Headlamp Motor: Testing and Inspection

Pop-up Mechanism:

LIGHT SWITCH CIRCUIT OPERATION

NOTE: Constant battery voltage is supplied to the lighting switch through fuse #1. This fuse also supplies voltage to the automatic seatbelt control unit, key reminder switch, passing control relay, seatbelt warning buzzer, taillight relay, and theft-alarm starter relay.

When the switch is in the "HEAD" position, current flows through the passing control relay, pop-up motor (switch in UP position), pop-up motor relay (pull in coil), and ground.

Current flow through the pop-up motor relay (pull in coil) closes the pop-up motor relay contacts, and current is supplied to the pop-up motor through fusible link 4. In this mode the pop-up motor opens the headlight to its upper limit, at which point the switch in the motor moves to the DOWN position. When the motor switch changes position it interrupts current flow through the pop-up motor relay (pull in coil), stopping the motor.

The retractable headlight will remain in its up position until the light switch is moved to the "OFF" or "TAIL" position. When the switch is moved to either of these positions current will flow through the circuit as described above, with the difference being the position of the switch inside the motor.

With the motor switch in the "DOWN" position the motor will close the headlamp until the DOWN limit has been reached, at which point the switch inside the motor moves from the DOWN position to the UP position. When the switch moves, current flow through the pop-up motor relay is interrupted and motor operation stops.

POP-UP SWITCH CIRCUIT OPERATION

Pop-up switch voltage is supplied through the "OFF" circuit of the light switch. Operation of the circuit with the pop-up switch in the "ON" position is the same as circuit operation with the light switch in the "HEAD" position.
Operation of the circuit with the pop-up switch in the "OFF" position is the same as circuit operation with the light switch in the "TAIL" or "OFF" position.

POP-UP HEADLAMP MECHANISM DIAGNOSIS

Headlamps Open Only With Lighting Switch

Switch Removal:

1. Remove the pop-up switch.
2. Inspect the connector for pushed out or spread terminals. Repair or replace the connector as needed and retest circuit operation.

Pop-up Switch:

Pop-up Switch Continuity Chart:

3. With the switch in the "OFF" position, check for continuity between terminals 1 and 4.
^ If there is no continuity replace the switch.
^ IF there is continuity go to step 5.
5. Move the switch to the "ON" position, and check for continuity between terminals 1 and 3.
^ If there is no continuity replace the switch.
^ If there is continuity, go to step 6.
6. Test for continuity between the pop-up switch connector terminal 3 and the passing control relay terminal 3.
^ If there is no continuity, repair open in circuit, install the pop-up switch, and test circuit operation.

Headlamps Open Only With Pop-Up Switch

Steering Column:

1. Unplug the 2 connectors to the column switch.
2. Inspect the connectors for pushed out, damaged or spread terminals. Repair or replace as needed and retest circuit operation.
3. Perform a diode check between terminal 14 of connector A and terminal 3 of the passing control relay. There should only be continuity in one direction only.
^ If the circuit passes the diode check go to step 4.
^ If the circuit is open in both directions repair wiring or replace the diode C-13 as needed and test circuit operation.
^ If there is continuity in both directions replace the diode and test circuit operation.

Diode Location:

4. Operate the column switch and perform the continuity checks in table 1.

Steering Column Light Switch Connectors:

TABLE 1

Lighting Switch:

3. If the circuit fails 1 or more of the continuity checks remove the column switch and inspect the wiring harness for any damage.
^ If there is repairable damage to wiring harness repair and retest circuit operation.
^ If there is no visible damage, or damage is not repairable, replace the switch and test circuit operation.

Steering Column:

