417-01-1 Exterior Lighting 417-01-1 DIAGNOSIS AND TESTING Visual Inspection Chart Turn Signal and Hazard Lamps Refer to Wiring Diagrams Cell 90 for schematic and Mechanical Electrical connector information. Multifunction switch Smart junction box Hazard lamp switch (SJB) Special Tool(s) Circuitry Bulbs 73III Automotive Meter 105-R0057 or equivalent 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) Worldwide Diagnostic System and select the vehicle to be tested from the (WDS) diagnostic tool menu. If the diagnostic tool does Vehicle Communication Module not communicate with the vehicle: (VCM) with appropriate adapters, or equivalent check that the program card is correctly diagnostic tool installed. check the connections to the vehicle. Flex Probe Kit check the ignition switch position. 105-R025B or equivalent 5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: Principles of Operation CAN or ISO circuit fault; all electronic control units no response/not equipped, refer The smart junction box (SJB) monitors the to Section 418-00. multifunction switch position by sending multiple response/not equipped for SJB, refer to voltage reference signals to the multifunction Section 419-10. switch. When the multifunction switch is in the LH or RH TURN positions, or the hazard lamp switch System passed, retrieve and record the is engaged, that input signal is routed to ground. continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the When the SJB receives a request for a turn signal or self-test diagnostics for the SJB. hazard lamps, the SJB supplies voltage to the appropriate turn lamps. 7. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Inspection and Verification Trouble Code (DTC) Index. 1. Verify the customer concern. 8. If no DTCs related to the concern are retrieved, 2. Visually inspect the following for obvious signs of mechanical or electrical damage. GO to Symptom Chart. Copyright 2005, Ford Motor Company Last updated: 06/30/2005
417-01-2 Exterior Lighting 417-01-2 Symptom Chart Symptom Chart Condition Possible Sources Action communication with the Circuitry REFER to Section 419-10. smart junction box (SJB) The turn signal lamps are Circuitry GO to Pinpoint Test L. inoperative Multifunction switch The turn signal lamps are Circuitry GO to Pinpoint Test M. always on Multifunction switch One turn signal/hazard lamp Circuitry GO to Pinpoint Test N. is inoperative/always on The hazard lamps are Circuitry GO to Pinpoint Test O. inoperative Hazard lamp switch The hazard lamps are always Circuitry GO to Pinpoint Test P. on Hazard lamp switch Pinpoint Tests Pinpoint Test L: The Turn Signal Lamps Are Inoperative rmal Operation The smart junction box (SJB) sends reference signals to the multifunction switch through circuit CLS39 (VT/WH) (LH turn input) and circuit CLS41 (GY/YE) (RH turn input). When the multifunction switch is switched to the LH or RH TURN positions, the voltage signal is routed to ground. When the SJB detects the multifunction switch in the LH or RH TURN position, the SJB sends voltage to the appropriate turn lamps. All the turn lamps are individually wired to the SJB. The timed on/off cycle is determined by the SJB and is set to flash approximately 80 times per minute if both the front and rear turn lamps operate correctly. If an individual turn signal lamp is inoperative, the SJB flashes the remaining turn lamp approximately 160 times per minute. Possible Causes Circuit CLS39 (VT/WH) open Circuit CLS41 (GY/YE) open Multifunction switch L1 L2 PINPOINT TEST L: THE TURN SIGNAL LAMPS ARE INOPERATIVE CHECK FOR CORRECT HIGH BEAM OPERATION Place the headlamp switch in the HEADLAMPS ON position. Place the multifunction switch in the HIGH BEAM position while PLACE the headlamp switch in the OFF observing the high beam headlamps. position. GO to L2. Do the high beams operate correctly? REFER to Headlamps in this section to continue diagnosis of the high beam headlamps. CHECK THE MULTIFUNCTION SWITCH Disconnect: Multifunction Switch C202. GO to L3. Carry out the multifunction switch component test. Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new multifunction switch. Is the multifunction switch OK? REFER to Section 211-05. TEST the system for normal operation. (Continued)
