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Test Y: Headlight Warning Chime Does Not Operate Properly

  1. Check operation of all exterior lights, including headlights. If all exterior lights operate properly, go to next step. If any exterior lights do not operate properly, repair as necessary. See EXTERIOR LIGHTS and HEADLIGHT SYSTEMS articles.
  2. Turn ignition switch to LOCK position. Connect New Generation Star (NGS) tester to Data Link Connector (DLC). DLC is located below driver's side of instrument panel, right of steering column. Turn ignition switch to RUN position. Monitor Generic Electronic Module (GEM) PIDs IGN_KEY, IGN_A, IGN_S and IGN_R while cycling ignition switch through all positions. If PIDs agree with ignition switch positions, go to next step. If PIDs do not agree with ignition switch positions, perform TEST V: KEY-IN-IGNITION WARNING CHIME DOES NOT OPERATE PROPERLY  .
  3. Using NGS tester, select GEM active command CHIME. Trigger active command CHIME on and off. If chime operates properly, go to next step. If chime does not operate properly, go to step  9 .
  4. Using NGS tester, monitor GEM PID D_DR_SW while opening and closing driver's door. If PIDs agree with door positions, go to next step. If PIDs do not agree with door positions, perform TEST X: DOOR AJAR WARNING CHIME DOES NOT OPERATE PROPERLY  .
  5. Using NGS tester, monitor GEM PID PARK_SW while turning headlight switch to ON and OFF positions. If PIDs do not agree with headlight switch positions, go to next step. If PIDs agree with headlight switch positions, go to step  9 .
  6. Using NGS tester, monitor GEM PID PARK_SW while opening and closing driver's door. If PID does not always indicate ON, go to next step. If PID always indicates ON, go to step  8 .
  7. Disconnect 26-pin Generic Electronic Module (GEM) harness connector C352. GEM is located behind left side of instrument panel, next to central junction box. Disconnect Gray 9-pin headlight switch harness connector C228. Measure resistance in Brown wire between GEM harness connector C352 terminal No. 7 and headlight switch harness connector C228 terminal "R". See Figure and Fig 1 . If resistance is 5 ohms or less, go to step  9 . If resistance is more than 5 ohms, repair open in Brown wire between GEM and headlight switch. See EXTERIOR LIGHTS article.
  8. Disconnect 26-pin Generic Electronic Module (GEM) harness connector C352. GEM is located behind left side of instrument panel, next to central junction box. Ensure headlight switch is in OFF position. Measure voltage between ground and GEM harness connector C352 terminal No. 7 (Brown wire). See Figure . If voltage does not exist, go to next step. If voltage exists, repair short to voltage in Brown wire between GEM and headlight switch. See EXTERIOR LIGHTS article.
  9. Disconnect all GEM harness connectors. Inspect all GEM harness connectors for loose, damaged or corroded terminals. If terminals are damaged, repair as necessary. If terminals are not damaged, reconnect all GEM harness connectors. Ensure GEM harness connectors are seated properly. If problem still exists, replace GEM. See REMOVAL & INSTALLATION  .
Fig 1: Identifying Headlight Switch Harness Connector C228 Terminals
G99F08206Courtesy of FORD MOTOR CO.
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