Headlamps

Special Tool(s)

	Fluke 77-IV Digital Multimeter FLU77-4 or equivalent
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
	Flex Probe Kit 105-R025D or equivalent

Principles of Operation

NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).

Exterior Lighting

The SJB monitors the headlamp switch position by sending voltage signals on multiple circuits to the headlamp switch. There is one circuit for each headlamp switch position. At any given time, one of the signal circuits is switched to ground.

If the SJB does not detect any of the inputs to the headlamp switch are active (switched to ground) for 5 seconds, the SJB turns the parking lamps and headlamps on and keeps them on until the battery saver feature times out.

Additionally, if the SJB detects multiple headlamp switch input circuits short to ground, the SJB turns the parking lamps and headlamps on and keeps them on until the battery saver feature times out.

Refer to Exterior Lighting in the Description and Operation portion of this section for information regarding the Battery Saver feature.

If either situation occurs, the SJB cannot be ruled immediately as being at fault. This is normal behavior of the SJB design as it has detected a fault with the inputs from the headlamp switch.

The SJB monitors the multifunction switch for a flash-to-pass or high beam request. There are 2 voltage reference circuits monitoring this. When the multifunction switch is in the FLASH-TO-PASS or HIGH BEAM position, the voltage signal is routed to ground.

NOTE: The flash-to-pass feature does not require any input from the headlamp switch.

When the SJB receives an input requesting the headlamps on, the SJB supplies voltage to the low beams. If the low beams are on and the SJB receives a request for high beams (or a flash-to-pass request), the SJB energizes an internal relay which routes voltage to the headlamps.

Headlamp Functionality

The High Intensity Discharge (HID) headlamps utilize a second (hot at all times) voltage feed to the HID ballasts.

When the low beams are requested (based on inputs to the SJB ), the HID ballasts energize and provide high voltage to the HID bulbs.

When the high beams are requested, the HID ballasts remain powered and a shutter within each headlamp is activated. This changes the headlamp beam pattern to illuminate a greater distance.

If the low beams are off when the flash-to-pass is requested, the HID ballasts and the shutters within the headlamps are activated for approximately 0.5 second. If the low beams are on when the flash-to-pass is requested, the shutters within the headlamps are activated as long as the multifunction switch is held in the FLASH-TO-PASS position.

Field-Effect Transistor (FET) Protection

Field-Effect Transistor (FET) is a type of transistor that when used with module software can be used to monitor and control current flow on module outputs. The FET protection strategy is used to prevent module damage in the event of excessive current flow.

The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, a headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault event is detected. A continuous DTC is stored at the fault event and a cumulative counter is started.

When the demand for the output is no longer present, the module resets the FET circuit protection to allow the circuit to function. The next time the driver requests a circuit to activate that has been shut down by a previous short ( FET protection) and the circuit remains shorted, the FET protection shuts off the circuit again and the cumulative counter advances.

When the excessive circuit load occurs often enough, the module shuts down the output until a repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to withstand it. A module lifetime level of fault events is established based upon the durability of the FET . If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would be 200, 400 and 600 fault events.

When each tolerance level is reached, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal operation until a successful self-test proves that the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs present), DTC B106E and the associated continuous DTC (the DTC related to the shorted circuit) automatically clear and the circuit function returns.

When the first or second level is reached, the continuous DTC (associated with the short circuit) sets along with DTC B106E. These DTCs can be cleared using the module on-demand self-test, then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected). The module never resets the fault event counter to zero and continues to advance the fault event counter as short circuit fault events occur.

If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set along with the associated continuous DTC. This DTC cannot be cleared and the module must be replaced.

The SJB FET protected output circuits for the headlamp system are the LH low beam and the RH low beam output circuits.

Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.
   
   

     Visual Inspection Chart

   Mechanical	Electrical
   Headlamp switch Multifunction switch Headlamp assembly	Battery Junction Box (BJB) fuse(s): 26 (20A) (LH ballast) 27 (20A) (RH ballast) Smart Junction Box (SJB) fuse(s): 7 (10A) (LH low beam) 8 (10A) (RH low beam) 23 (15A) (high beams) Bulb(s) Wiring, terminals or connectors SJB

   
   

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. NOTE: Make sure to use the latest scan tool software release.

   If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).

5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM .

   If the scan tool does not communicate with the VCM :
   • Check the VCM connection to the vehicle.
   • Check the scan tool connection to the VCM .
   • Refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.

6. If the scan tool does not communicate with the vehicle:
   • Verify the ignition key is in the ON position.
   • Verify the scan tool operation with a known good vehicle.
   • Refer to Section 418-00 to diagnose no response from the PCM.

7. Carry out the network test.
   • If the scan tool responds with no communication for one or more modules, refer to Section 418-00 .
   • If the network test passes, retrieve and record the continuous memory DTCs.

8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB .

9. If the DTCs retrieved are related to the concern, refer to Diagnostic Trouble Code (DTC) Chart in this section. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .

10. If no DTCs related to the concern are retrieved, GO to Symptom Chart .

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Pinpoint Tests

Pinpoint Test A: Both High Beams Are Inoperative

Refer to Wiring Diagrams Cell 85 , Headlamps/Autolamps for schematic and connector information.

