Inspection and Verification -- Headlamps (Without Autolamps/Exit Delay)
1. Verify the customer concern by operating the headlamp system.
2. Visually inspect the components of the headlamp system.
3. Check the wiring harness for obvious signs of shorts, opens, bad connections, or damage.
4. Check for improperly installed accessories.
5. If fault is not visually evident, determine the symptom and proceed to the following Symptom Chart.
VISUAL INSPECTION CHART
Electrical
ù Blown fuse(s)
ù Damaged headlamp bulb
ù Damaged wiring harness
ù Loose or corroded connections
PINPOINT TEST E: ONE HIGH OR ONE LOW BEAM HEADLAMP INOPERATIVE
E2 BATTERY FEED TO LAMP
l Turn headlamp switch ON and dimmer switch in required position.
l Check for battery voltage at headlamp feed wire (Aerostar, Ranger, Explorer HI beam -- LG/BK; Aerostar LO beam -- R/BK; Ranger, Explorer RH LO beam -- W/LG; Ranger, Explorer LH LO beam -- DB/LG).
l Is battery voltage present?
Yes
GO to «E3».
No
On Aerostar, REPAIR open in battery feed wire. On Ranger, Explorer, without lamp outage module, CHECK fuse 4 for LH LO beam headlamp or fuse 8 for RH LO beam headlamp. On Ranger, Explorer with HI beam headlamp inoperative, REPAIR open in battery feed wire. On Ranger, Explorer with lamp outage module and LO beam inoperative, GO to «E4».
PINPOINT TEST E: ONE HIGH OR ONE LOW BEAM HEADLAMP INOPERATIVE
E3 GROUND CIRCUIT
l Check for continuity between connector ground terminal and clean chassis ground.
l Is there continuity?
Yes
INSPECT lamp assembly for condition that could prevent lamp from coming on.
No
REPAIR ground circuit.
PINPOINT TEST E: ONE HIGH OR ONE LOW BEAM HEADLAMP INOPERATIVE
E4 HEADLAMP FEED TO LAMP OUTAGE MODULE
l Disconnect wiring at lamp outage module.
l Headlamp switch ON and dimmer switch in LO beam position.
l Check for battery voltage at module connector terminal 12 (DB/LG).
l Is battery voltage present?
Yes
GO to «E5».
No
REPAIR open between module and fuse panel.
PINPOINT TEST E: ONE HIGH OR ONE LOW BEAM HEADLAMP INOPERATIVE
E5 ISOLATE MODULE
l Install jumper between module connector terminals as follows:
-- With LH lamp out, terminals 1 (W/LG) and 11 (DB/W).
-- With RH lamp out, terminals 12 (DB/LG) and 13 (DG/O).
l Is headlamp on?
Yes
REPLACE lamp outage module.
No
REPAIR open between module and headlamps.