headlamp FORD MUSTANG 2003 Workshop Manual

(+40°F) or colder at
first start of the day
between ball
bearings and
bearing race.
z Power steering moan
— occurs at high idle
and possibly at idle
during the first cold
start of the day in
temperatures of
approximately - 18°C
(0°F) or colder. Noise
can even be a severe
screech for less than
one minute in very
cold temperatures of
approximately - 29°C
(- 20°F) or colder z
High fluid
viscosity, or
plugged
reservoir screen
in power
steering
reservoir
starves pump
causing
cavitation. z
Go To Pinpoint Test D .
z Generator whine —
during high electrical
loads at idle or high
idle, a high pitch
whine or moan is
emitted from the
generator z
Generator
electrical field
noise. z
Using an EngineEAR,
PROBE near the generator
housing. LISTEN for
changes in the noise level
while changing electrical
loads (such as rear defrost,
headlamps, etc.). CARRY
OUT a generator load test. If
the system passes the load
test, the noise is from the
generator bearings,
INSTALL new bearings. If
the system fails the load
test, INSTALL a new
generator. REFER to
Section 414 - 02 .
z Engine- driven cooling
fan moan — occurs
during the first start of
the day. It is most
objectionable near
idle speeds up to
2000 rpm. The noise
increases with rpm z
The viscous
cooling fan
clutch engages
until the fluid in
the clutch
reaches normal
operating
temperature,
causing the fan
to fully engage. z
Go To Pinpoint Test E .
z Drumming noise —
occurs inside the
vehicle during idle or
high idle, hot or cold.
Very low- frequency
drumming is very rpm
dependent z
Exhaust system
vibration excites
the body
resonances
inducing interior
noise.
z Engine vibration
excites the
body
resonances
inducing interior
noise. z
Go To Pinpoint Test F .
z Hissing noise —
occurs during idle or
high idle that is
apparent with the
hood open z
Vacuum leak or
idle air control
(IAC) valve flow
noise. z
Use the Ultrasonic Leak
Detector/EngineEAR to
locate the source. Scan the
air intake system from the
inlet to each cylinder intake Klj . 29 ba
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DESCRIPTION AND OPERATION
Steering Column Switches
The steering column switches system consists of the following components:
zmultifunction switch (13K359)
z key release button (manual transmission only) (3F527)
z ignition switch (11572)
The integrated multifunction switch is mounted to the LH side of the steering column and controls the
turn signals, hazard flasher, windshield wiper/washer control, and headlamp dimmer/flash- to-pass.
The key release button is equipped with manual transmissions only.
The ignition switch is mounted below the steering column and is activated by rotating the key lock
cylinder on the steering column. SECTION 211-
05: Steering Column Switches 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Steering Column Switches
Refer to Wiring Diagrams Cell
13 , Power Distribution for schematic and connector information.
Refer to Wiring Diagrams Cell 81 , Interval Wiper/Washer for schematic and connector information.
Refer to Wiring Diagrams Cell 85 , Headlamps for schematic and connector information.
Refer to Wiring Diagrams Cell 90 , Turn/Stop/Hazard Lamps for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the multifunction or ignition switch.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
SECTION 211-
05: Steering Column Switches 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool 73 Digital Multimeter
105-
R0051 or equivalent
Visual Inspection Chart Mechanical Electrical
z
Ignition key
z Ignition switch
z Multifunction switch
z Turn signal switch
z Hazard/flasher switch z
Battery junction box (BJB) Fuses:
„(3) IGN (40A)
z Central junction box (CJB) Fuses:
„6 (25A)
„ 39 (5A)
z Damaged wiring harness
z Loose or corroded connections Klj . 1 ba
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z
check the connections to the vehicle.
z check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: zCKT914, CKT915 or CKT70 =ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the GEM.
6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
GEM Diagnostic Trouble Code (DTC) Index GEM Diagnostic Trouble Code (DTC) Index DTC Description Source Action
B1217 Horn Relay Coil Circuit Failure GEM REFER to
Section 413 - 06 .
B1218 Horn Relay Coil Circuit Short to
Vbatt GEM REFER to
Section 413 - 06 .
B1312 Lamp Headlamp Input Circuit
Short to Battery GEM REFER to
Section 417 - 01 .
B1317 Battery Voltage High GEM REFER to
Section 414 - 00 .
B1318 Battery Voltage Low GEM REFER to
Section 414 - 00 .
B1322 Driver Door Ajar Circuit Short to
Ground GEM REFER to
Section 417 - 02 .
B1330 Passenger Door Ajar Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1334 Decklid Ajar Rear Door Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1339 Chime Input Request Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1340 Chime Input Request Circuit
Short to Ground GEM REFER to
Section 413 - 09 .
