Lighting - HID Headlamp DTC's 01534 Or 01535
94 09 08Aug. 26, 2009
2018625, Supersedes T.B. Group 94 number 08-04 dated Sept. 17, 2008 to update warranty detail.
Vehicle Information
Condition
High Intensity Gas Discharge Lamp (HID) Range Control Motor Replacement for Fault 01534 or 01535
Technical Background
When repairing auto leveling system for faults 01534 or 01535 - Range control adjustment motor failure, it is not necessary to replace headlight assembly.
NOTE:
- If entire headlight is replaced for Range control adjustment motor, the claim is subject to debit if it is determined the headlight is not the causal part.
- All GFF test plan documentation is required for headlight wiring and connector failures, or adjustment motor replacement.
Production Solution
No production change required.
Service
Checking Headlight Internal Wiring
- Remove headlight assembly.
- Inspect wiring and connectors at range control motor 4 pin connector and headlight 12 pin connector.
- Test for open or shorted wiring between motor connector and headlight connector using a D.V.O.M ( Figure 1) and repair as necessary.
a. Pin 1 to 1
b. Pin 2 to 2
c. Pin 3 to 3
d. Pin 4 to 4
Xenon Headlight Range Control Motor Replacement
NOTE: (Headlights built by Hella or Visteon have twist lock adjustment motors and DO NOT require the following procedure.)
- Prepare headlight for range control motor removal. (For Automotive Lighting type headlights.)
- Using a standard utility knife, trim plastic tip off flush with rear of the headlight case.
- Using a small sharp tipped knife, make a small pilot hole directly in center of hex tip that was previously removed.
NOTE:
Ensure pilot hole is centered in middle of the hex for proper cap installation after motor installation. If hole is not centered sealing cap will not fasten. Headlights cannot be claimed for accidentally drilling oversized holes or damage from this procedure.
- Using a � inch drill, drill on a slow speed into pilot hole shown in Fig 4.
- Leave a clean edge for sealing cap.
TIP: Using a slow drill speed and only applying light pressure will ensure hole will be straight and clean for cap installation.
NOTE: DO NOT drill out the entire surface of the access plate. This will cause the hole to be oversized and not sealable. Headlights cannot be claimed for accidentally drilling oversized holes or damage from this procedure.
- Remove two T20 screws from motor.
- Position headlight in upright position, tip of range control motor slides out of pivot clip towards bottom of headlight.
TIP: When installing the motor, pull the headlight mechanism so that the clip is close to the mounting bracket as shown in Figure 7.
- Slide tip of motor into clip.
- Reinstall T20 screws to secure motor.
- Insert cap part number 4E0941041 into 1/4 inch access hole.
- Reinstall HID bulb, retainer, and igniter.
- Reinstall headlight access cover.
Repair Verification
NOTE:
DO NOT assemble headlight into vehicle or install front fascia before running Output Diagnostic Test.
- Run Guided Functions Output Diagnostic Test.
- Plug headlight in to engine harness and cycle key on.
- Clear all DTCs using Vehicle Self Diagnostics.
- Use Guided Functions, select Automatic Vertical Headlight Aim Control.
- Select Output Diagnostic Test Mode (DTM)
Motor passes output test:
- Perform Basic Settings.
Motor does not pass output diagnostic test:
- Recheck fault codes, wiring and connections.
Warranty
Required Parts and Tools
No Special Tools Required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. for the latest information.