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Test Y: Headlight Warning Chime Does Not Operate Properly

NOTE: Perform all voltage and resistance tests using a Digital Volt-Ohm Meter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate wiring harness shorts or opens.
  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 in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
  2. Turn ignition switch to LOCK position. Connect Worldwide Diagnostic System (WDS) tester or New Generation Star (NGS) tester to Data Link Connector (DLC). See Figure. DLC is located under instrument panel between steering column and the radio. See Figure. 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 WDS or 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 WDS or 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 WDS or 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 WDS or 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 Generic Electronic Module (GEM) 26-pin harness connector C201e. See Figure. GEM is located behind left side of instrument panel, next to central junction box. See Figure. Disconnect headlight switch 9-pin harness connector C205. See Fig 1. Measure resistance between GEM harness connector C201e terminal No. 7 and headlight switch harness connector C205 terminal "R1" (Brown wire). If resistance is 5 ohms or less, go to step  9. If resistance is more than 5 ohms, repair open circuit in Brown wire between GEM and headlight switch. For WARNING SYSTEMS circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
  8. Disconnect Generic Electronic Module (GEM) 26-pin harness connector C201e. See Figure. GEM is located behind left side of instrument panel, next to central junction box. See Figure. Ensure headlight switch is in OFF position. Measure voltage between ground and GEM harness connector C201e terminal No. 7 (Brown wire). See Figure. If voltage does not exist, go to next step. If voltage exists, repair short circuit in Brown wire between GEM and headlight switch. For WARNING SYSTEMS circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
  9. Disconnect all GEM harness connectors. Inspect all GEM harness connectors for loose, damaged or corroded terminals. If terminals are damaged, repair or replace 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 GENERIC ELECTRONIC MODULE  under REMOVAL & INSTALLATION. After repair, clear DTCs, repeat self-test and check system for normal operation.
Fig 1: Identifying Headlight Switch Harness Connector C205 Terminals
G99F08206Courtesy of FORD MOTOR CO.