B1342 ECU Is Defective GEM CLEAR the DTC. Retrieve the DTCs. If DTC
B1342 is retrieved, INSTALL a new GEM. REFER to Section 419 - 10 .
B1353 Ignition Key-
In Circuit Open GEM REFER to
Section 413 - 09 .
B1359 Ignition Run/Acc Circuit Failure GEM GO to
Pinpoint Test E .
B1396 Power Door Lock Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1397 Power Door Unlock Circuit
Short to Battery GEM REFER to
Section 501 - 14B . Klj . 2 ba
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DIAGNOSIS AND TESTING
Instrument Cluster and Panel Illumination
Refer to Wiring Diagrams Cell
71 , Instrument Illumination for schematic and connector information.
Inspection and Verification
NOTE: A new instrument cluster must be reconfigured. Refer to Section 418 - 01 .
NOTE: The instrument panel dimmer switch is a part of the headlamp switch.
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart.
Symptom Chart SECTION 413-
00: Instrument Cluster and Panel Illumination 2003 Mustang Workshop Manual Special Tool(s)
73III Automotive Meter
105-
R0057 or equivalent
Visual Inspection Chart Electrical
z
Central junction box (CJB) fuses:
„5 (15A)
„ 21 (5A)
„ 34 (20A)
„ 37 (5A)
„ 32 (15A)
„ 27 (20A)
z Circuitry
z Damaged switch
Symptom Chart Condition
Possible Sources Action
z The control illumination is
inoperative z
Central junction box
(CJB) fuse 37 (5A).
z Circuitry.
z Headlamp switch. z
Go To Pinpoint Test A .
z The instrument cluster
illumination is inoperative z
Circuitry.
z Instrument cluster. z
Go To Pinpoint Test B . Klj . 1 ba
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Pinpoint Tests
PINPOINT TEST A: THE CONTROL ILLUMINATION IS INOPERATIVE
PINPOINT TEST B: THE INSTRUMENT CLUSTER ILLUMINATION IS
INOPERATIVE z
Bulb(s).
z The climate control
illumination is inoperative z
Circuitry.
z Bulb(s). z
Go To Pinpoint Test C .
z The audio system
illumination is inoperative z
Circuitry.
z Audio unit. z
Go To Pinpoint Test D .
z A single illumination source
is inoperative z
Circuitry.
z Switch. z
Go To Pinpoint Test E .
Test Step Result / Action to Take
A1 CHECK PARKING LAMPS
z
Place the headlamp switch in the ON
position.
z Are the exterior lamps on? Yes
Place the headlamp switch in the OFF position.
GO to
A2 .
No
REFER to Section 417 - 01 .
A2 CHECK HEADLAMP SWITCH
z
Key in OFF position.
z Carry out the headlamp switch
components test;
Refer to Wiring Diagrams Cell 149 for
schematic and connector information.
.
z Is the headlamp switch OK? Yes
RECONNECT the headlamp switch. GO to
A3 .
No
INSTALL a new headlamp switch. REFER to
Section 417 - 01 . TEST the system for normal
operation. A3 CHECK CIRCUIT 1045 (DB/WH)
z
Place the headlamp switch in the ON
position.
z Rotate the instrument panel dimmer
switch to the full illumination position.
z Measure voltage between central
junction box (CJB) fuse 37 (5A) and
ground.
z Is the voltage greater than 10 volts? Yes
REPAIR circuit 19 (LB/RD). TEST the system for
normal operation.
No
REPAIR circuit 1045 (DB/WH). TEST the system
for normal operation.
Test Step Result / Action to Take
B1 CHECK VOLTAGE TO INSTRUMENT CLUSTER
ILLUMINATION z
Disconnect: Instrument Cluster .
z Place the headlamp switch in the ON position.
z Rotate the instrument panel dimmer switch to the full Yes
GO to
B2 . Klj . 2 ba
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PINPOINT TEST C: THE CLIMATE CONTROL ILLUMINATION IS
INOPERATIVE illumination position.
z Measure the voltage between the instrument cluster C220b
pin 4, circuit 19 (LB/RD), harness side and ground.
z Is the voltage greater than 10 volts? No
REPAIR the circuit. TEST
the system for normal
operation.
B2 CHECK GROUND TO INSTRUMENT CLUSTER
z
Place the headlamp switch in the OFF position.
z Measure the resistance between the instrument cluster
C220b pin 1, circuit 1205 (BK), harness side and ground.
z Are the resistances less than 5 ohms? Yes
INSTALL a new instrument
cluster. REFER to
Section 413 - 01 . TEST the system
for normal operation.