417-01-3 Exterior Lighting 417-01-3 L3 PINPOINT TEST L: THE TURN SIGNAL LAMPS ARE INOPERATIVE (Continued) CHECK CIRCUIT CLS39 (VT/WH) (LH TURN SIGNAL) OR CLS41 (GY/YE) (RH TURN SIGNAL) FOR AN OPEN Disconnect: SJB C2280d. Ignition ON. Measure the resistance between the multifunction switch C202-2 (LH turn lamps), circuit CLS39 (VT/WH), harness side and the SJB C2280d-14, circuit CLS39 (VT/WH), harness side; or between the multifunction switch C202-3 (RH turn lamps), circuit CLS41 (GY/YE), harness side and the SJB C2280d-24, circuit CLS41 (GY/YE), harness side. L4 GO to L4. Is the resistance less than 5 ohms? normal operation. CHECK FOR CORRECT SJB OPERATION Disconnect all the SJB connectors. Check for: INSTALL a new SJB. REFER to Section corrosion 419-10. TEST the system for normal pushed-out pins operation. Connect all the SJB connectors and make sure they seat correctly. The system is operating correctly at this Operate the system and verify the concern is still present. time. The concern may have been caused Is the concern still present? by a loose or corroded connector. Pinpoint Test M: The Turn Signal Lamps Are Always On rmal Operation The smart junction box (SJB) sends voltage reference signals to the multifunction switch through circuit CLS39 (VT/WH) (LH turn input) and circuit CLS41 (GY/YE) (RH turn input). When the multifunction switch is switched to the LH or RH TURN positions, the voltage signal is routed to ground. When the SJB detects the multifunction switch in the LH or RH TURN position, the SJB sends voltage to the appropriate turn lamps. Possible Causes Circuit CLS39 (VT/WH) short to ground Circuit CLS41 (GY/YE) short to ground Multifunction switch
417-01-4 Exterior Lighting 417-01-4 M1 M2 PINPOINT TEST M: THE TURN SIGNAL LAMPS ARE ALWAYS ON CHECK THE MULTIFUNCTION SWITCH Disconnect: Multifunction Switch C202. GO to M2. Ignition ON. Do the turn lamps continue to flash on and off? INSTALL a new multifunction switch. REFER to Section 211-05. CLEAR the DTCs. REPEAT the self-test. CHECK CIRCUIT CLS39 (VT/WH) (LH TURN SIGNAL) OR CIRCUIT CLS41 (GY/YE) (RH TURN SIGNAL) FOR A SHORT TO GROUND Disconnect: SJB C2280d. Measure the resistance between the multifunction switch C202-2 (LH turn lamps), circuit CLS39 (VT/WH), harness side and ground; or between the multifunction switch C202-3 (RH turn lamps), circuit CLS41 (GY/YE), harness side and ground. M3 GO to M3. REPAIR the circuit. CLEAR the DTCs. Is the resistance greater than 10,000 ohms? REPEAT the self-test. CHECK FOR CORRECT SJB OPERATION Disconnect all the SJB connectors. Check for: INSTALL a new SJB. REFER to Section corrosion 419-10. TEST the system for normal pushed-out pins operation. Connect all the SJB connectors and make sure they seat correctly. The system is operating correctly at this Operate the system and verify the concern is still present. time. The concern may have been caused Is the concern still present? by a loose or corroded connector. CLEAR any DTCs. REPEAT the self-test. Pinpoint Test N: One Turn Signal/Hazard Lamp Is Inoperative/Always On rmal Operation Fusion When the smart junction box (SJB) detects the multifunction switch in the LH TURN position, the SJB sends voltage through circuit CLS21 (BU/GN) to the LH front turn lamp. When the SJB detects the multifunction switch in the RH TURN position, the SJB sends voltage through circuit CLS25 (YE/VT) to the RH front turn lamp. Circuit GD123 (BK/GY) and circuit GD121 (BK/YE) provide ground for the LH and RH front turn lamps, respectively. The rear turn lamps are controlled utilizing the rear stoplamp circuits. rmal Operation Milan When the SJB detects the multifunction switch in the LH TURN position, the SJB sends voltage through circuit CLS21 (BU/GN) to the LH front turn lamp, and through circuit CLS18 (GY/BN) to the LH rear turn lamp. When the SJB detects the multifunction switch in the RH TURN position, the SJB sends voltage through circuit CLS25 (YE/VT) to the RH front turn lamp, and through circuit CLS19 (VT/OG) to the RH rear turn lamp. Circuit GD123 (BK/GY) and circuit GD121 (BK/YE) provide ground for the LH and RH front turn lamps, respectively. Circuit GD171 (BK/GY) provides ground for the rear turn lamps.
