .
3
CHECK Fuse F18 (20 A) .

Is the fuse OK.?
Yes
No
INSTALL a new fuse F18 (20 A). If fuse blows again, LOCATE and REMEDY the short to ground with the aid of the wiring diagrams. CHECK the operation of the system.
B26: CHECK THE VOLTAGE AT FUSE F18 (BJB)
1
Connect Fuse F18 (BJB) .
2
Ignition switch in position II.
3
Measure the voltage between fuse F18 (20A) (BJB) and ground.

Is battery voltage displayed?
Yes
No
LOCATE AND RECTIFY the break in voltage supply of fuse F18 (BJB) with the aid of the wiring diagrams, if necessary TEST AND RENEW the BJB. CHECK the operation of the system.
B27: CHECK RIGHT-HAND DIPPED BEAM CONTROL CIRCUIT FOR OPEN CIRCUIT

1
Measure the voltage between right-hand gas discharge lamp, connector C1147, pin 14, circuit 15S-LE23 (GN/WH), wiring harness side and ground.

Is battery voltage displayed?
Yes
No
LOCATE and RECTIFY break in circuit between fuse F18 (BJB) and gas discharge lamp with the aid of the wiring diagrams. CHECK the operation of the system.
B28: CHECK GROUND CONNECTION OF RIGHT-HAND GAS DISCHARGE LAMP FOR OPEN CIRCUIT
1
Ignition switch in position 0.

2
Measure the resistance between right-hand gas discharge lamp, connector C1147, pin 11, circuit 31-LE30 (BK), wiring harness side and ground.

Is the resistance less than 2 ohms?
Yes
No
LOCATE and RECTIFY break in circuit between gas discharge lamp and soldered connection S317 with the aid of the wiring diagrams. CHECK the operation of the system.
B29: CHECK RIGHT-HAND GAS DISCHARGE LAMP CONTROL CIRCUIT FOR SHORT TO BATTERY VOLTAGE
1
Ignition switch in position II.

2
Measure the voltage between right-hand gas discharge lamp, connector C1147, pin 3, circuit 8-LE46 (WH/RD), wiring harness side and ground.

Is battery voltage displayed?
Yes
LOCATE and RECTIFY short to battery voltage in circuit between left-hand gas discharge lamp and right-hand gas discharge lamp with the aid of the wiring diagrams. CHECK the operation of the system.
No
B30: CHECK RIGHT-HAND GAS DISCHARGE LAMP CONTROL CIRCUIT FOR SHORT TO GROUND
1
Ignition switch in position 0.

2
Measure resistance between right-hand headlamp, connector C1147, pin 3, circuit 8-LE46 (WH/RD), wiring harness side and ground.

Is the resistance more than 10,000 Ohm?
Yes
No
LOCATE and RECTIFY short to ground in circuit between left-hand gas discharge lamp and right-hand gas discharge lamp with the aid of the wiring diagrams. CHECK the operation of the system.
B31: CHECK RIGHT-HAND GAS DISCHARGE LAMP CONTROL CIRCUIT FOR OPEN CIRCUIT
1
Disconnect Left-hand gas discharge lamp from connector C1146 .

2
Measure resistance between left-hand gas discharge lamp, connector C1146, pin 3, circuit 8-LE46 (WH/RD), wiring harness side and right-hand gas discharge lamp, connector C1147, pin 3, circuit 8-LE46 (WH/RD), wiring harness side.

Is the resistance less than 2 ohms?
Yes
No
LOCATE and RECTIFY break in circuit between left-hand gas discharge lamp and right-hand gas discharge lamp with the aid of the wiring diagrams. CHECK the operation of the system.
B32: CHECK RIGHT-HAND HEADLAMP LEVELLING MOTOR
1
Remove the right-hand gas discharge lamp.
2
Disconnect Right-hand headlamp levelling motor .

3
Measure resistance at right-hand gas discharge lamp, connector C1147, pin 5, circuit (BU), component side and the headlamp levelling motor, circuit (BU), wiring harness side.

4
Measure resistance at right-hand gas discharge lamp, connector C1147, pin 11, circuit (BK), component side and the headlamp levelling motor, circuit (BK), wiring harness side.

5
Measure resistance at right-hand headlamp between connector C1147, pin 14, circuit (VT/YE), component side and the headlamp levelling motor, circuit (VT/YE), wiring harness side.

Is the resistance in all three measurements less than 2 ohms?
Yes
CHECK right-hand headlamp levelling motor and RENEW if necessary. CHECK the operation of the system. If the concern persists, CHECK and if necessary RENEW the right-hand gas discharge lamp. CHECK the operation of the system.
No
LOCATE and RECTIFY break in circuit between headlamp levelling motor and gas discharge lamp. CHECK the operation of the system.

General Procedures > < Trailer Lamps