No
REPAIR the circuit. TEST
the system for normal
operation. Test Step Result / Action to Take
C1 CHECK VOLTAGE TO CLIMATE CONTROL ILLUMINATION
z
Disconnect: Function Selector Switch C294b .
z Place the headlamp switch in the ON position.
z Rotate the instrument panel dimmer switch to the full
illumination position.
z Measure the voltage between the function selector switch
C294b pin 2, circuit 19 (LB/RD), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
C2 .
No
REPAIR the circuit.
TEST the system for
normal operation. C2 CHECK GROUND TO CLIMATE CONTROL Klj . 3 ba
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PINPOINT TEST D: THE AUDIO SYSTEM ILLUMINATION IS
INOPERATIVE z
Measure the resistance between the function selector switch
C294b pin 1, circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
INSTALL new
illumination bulb(s).
REFER to
Section 412 -
04 .
No
REPAIR the circuit.
TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK VOLTAGE TO AUDIO UNIT
z
Disconnect: Audio Unit C290a.
z Place the headlamp switch in the ON position.
z Rotate the instrument panel dimmer switch to the full
illumination position.
z Measure the voltage between the audio unit C290a pin
1, circuit 19 (LB/RD), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
D2 .
No
REPAIR the circuit. TEST the
system for normal operation. D2 CHECK GROUND TO AUDIO UNIT
z
Measure the resistance between the audio unit C290a
pin 2, circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
REMOVE the audio unit and
SEND it to an authorized Ford
audio systems repair facility.
TEST the system for normal
operation.
No
REPAIR the circuit. TEST the
system for normal operation. Klj . 4 ba
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PINPOINT TEST E: A SINGLE ILLUMINATION SOURCE IS
INOPERATIVE
Test Step Result / Action to Take
E1 CHECK VOLTAGE TO THE SINGLE
ILLUMINATION SOURCE z
Disconnect: Inoperative Illumination Source.
z Place the headlamp switch in the ON position.
z Rotate the instrument panel dimmer switch to the
full illumination position.
z Measure the voltage between the inoperative
illumination source, circuit 19 (LB/RD), harness
side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
E2 .
No
REPAIR the circuit. TEST the system
for normal operation. E2 CHECK SINGLE ILLUMINATION SOURCE
GROUND z
Measure the resistance between inoperative
illumination source, circuit 1205 (BK), harness side
and ground.
z Is the resistance less than 5 ohms? Yes
INSTALL a new component in
question. TEST the system for normal
operation.
No
REPAIR the circuit. TEST the system
for normal operation. Klj . 5 ba
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GEM Diagnostic Trouble Code (DTC) Index
DTC Description Source Action
B1218 Horn Relay Coil Circuit Short to
VBatt GEM REFER to
Section 501 - 14B .
B1312 Lamp Headlamp Input Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1317 Battery Voltage High GEM REFER to
Section 414 - 00 .
B1318 Battery Voltage Low GEM REFER to
Section 414 - 00 .
B1322 Driver Door Ajar Circuit Short to
Ground GEM REFER to
Section 417 - 02 .
B1330 Passenger Door Ajar Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1334 Decklid Ajar Rear Door Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1339 Chime Input Request Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1340 Chime Input Request Circuit
Short to Ground GEM REFER to
Section 413 - 09 .
B1342 ECU is Defective GEM Clear the DTCs. Retrieve the DTCs. If DTC B1342
is retrieved, INSTALL a new GEM. REFER to Section 419 - 10 .
B1353 Ignition Key-
In Circuit Open GEM REFER to
Section 413 - 09 .
B1359 Ignition Run/Acc Circuit Failure GEM REFER to
Section 211 - 05 .
B1396 Power Door Lock Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1397 Power Door Unlock Circuit
Short to Battery GEM REFER to
Section 501 - 14B .
B1405 Driver Power Window Down
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1408 Driver Power Window Up
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1426 Lamp Safety Belt Circuit Short
to Battery GEM Go To Pinpoint Test K .
B1428 Lamp Safety Belt Circuit Failure GEM Go To Pinpoint Test K .
B1431 Wiper Brake/Run Relay Circuit
Failure GEM REFER to
Section 501 - 16 .
B1432 Wiper Brake/Run Relay Circuit
Short to Battery GEM REFER to
Section 501 - 16 .
B1434 Wiper Hi/Low Speed Relay Coil
Circuit Failure GEM REFER to
Section 501 - 16 .
B1436 Wiper Hi/Low Speed Relay Coil
Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1438 Wiper Mode Select Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1441 Wiper Mode Select Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 . Klj . 8 ba
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