2002 F-Super Duty /Excursion Workshop Manual

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1 Page 1 of 9 SECTION : Exterior Lighting 2002 F-Super Duty /Excursion Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 05/23/2001 Turn Signal and Hazard Lamps Refer to Wiring Diagrams Cell 90, Turn/Stop/Hazard Lamps for schematic and connector information. Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent Inspection and Verification 1. Verify the customer concern by operating the turn signal/hazard lamps. 2. Visually inspect the following for obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Multifunction switch Electrical Central junction box (CJB) fuses: 18 (20A) 27 (15A) Circuitry Electronic flasher Signal/hazard lamp 3. If the concern is not visually evident, verify the symptom and proceed to the Symptom Chart. Symptom Chart NOTE: Refer to Wiring Diagrams for the connector numbers stated in the pinpoint tests. Symptom Chart Condition Possible Sources Action The turn signal lamps are never on One turn signal/hazard lamp is never on The hazard lamps are inoperative Central junction box (CJB) fuse 27 (15A). Circuitry. Electronic flasher. Multifunction switch. CJB. Turn signal/hazard flasher lamp. Multifunction switch. Circuitry. Central junction box (CJB) fuse 18 (20A). Circuitry. Electronic flasher. Multifunction switch. CJB. GO to Pinpoint Test K. GO to Pinpoint Test L. GO to Pinpoint Test M. The turn signal lamps are always on Multifunction switch. INSTALL a new multifunction switch. REFER to Section TEST the system for normal operation. The hazard lamps are always on Multifunction switch. INSTALL a new multifunction switch. REFER to Section TEST the system for normal operation. The turn signal lamps are never on signal mirror (Excursion) Circuitry. Signal mirror. GO to Pinpoint Test N. Pinpoint Tests PINPOINT TEST K: THE TURN SIGNAL LAMPS ARE NEVER ON CONDITIONS K1 CHECK THE VOLTAGE TO THE ELECTRONIC FLASHER DETAILS/RESULTS/ACTIONS

2 Page 2 of 9 Electronic Flasher Measure the voltage between the electronic flasher connector pin 30, circuit 295 (LB/PK), Is the voltage greater than 10 volts? GO to K3. K2 CHECK THE CENTRAL JUNCTION BOX (CJB) GO to K2. CJB C270a Measure the voltage between the CJB C270a pin 21, circuit 295 (LB/PK), component side and ground. Is the voltage greater than 10 volts?

3 Page 3 of 9 REPAIR circuit 295 (LB/PK). TEST the system for normal operation. K3 CHECK CIRCUIT 57 (BK) FOR AN OPEN INSTALL a new CJB. TEST the system for normal operation. Measure the resistance between the electronic flasher connector pin 86, circuit 57 (BK), Is the resistance less than 5 ohms? K4 CHECK CIRCUIT 44 (LB) FOR OPEN OR SHORT TO GROUND GO to K4. Multifunction Switch C202a Measure the resistance between the multifunction switch C202a pin 2, circuit 44 (LB), harness side and the electronic flasher connector pin 87, circuit 44 (LB), harness side; and between the multifunction switch C202a pin 2, circuit 44 (LB), Is the resistance less than 5 ohms between the multifunction switch and the electronic flasher, and greater than 10,000 ohms between the multifunction switch and ground? K5 CHECK CIRCUIT 385 (WH/RD) FOR SHORT TO GROUND GO to K5. Measure the resistance between the multifunction switch C202a pin 3, circuit 385 (WH/RD),

4 Page 4 of 9 Is the resistance greater than 10,000 ohms? GO to K6. K6 CHECK THE MULTIFUNCTION SWITCH Carry out the multifunction switch component test. Refer to Wiring Diagrams Cell 149 for component testing. Is the multifunction switch OK? INSTALL a new electronic flasher. TEST the system for normal operation. INSTALL a new multifunction switch. REFER to Section TEST the system for normal operation. PINPOINT TEST L: ONE TURN SIGNAL/HAZARD LAMP IS NEVER ON CONDITIONS L1 CHECK THE BRAKE LAMPS FOR CORRECT OPERATION DETAILS/RESULTS/ACTIONS Press and release the brake pedal. Do the brake lamps operate correctly? GO to L2. L2 CHECK THE VOLTAGE TO THE INOPERATIVE LAMP REFER to Stoplamps in this section. Inoperative Turn Signal/Hazard Flasher Lamp Place the hazard flasher lamp switch in the ON position. Measure the voltage between the lamp connector and ground: LF circuit 3 (LG/WH) RF circuit 2 (WH/LB) LR circuit 9 (LG/OG) RR circuit 5 (OG/LB) Does the voltage alternate between less than 1 volt and greater than 10 volts? REPAIR circuit 57 (BK). TEST the system for normal operation. If rear lamp, INSTALL a new multifunction switch. REFER to Section TEST the system for normal operation.