417-01-5 Exterior Lighting 417-01-5 rmal Operation Zephyr When the SJB detects the multifunction switch in the LH TURN position, the SJB sends voltage through circuit CLS21 (BU/GN) to the LH front turn lamp, and through circuit CLS18 (GY/BN) to the LH rear turn lamp. When the SJB detects the multifunction switch in the RH TURN position, the SJB sends voltage through circuit CLS25 (YE/VT) to the RH front turn lamp, and through circuit CLS19 (VT/OG) to the RH rear turn lamp. Circuit GD123 (BK/GY) and circuit GD121 (BK/YE) provide ground for the LH and RH front turn lamps, respectively. Circuit GD171 (BK/GY) provides ground for the rear turn lamps. On vehicles equipped with daytime running lamps (DRL), the front turn lamps are utilized as the DRL. Possible Causes Circuit CLS18 (GY/BN) open, short to ground or voltage Circuit CLS19 (VT/OG) open, short to ground or voltage Circuit CLS21 (BU/GN) open, short to ground or voltage Circuit CLS25 (YE/VT) open, short to ground or voltage Circuit GD121 (BK/YE) open Circuit GD123 (BK/GY) open Circuit GD171 (BK/GY) open N1 N2 PINPOINT TEST N: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE/ALWAYS ON DETERMINE IF A TURN LAMP IS ALWAYS ON Ignition ON. Monitor the turn lamps while placing the multifunction switch in GO to N4. the RH TURN, LH TURN and NEUTRAL positions. Is any turn lamp always on? GO to N2. CHECK THE TURN LAMP GROUND CIRCUITRY FOR AN OPEN Disconnect: Inoperative Turn Lamp. Measure the resistance between the inoperative turn lamp, harness side and ground as follows: Inoperative Turn Lamp Connector-Pin Circuit LH front C1023-1 GD123 (BK/GY) RH front C1043-1 GD121 (BK/YE) LH rear (Milan, C413-1 GD171 (BK/GY) Zephyr) RH rear (Milan, C416-1 GD171 (BK/GY) GO to N3. Zephyr) REPAIR the circuit in question. CLEAR the Is the resistance less than 5 ohms? DTCs. REPEAT the self-test N3 CHECK THE TURN LAMP VOLTAGE SUPPLY CIRCUITRY FOR AN OPEN AND A SHORT TO GROUND Disconnect: SJB C2280e (Rear Lamp) or C2280a (Front Lamp). Measure the resistance between the inoperative turn lamp, harness side and the SJB, harness side; and between the inoperative turn lamp, harness side and ground as follows: (Continued)
417-01-6 Exterior Lighting 417-01-6 N3 PINPOINT TEST N: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE/ALWAYS ON (Continued) CHECK THE TURN LAMP VOLTAGE SUPPLY CIRCUITRY FOR AN OPEN AND A SHORT TO GROUND (Continued) Inoperative Turn Lamp Connector-Pin SJB Connector-Pin Circuit LH front C1023-3 C2280a-21 CLS21 (BU/GN) RH front C1043-3 C2280a-9 CLS25 (YE/VT) LH rear (Milan, C2280e-11 CLS18 (GY/BN) Zephyr) C413-3 RH rear (Milan, C2280e-7 CLS19 (VT/OG) Zephyr) C416-3 GO to N5. Is the resistance less than 5 ohms between the inoperative turn lamp and the SJB, and greater than 10,000 ohms REPAIR the circuit in question. CLEAR the between the inoperative turn lamp and ground? DTCs. REPEAT the self-test N4 CHECK THE TURN LAMP VOLTAGE SUPPLY CIRCUITRY FOR A SHORT TO VOLTAGE Disconnect: SJB C2280e (Rear Lamp) or C2280a (Front Lamp). For the LH front turn lamp, REPAIR circuit Ignition ON. CLS21 (BU/GN). CLEAR the DTCs. Does the turn lamp in question continue to illuminate? REPEAT the self-test. For the RH front turn lamp, REPAIR circuit CLS25 (YE/VT). CLEAR the DTCs. REPEAT the self-test. For the LH rear turn lamp, REPAIR circuit CLS18 (GY/BN). CLEAR the DTCs. REPEAT the self-test. For the RH rear turn lamp, REPAIR circuit CLS19 (VT/OG). CLEAR the DTCs. REPEAT the self-test. GO to N5. N5 CHECK FOR CORRECT SJB OPERATION Disconnect all the SJB connectors. INSTALL a new SJB. REFER to Section Check for: 419-10. TEST the system for normal corrosion operation. pushed-out pins Connect all the SJB connectors and make sure they seat The system is operating correctly at this correctly. time. The concern may have been caused Operate the system and verify the concern is still present. by a loose or corroded connector. CLEAR Is the concern still present? the DTCs. REPEAT the self-test. Pinpoint Test O: The Hazard Lamps Are Inoperative rmal Operation The smart junction box (SJB) sends a voltage reference signal to the hazard lamp switch through circuit CLS32 (BN/YE). When the hazard switch is engaged, the voltage signal is routed to ground through circuit GD116 (BK/VT). When the SJB detects a request for the hazard lamps, the SJB sends voltage to the appropriate turn lamps. Possible Causes Circuit CLS32 (BN/YE) open or short to ground Circuit GD116 (BK/VT) open Hazard lamp switch
