Note that this procedure requires frequent removal and installation of the fuses. Be sure to remove them before connecting or disconnecting any electrical components! Failure to do so could result in serious injury! Ensure that all warnings are heeded.
This procedure assumes that the system operates abnormally with the black box not installed. If the system operates normally with the black box not installed, check other possibilities.
First do the following:
If no faults were found to this point, with the spliced connections re-taped, disconnect the new connectors and the original actuator connector. Check all connectors for bent or broken pins. Proceed with the following energized test:
If the fuses are ok, verify the following voltages on each side (with the fuses installed) at the new connectors (1M5F) using a multi meter or a simple 12V tester:
|New Connector||Dash Switch Up||Dash Switch Down|
If the above check is not correct, the color changes from the car's wiring harness to the new connector are not correct or the car's wiring harness is not standard. Investigate and correct.
If the above checks are ok, remove the fuses again, and connect the 1M5F connector from the car's wiring harness on one side to the 5M1F connector attached to the original actuator connector (leave the original actuator connecter disconnected.) Remove the original actuator connector from the frame, place it where it will not come in contact with any metal parts and reinstall the fuses.
Check the fuses. If a fuse blows, the problem is in the wiring between the 5M1F portion of the new connector and the original actuator connector.
If the fuses are ok, verify the following voltages (with the fuses installed) at the original actuator connector (female end.)
|Color of wire||Dash switch|
If these checks are not correct the wiring/color changes from the 5M1F new connector are not correct. Investigate and correct.
If these checks are ok, perform the above tests on the other side.
If these checks are also correct, remove the fuses, and reconnect the original actuator connector on one side.
Put the dash switch back in the Up position and Reinstall the fuses. Cycle the headlight down and up with the dash switch. If the fuse blows again the actuator on that side is faulty.
Remove the fuses again, and connect the other original actuator connector. Cycle both headlights down and up with the dash switch. If the fuse blows again the actuator on this side is faulty.