5 Page 5 of 9 L3 CHECK THE MULTIFUNCTION SWITCH If front lamp, GO to L3. Carry out the multifunction switch component test. Refer to Wiring Diagrams Cell 149 for component testing. Is the multifunction switch OK? REPAIR circuit 3 (LG/WH) or 2 (WH/LB). TEST the system for normal operation. INSTALL a new multifunction switch. REFER to Section TEST the system for normal operation. PINPOINT TEST M: THE HAZARD LAMPS ARE NEVER ON CONDITIONS M1 CHECK THE VOLTAGE TO THE ELECTRONIC FLASHER DETAILS/RESULTS/ACTIONS Electronic Flasher Measure the voltage between the electronic flasher connector pin 85, circuit 10 (LG/OG), harness side and ground Is the voltage greater than 10 volts? GO to M3. M2 CHECK THE CENTRAL JUNCTION BOX (CJB) GO to M2. CJB C270b Measure the voltage between the CJB C270b pin 2, circuit 10 (LG/OG), component side and ground.

6 Page 6 of 9 Is the voltage greater than 10 volts? REPAIR circuit 10 (LG/OG). TEST the system for normal operation. M3 CHECK CIRCUIT 57 (BK) FOR AN OPEN INSTALL a new CJB. TEST the system for normal operation. Measure the resistance between the electronic flasher connector pin 86, circuit 57 (BK), Is the resistance less than 5 ohms? GO to M4. M4 CHECK CIRCUIT 385 (WH/RD) FOR OPEN OR SHORT TO GROUND Multifunction Switch C202a Measure the resistance between the multifunction switch C202a pin 3, circuit 385 (WH/RD), harness side and the electronic flasher connector pin 87a, circuit 385 (WH/RD), harness side; and between the multifunction switch C202a pin 3, circuit 385 (WH/RD), harness side and ground.

7 Page 7 of 9 Is the resistance less than 5 ohms between the multifunction switch and the electronic flasher, and greater than 10,000 ohms between the multifunction switch and ground? GO to M5. M5 CHECK CIRCUIT 44 (LB) FOR SHORT TO GROUND Measure the resistance between the multifunction switch C202a pin 2, circuit 44 (LB), harness side and ground. Is the resistance greater than 10,000 ohms? GO to M6. M6 CHECK THE MULTIFUNCTION SWITCH Carry out the multifunction switch component test. Refer to Wiring Diagrams Cell 149 for component testing. Is the multifunction switch OK? INSTALL a new electronic flasher. TEST the system for normal operation. INSTALL a new multifunction switch. REFER to Section TEST the system for normal operation. PINPOINT TEST N: THE TURN SIGNAL LAMPS ARE NEVER ON SIGNAL MIRROR (EXCURSION) CONDITIONS N1 VERIFY THE INOPERATIVE SIGNAL MIRROR DETAILS/RESULTS/ACTIONS Verify the signal mirror operation. Are the signal mirrors OK? System is OK. If both the LH and RH signal mirrors are inoperative, REPAIR circuit 57 (BK). TEST the system for normal operation. If the LH signal mirror is inoperative, GO to N2. N2 CHECK CIRCUIT 3 (LG/WH) FOR AN OPEN If the RH signal mirror is inoperative, GO to N3.

8 Page 8 of 9 LH Outside Rear View Mirror C521 Place the multifunction switch in the left turn position. Measure the voltage between LH outside rear view mirror C521 pin 3, circuit 3 (LG/WH), Does the voltage vary between 0 and greater than 10 volts? INSTALL a new LH outside rear view mirror. REFER to Section TEST the system for normal operation. N3 CHECK CIRCUIT 2 (WH/LB) FOR AN OPEN RH Outside Rear View Mirror C601 Place the multifunction switch in the right turn position. Measure the voltage between RH outside rear view mirror C601 pin 3, circuit 2 (WH/LB), Does the voltage vary between 0 and greater than 10 volts? INSTALL a new RH outside rear view mirror. REFER to Section TEST the system for normal operation.

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