417-01-7 Exterior Lighting 417-01-7 O1 PINPOINT TEST O: THE HAZARD LAMPS ARE INOPERATIVE CHECK CIRCUIT GD116 (BK/VT) FOR AN OPEN Disconnect: Hazard Lamp Switch C2355. Measure the resistance between the hazard lamp switch C2355-1, circuit GD116 (BK/VT), harness side and ground. O2 GO to O2. Is the resistance less than 5 ohms? normal operation. CHECK CIRCUIT CLS32 (BN/YE) FOR A SHORT TO GROUND Disconnect: SJB C2280d. Measure the resistance between the SJB C2280d-20, circuit CLS32 (BN/YE), harness side and ground. O3 GO to O3. Is the resistance greater than 10,000 ohms? normal operation CHECK CIRCUIT CLS32 (BN/YE) FOR AN OPEN Measure the resistance between the hazard lamp switch C2355-5, circuit CLS32 (BN/YE), harness side and the SJB C2280d-20, circuit CLS32 (BN/YE), harness side. GO to O4. Is the resistance less than 5 ohms? normal operation. (Continued)
417-01-8 Exterior Lighting 417-01-8 O4 PINPOINT TEST O: THE HAZARD LAMPS ARE INOPERATIVE (Continued) CHECK THE HAZARD LAMP SWITCH Connect: Hazard Lamp Switch C2355. While pressing an releasing the hazard lamp switch, measure the resistance between the SJB C2280d-20, circuit CLS32 (BN/YE), harness side and ground. O5 GO to O5. INSTALL a new hazard lamp switch. REFER to Hazard Flasher Lamp Switch in Is the resistance less than 5 ohms with the switch pressed this section. TEST the system for normal and greater than 10,000 ohms with the switch released? operation. CHECK FOR CORRECT SJB OPERATION Disconnect all the SJB connectors. Check for: INSTALL a new SJB. REFER to Section corrosion 419-10. TEST the system for normal pushed-out pins operation. Connect all the SJB connectors and make sure they seat correctly. The system is operating correctly at this Operate the system and verify the concern is still present. time. The concern may have been caused Is the concern still present? by a loose or corroded connector. Pinpoint Test P: The Hazard Lamps Are Always On rmal Operation The smart junction box (SJB) sends a voltage reference signal to the hazard lamp switch through circuit CLS32 (BN/YE). When the hazard switch is engaged, the voltage signal is routed to ground through circuit GD116 (BK/VT). When the SJB detects a request for the hazard lamps, the SJB sends voltage to the appropriate turn lamps. Possible Causes Circuit CLS32 (BN/YE) open or short to ground Circuit GD116 (BK/VT) open Hazard lamp switch P1 PINPOINT TEST P: THE HAZARD LAMPS ARE ALWAYS ON CHECK CIRCUIT GD116 (BK/VT) FOR AN OPEN Disconnect: Hazard Lamp Switch C2355. (Continued)
417-01-9 Exterior Lighting 417-01-9 P1 PINPOINT TEST P: THE HAZARD LAMPS ARE ALWAYS ON (Continued) CHECK CIRCUIT GD116 (BK/VT) FOR AN OPEN (Continued) Measure the resistance between the hazard lamp switch C2355-1, circuit GD116 (BK/VT), harness side and ground. P2 GO to P2. Is the resistance less than 5 ohms? normal operation. CHECK CIRCUIT CLS32 (BN/YE) FOR A SHORT TO GROUND Disconnect: SJB C2280d. Measure the resistance between the SJB C2280d-20, circuit CLS32 (BN/YE), harness side and ground. P3 GO to P3. Is the resistance greater than 10,000 ohms? normal operation CHECK CIRCUIT CLS32 (BN/YE) FOR AN OPEN Measure the resistance between the hazard lamp switch C2355-5, circuit CLS32 (BN/YE), harness side and the SJB C2280d-20, circuit CLS32 (BN/YE), harness side. P4 GO to P4. Is the resistance less than 5 ohms? normal operation. CHECK THE HAZARD LAMP SWITCH Connect: Hazard Lamp Switch C2355. (Continued)
417-01-10 Exterior Lighting 417-01-10 P4 PINPOINT TEST P: THE HAZARD LAMPS ARE ALWAYS ON (Continued) CHECK THE HAZARD LAMP SWITCH (Continued) While pressing an releasing the hazard lamp switch, measure the resistance between the SJB C2280d-20, circuit CLS32 (BN/YE), harness side and ground. P5 GO to P5. INSTALL a new hazard lamp switch. REFER to Hazard Flasher Lamp Switch in Is the resistance less than 5 ohms with the switch pressed this section. TEST the system for normal and greater than 10,000 ohms with the switch released? operation. CHECK FOR CORRECT SJB OPERATION Disconnect all the SJB connectors. Check for: INSTALL a new SJB. REFER to Section corrosion 419-10. TEST the system for normal pushed-out pins operation. Connect all the SJB connectors and make sure they seat correctly. The system is operating correctly at this Operate the system and verify the concern is still present. time. The concern may have been caused Is the concern still present? by a loose or corroded connector.