Headlamp: Service Precautions

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SERVICE PRECAUTIONS [DISCHARGE HEADLIGHT]

Before checking the discharge headlight related parts, be sure to read the following warnings and precautions carefully, and then perform necessary operations.
DANGER:

- Do not touch the socket and the connector while the headlights are on. High voltage is applied to the bulb socket and connector during headlight operation. The operator may be burnt or dead due to an electric shock by high voltage.
- Do not attempt to use a tester to check them. If the bulb socket and connectors should be inspected using a tester, the operator may be burnt or dead due to an electric shock by high voltage.
- Do not turn ON the headlights while the controller or the bulb is removed. If the headlights are turned ON with the controller or bulb removed, the operator may get burned by the high temperature of the bulb. The operator may be burnt or dead due to an electric shock by high voltage.
- Before service work, turn the lighting switch OFF and disconnect the battery terminal and the controller connector in a dry place. Do not touch the components with wet hands. If you work on the components with wet hands or in wet conditions, the operator may be burnt or dead due to an electric shock by high voltage.

WARNING:
Do not illuminate the bare headlight bulb. (Do not illuminate the headlight using other than the vehicle power supply.) If the headlight bulb illuminates without fitting it in the headlight unit, it may burst due to rise in its internal pressure.

CAUTION:
When reusing the controller with the discharge headlight damaged, observe the inspection procedures for the related parts of the discharge headlight before determining the reusability of the controller. If you fail to observe "How to check discharge headlight components," the vehicle may be damaged.

1. CHECKING PROCEDURE FOR DISCHARGE HEADLIGHT RELATED PARTS (INSPECTION PROCEDURE WHEN REUSING THE CONTROLLER)

1 - 1 VISUAL CHECK OF CONTROLLER (CASE)

If any of the check items below are found, replace the controller.






1 - 2 CHECK OF WIRING HARNESS BETWEEN CONTROLLER AND BULB

If any of the check items below are found, replace the wiring harness between the controller and the bulb.
DANGER:
If the wiring harness between the controller and the bulb is damaged, always replace it. Attempting to repair the wiring harness may cause a melted harness wire, or may result in a burn or death due to an electric shock by high voltage.





1 - 3 CHECK OF CONTROLLER OPERATION

If any of the abnormalities below are found, replace the controller.
NOTE:
Ensure that the headlight control system and its circuit (power supply control at engine start and during steady illumination, high-voltage generating circuit, etc.) are working normally. Then, check whether any internal breakage has occurred in the controller. However, some internal breakage may not be found.





2. Troubleshooting procedure for discharge headlight (diagnostic procedure for malfunctions)

1. Check that the connectors are connected securely and the fuse has not been blown.

2. Before troubleshooting, read through the "Symptom chart" to understand what and how you should do. Follow all the procedures carefully.

3. The components should be checked with their connectors disconnected.

SYMPTOM CHART





NOTE:
4. The numbers indicate the sequence in which the component is checked.

5. For the troubleshooting of other than the above, refer to Trouble Symptom Chart Symptom Chart.

6. If ETACS-ECU fails, only the low-beam headlights will illuminate as a fail-safe measure.