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Pinpoint Test C: One Low Beam Headlamp Is Inoperative

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. C1 CHECK THE HEADLAMP GROUND CIRCUIT FOR AN OPEN 
    • Key in OFF position.
    • Disconnect: Inoperative Headlamp.
    • Measure the resistance between the LH headlamp C1021-1, circuit GD121 (BK/YE), harness side and ground; or between the RH headlamp C1041-1, circuit GD123 (BK/GY), harness side and ground.
      Fig 1: Checking Headlamp Ground Circuit For Open
      G04682791Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 

    Yes  : GO to C2.

    No  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.

  2. C2 CHECK FOR VOLTAGE TO THE HEADLAMP 
    • Place the headlamp switch in the HEADLAMPS ON position.
    • Measure the voltage between the inoperative headlamp, harness side and ground as follows:
      CONNECTOR-PIN SPECIFICATION

      Inoperative Headlamp Connector-Pin Circuit
      LH halogen LH HID C1021-6 CLF04 (BN/BU) CLF30 (VT/BN)
      RH halogen RH HID C1041-6 CLF05 (BU/GN) CLF31 (YE/GY)
      Fig 2: Checking For Voltage To Headlamp
      G04682792Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 10 volts? 

    Yes  : For HID headlamps, GO to C3.

    For halogen headlamps, REPAIR or INSTALL a new headlamp assembly. REFER to HEADLAMP ASSEMBLY . CLEAR the DTCs. REPEAT the self-test.

    No  : For HID headlamps, GO to  C5.

    For halogen headlamps, GO to  C10.

  3. C3 CHECK THE BALLAST 
    • Place the headlamp switch in the OFF position.
    • Install a known good ballast.
    • Place the headlamp switch in the HEADLAMPS ON position.
    • Does the inoperative headlamp now illuminate? 

    Yes  : INSTALL a new ballast. REFER to BALLAST . CLEAR the DTCs. REPEAT the self-test.

    No  : GO to C4.

  4. C4 CHECK THE HID BULB 
    • Place the headlamp switch in the OFF position.
    • Install the original ballast.
    • Install a known good HID bulb.
    • Place the headlamp switch in the HEADLAMPS ON position.
    • Does the inoperative headlamp now illuminate? 

    Yes  : INSTALL a new HID bulb. REFER to HEADLAMP BULB - LH  or HEADLAMP BULB - RH . CLEAR the DTCs. REPEAT the self-test.

    No  : REPAIR or INSTALL a new headlamp assembly. REFER to HEADLAMP ASSEMBLY . CLEAR the DTCs. REPEAT the self-test.

  5. C5 CHECK CIRCUIT CLF04 (BN/BU) (LH HEADLAMP) OR CIRCUIT CLF05 (BU/GN) (RH HEADLAMP) FOR VOLTAGE 
    • Place the headlamp switch in the OFF position.
    • Disconnect: Suspect HID Relay.
    • Place the headlamp switch in the HEADLAMPS ON position.
    • Measure the voltage between the LH HID relay pin 1, circuit CLF04 (BN/BU), harness side and ground; or between the RH HID relay pin 1, circuit CLF05 (BU/GN), harness side and ground.
      Fig 3: Checking Circuit CLF04 (BN/BU) (LH Headlamp) Or Circuit CLF05 (BU/GN) (RH Headlamp) For Voltage
      G04682793Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 10 volts? 

    Yes  : TURN the headlamps off. GO to  C7.

    No  : TURN the headlamps off. GO to C6.

  6. C6 CHECK CIRCUIT CLF04 (BN/BU) (LH HEADLAMP) OR CIRCUIT CLF05 (BU/GN) (RH HEADLAMP) FOR AN OPEN OR SHORT TO GROUND (HID HEADLAMPS) 
    • Disconnect: SJB C2280a.
    • Measure the resistance between the suspect HID relay, harness side and the SJB, harness side; and between the suspect HID relay, harness side and ground as follows:
      SJB CONNECTOR-PIN SPECIFICATION

      Inoperative Headlamp Suspect Relay SJB Connector-Pin Circuit
      LH LH HID relay pin 1 C2280a-5 CLF04 (BN/BU)
      RH RH HID relay pin 1 C2280a-6 CLF05 (BU/GN)
    • Is the resistance less than 5 ohms between the HID relay and the SJB, and greater than 10,000 ohms between the HID relay and ground? 

    Yes  : GO to  C11.

    No  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.

  7. C7 CHECK CIRCUIT SBB26 (YE/RD) (LH HID RELAY) OR CIRCUIT SBB27 (BU/RD) (RH HID RELAY) FOR VOLTAGE 
    • Measure the voltage between the LH HID relay pin 3, circuit SBB26 (YE/RD), harness side and ground; or between the RH HID relay pin 3, circuit SBB27 (BU/RD), harness side and ground.
      Fig 4: Checking Circuit SBB26 (YE/RD) (LH HID Relay) Or Circuit SBB27 (BU/RD) (RH HID Relay) For Voltage
      G04682794Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 10 volts? 

    Yes  : GO to C8.

    No  : VERIFY the BJB fuse 26 (15A) (LH HID relay) or fuse 27 (15A) (RH HID relay) is OK. If OK, REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.

  8. C8 CHECK THE HID RELAY GROUND CIRCUIT FOR AN OPEN 
    • Measure the resistance between the LH HID relay pin 2, circuit GD121 (BK/YE), harness side and ground; or between the RH HID relay pin 2, circuit GD121 (BK/YE), harness side and ground.
      Fig 5: Checking HID Relay Ground Circuit For Open
      G04682795Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 

    Yes  : GO to C9.

    No  : REPAIR circuit GD121 (BK/YE). CLEAR the DTCs. REPEAT the self-test.

  9. C9 CHECK THE HID RELAY 
    • Carry out the HID relay component test. Refer to COMPONENT TESTING .
    • Is the HID relay OK? 

    Yes  : REPAIR circuit CLF30 (VT/BN) (LH HID relay) or circuit CLF31 (YE/GY) (RH HID relay) as necessary. CLEAR the DTCs. REPEAT the self-test.

    No  : INSTALL a new HID relay. CLEAR the DTCs. REPEAT the self-test.

  10. C10 CHECK CIRCUIT CLF04 (BN/BU) (LH HEADLAMP) OR CIRCUIT CLF05 (BU/GN) (RH HEADLAMP) FOR AN OPEN OR SHORT TO GROUND (HALOGEN HEADLAMPS) 
    • Disconnect: SJB C2280a.
    • Measure the resistance between the inoperative headlamp, harness side and the SJB, harness side; and between the inoperative headlamp, harness side and ground as follows:
      SJB CONNECTOR-PIN SPECIFICATION

      Inoperative Headlamp Headlamp Connector-Pin SJB Connector-Pin Circuit
      LH C1021-6 C2280a-5 CLF04 (BN/BU)
      RH C1041-6 C2280a-6 CLF05 (BU/GN)
    • Is the resistance less than 5 ohms between the headlamp and the SJB, and greater than 10,000 ohms between the headlamp and ground? 

    Yes  : GO to C11.

    No  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.

  11. C11 CHECK FOR CORRECT SJB OPERATION 
    • Disconnect all the SJB connectors.
    • Check for:
      • Corrosion
      • Pushed-out pins
    • Connect all the SJB connectors and make sure they seat correctly.
    • Operate the system and verify the concern is still present.
    • Is the concern still present? 

    Yes  : INSTALL a new SJB. REFER to MULTIFUNCTION ELECTRONIC CONTROL MODULES . TEST the system for normal operation.

    No  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.

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