Both Headlamps Will Not Retract

1. Verify that the pop-up switch is in the "OFF" position.
2. Check fuse 1 and sub fusible link 4.
^ If fuse 1 is not blown and sub fusible link 4 is good, go to step 7.
^ If fuse 1 is blown go to step 3.
^ If sub fusible link 4 is fused go to step 4.
3. Place the light switch and the pop-up switch in the "OFF" position and measure the resistance between the switch side of the fuse holder and ground.
^ If there is continuity to ground, locate and repair short in circuit.
^ If circuit is not shorted to ground, replace the fuse and test circuit operation.
4. Check for continuity between the sub fusible link 4 load end and ground.
^ If there is continuity, locate and repair short to ground, and test circuit operation.
^ If circuit is not shorted to ground go to step 5.
5. Inspect the pop-up headlamp mechanism for any obstructions or bent components which would hinder the movement of the headlamps. Repair or replace any visible problems before proceeding.
6. Lower headlamps manually to check for binding or mechanical problems.
^ If a mechanism is binding, repair or replace as needed and test circuit operation.
^ If no binding is encountered, replace the sub fusible link, and test circuit operation.
7. Remove the cluster panel, set the column switch in the "OFF" position, and using a voltmeter or test light, test for voltage at the blue/white wire at the back of the pop-up switch connector.
^ If there is voltage go to step 8.
^ If there is no voltage present at the pop-up switch, test for voltage in circuit, working back toward the fuse box. Repair open in circuit and test circuit operation.
8. If there is voltage present at terminal 1 (blue/white wire) of the pop-up switch, move the probe to the blue/black wire of the pop-up switch connector, and test for voltage.
^ If there is no voltage present, replace the pop-up switch.
^ If there is voltage present go to step 9.
9. Move the probe to terminal 5 (blue/black wire) of the passing control relay connector, and test for voltage.
^ If there is no voltage, repair open in wiring between the pop-up switch and the passing control relay and test circuit operation.
^ If there is voltage at terminal 5 (blue/black wire) go to step 10.
10. Test for voltage at terminal 2 (blue/red wire) of the passing control relay connector.
^ If no voltage is present at terminal 2 (blue/red wire) of the passing control relay connector, replace the passing control relay.
^ If voltage is present at this point go to step 11.
11. Test for voltage at the pop-up motor connectors (blue/red wires).
^ If no voltage is present at this point repair open in wiring and test circuit operation.
^ If voltage is present at this point go to step 12.
12. Test for voltage at the pop-up motor relay terminals 4 (red/black wire) and 8 (red/blue wire).
^ If voltage is present at this point go to step 13.
^ If no voltage is present at this point, perform pop-up motor switch continuity range test below.

Pop-up Motor Switch Adjustment:

Pop-up Motor Switch Continuity Range Checks:

13. Test for voltage at the pop-up motor connectors (red/yellow wire of the left motor and the red/white wire of the right motor).
^ If voltage is present go to step 14.
^ If no voltage is present repair open in circuit between the pop-up motors and the pop-up motor relay, and test circuit operation.
14. Test for continuity between the pop-up motors and ground, (black/white wire of left motor, and black wire of right motor).
^ If there is continuity replace pop-up motors, one at a time and test circuit operation.
^ If there is no continuity, repair circuit (open in wire, loose or corroded ground connection) and test circuit operation.


Both Headlamps Will Not Open

1. Check fuse 1 and sub fusible link 4.
^ If fuse 1 is not blown and sub fusible link 4 is good, go to step 5.
^ If fuse 1 is blown go to step 2.
^ If sub fusible link 4 is fused go to step 3.
2. Place the light switch in the "HEAD" position and measure the resistance between the switch side of the fuse holder and ground.
^ If there is continuity to ground, locate and repair short in circuit.
^ If circuit is not shorted to ground, replace the fuse and test circuit operation.
3. Check for continuity between the sub fusible link 4 load end and ground.
^ If there is continuity, locate and repair short to ground, and test circuit operation.
^ If circuit is not shorted to ground go to step 4.
4. Raise headlamps manually to check for binding or mechanical problems.
^ If a mechanism is binding, repair or replace as needed and test circuit operation.
^ If no binding is encountered, replace the sub fusible link, and test circuit operation.
5. Remove the cluster panel, set the column switch in the "HEAD" position, and using a voltmeter or test light, test for voltage at the blue/yellow wire at the back of the pop-up switch connector.
^ If there is voltage go to step 6.
^ If there is no voltage present at the pop-up switch, test for voltage in circuit, working back toward the fuse box. Repair open in circuit and test circuit operation.
6. If there is voltage present at terminal 1 (blue/yellow wire) of the pop-up switch, move the probe to the black/blue wire of the passing control relay connector, and test for voltage.
^ If there is no voltage present, locate and repair the open in the circuit and test circuit operation.
^ If there is voltage present go to step 7.
7. Test for voltage at terminal 2 (blue/yellow wire) of the passing control relay connector.
^ If no voltage is present at terminal 2 (blue/yellow wire) of the passing control relay connector, replace the passing control relay.
^ If voltage is present at this point go to step 8.
8. Test for voltage at the pop-up motor connectors (blue/yellow wires).
^ If no voltage is present at this point repair open in wiring and test circuit operation.
^ If voltage is present at this point go to step 9.
9. Test for voltage at the pop-up motor relay terminals 4 (red/black wire) and 8 (red/blue wire).
^ If voltage is present at this point go to step 10.
^ If no voltage is present at this point, perform pop-up motor switch continuity range test below.

Pop-up Motor Switch Adjustment:

Pop-up Motor Switch Continuity Range Checks:

10. Test for voltage at the pop-up motor connectors (red/yellow wire of the left motor and the red/white wire of the right motor).
^ If voltage is present go to step 11.
^ If no voltage is present repair open in circuit between the pop-up motors and the pop-up motor relay, and test circuit operation.
11. Test for continuity between the pop-up motors and ground, (black/white wire of left motor, and black wire of right motor).
^ If there is continuity replace pop-up motors, one at a time and test circuit operation.
^ If there is no continuity, repair circuit (open in wire, loose or corroded ground connection) and test circuit operation.