Normal Operation

When the headlamp switch is placed in the HEADLAMPS ON position, the Smart Junction Box (SJB) monitors the high beam request circuit from the multifunction switch. When the multifunction switch is placed in the HIGH BEAM position, the signal is routed to ground. The SJB then energizes the high beam relay (integrated into the SJB ) which supplies voltage to the headlamps.

This pinpoint test is intended to diagnose the following:

• Fuse
• Wiring, terminals or connectors
• Multifunction switch
• SJB

PINPOINT TEST A: BOTH HIGH BEAMS ARE INOPERATIVE

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Pinpoint Test B: One Low Beam Headlamp Is Inoperative

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Refer to Wiring Diagrams Cell 85 , Headlamps/Autolamps for schematic and connector information.

Normal Operation and Fault Conditions

When the Smart Junction Box (SJB) detects the headlamp switch in the HEADLAMPS ON position and the multifunction switch in the LOW BEAM position, the SJB provides voltage to the LH and RH low beam headlamps.

The headlamps utilize a second (hot at all times) voltage feed to the ballasts from the Battery Junction Box (BJB).

When the ballasts receive the headlamp on voltage from the SJB , the ballasts provide high voltage to the HID bulbs.

PINPOINT TEST B: ONE LOW BEAM HEADLAMP IS INOPERATIVE

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Pinpoint Test C: One High Beam Headlamp Is Inoperative

Refer to Wiring Diagrams Cell 85 , Headlamps/Autolamps for schematic and connector information.

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Normal Operation and Fault Conditions

When the Smart Junction Box (SJB) detects the headlamp switch in the HEADLAMPS ON position and the multifunction switch in the HIGH BEAM position, the SJB energizes the high beam relay (integrated into the SJB ). When the relay is energized, the relay routes voltage to the headlamps.

The High Intensity Discharge (HID) headlamps utilize a shutter within each headlamp. When the shutter is activated, the headlamp beam pattern changes to illuminate a greater distance.

PINPOINT TEST C: ONE HIGH BEAM HEADLAMP IS INOPERATIVE

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Pinpoint Test D: The Low Beam(s) Are Always On

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Refer to Wiring Diagrams Cell 85 , Headlamps/Autolamps for schematic and connector information.

Normal Operation and Fault Conditions

The Smart Junction Box (SJB) sends voltage signals to the headlamp switch (OFF, PARKING LAMPS and HEADLAMPS). At any given time, the headlamp switch routes one of the input circuits to ground.

When the SJB detects the headlamp switch in the HEADLAMPS ON position (or a fault with one of the headlamp switch input circuits for more than 5 seconds) and the multifunction switch in the LOW BEAM position, the SJB provides voltage to the low beam headlamps.

The headlamps utilize a second (hot at all times) voltage feed to the HID ballasts.

When the ballasts receive the headlamp on voltage from the SJB , the ballasts provide high voltage to the HID bulbs.

PINPOINT TEST D: THE LOW BEAM(S) ARE ALWAYS ON

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Pinpoint Test E: The High Beam(s) Are Always On

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Refer to Wiring Diagrams Cell 85 , Headlamps/Autolamps for schematic and connector information.

Normal Operation and Fault Conditions

The Smart Junction Box (SJB) sends a voltage signal to the multifunction switch. When the multifunction switch is placed in the FLASH-TO-PASS or HIGH BEAM position, the voltage signal is routed to ground. When the SJB detects a request for flash-to-pass or high beams (when the low beams are on), the SJB energizes the high beam relay (integrated into the SJB ), which routes voltage to the headlamps.

NOTE: If the high beam circuit is supplied voltage when the headlamps are not on, the headlamps do not illuminate. The circuit only supplies voltage to activate the high beam shutters within the headlamp assemblies. The low beams must be on for light to illuminate from the headlamps.

• DTC B1510 (Flash To Pass Switch Circuit Short to Ground) — an on-demand DTC that sets when the SJB detects the flash-to-pass request input circuit is short to ground.
• DTC B2A23 (High Beam Input Circuit Short to Ground) — an on-demand DTC that sets when the SJB detects a short to ground on the high beam request input circuit.

PINPOINT TEST E: THE HIGH BEAM(S) ARE ALWAYS ON

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

Pinpoint Test F: The Flash-To-Pass Feature Is Inoperative

Refer to Wiring Diagrams Cell 85 , Headlamps/Autolamps for schematic and connector information.

Normal Operation

The Smart Junction Box (SJB) sends a voltage signal to the multifunction switch. When the multifunction switch is placed in the FLASH-TO-PASS position, the voltage signal is routed to ground. When the SJB detects a request for flash-to-pass, the SJB provides voltage to the high beam headlamps.

If the low beams are off when flash-to-pass is requested, the HID ballasts and the shutters within the headlamps are activated for approximately 0.5 seconds. If the low beams are on when flash-to-pass is requested, the shutters within the headlamps are activated as long as the multifunction switch is held in the FLASH-TO-PASS position.

This pinpoint test is intended to diagnose the following:

• Wiring, terminals or connectors
• Multifunction switch
• SJB

PINPOINT TEST F: THE FLASH-TO-PASS FEATURE IS INOPERATIVE

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.