My Fiesta was due MOT in few months, and it’s will failed mot because levelling devices is inoperable.

I had tried following as;

- Fuses, couldn’t see anything blown and headlight all bulbs are functioning.

- Switch, tested other Focus Mk2 with same switch and working levelling, my switch was actually working no issues.

- Headlight, I had replaced both new headlight and still not working levelling.

 

 

Unfortunately, it’s look like it’s down with problem wiring looms as it’s only one possible source of issues. Do anyone know what colours and diagrams of wiring for headlight levelling adjustable? I can’t find anywhere the Google!!!

 

Vehicle Spec;

Fiesta 2006 (FACELIFT)

1.4 petrol

Non automatic headlight model 

Can you post a picture of the fusebox diagram from your car?  Levelling fuse is separate from bulbs fuse.  The pictograms may not be immediately obvious.

Is manual headlamp levelling an MOT item then?

I thought, as long as the beam was in spec, it passed?????

3 minutes ago, DaveT70 said:

Is manual headlamp levelling an MOT item then?

I thought, as long as the beam was in spec, it passed?????

Manual levelling is an MOT requirement.  It's a safety issue if you're dazzling other driver with the boot fully loaded.

Though I'm not sure many testers actually check it in reality.

 

Defect	Category
(a) Headlamp levelling device inoperative	Major
(b) Manual levelling device cannot be operated from the driver’s seat	Major

Just now, TomsFocus said:

Though I'm not sure many testers actually check it in reality.

Nor me.

I'd be tempted to make sure the beam was correct and have it tested at another centre

6 hours ago, Tomush said:

levelling devices is inoperable.

So if this is the manual control on the light switch, it is fed from headlight fuse, which appears to be OK.  No automatic levelling on this age of Fiesta.

Haynes wiring diagram 4 shows a single wiper pot feeding both headlamps, so if neither move, could be the control or the bu/rd core is o/c somewhere. if only one moves, then could be the wiring to the other or the headlamp motor is defective.

4 hours ago, DaveT70 said:

I'd be tempted to make sure the beam was correct and have it tested at another centre

Wind the control  up to the highest position, then use manual adjustment on the individual headlamp units to get it correct.

New Headlights from Ford ?

1 hour ago, Paulkp said:

So if this is the manual control on the light switch, it is fed from headlight fuse, which appears to be OK.  No automatic levelling on this age of Fiesta.

Haynes wiring diagram 4 shows a single wiper pot feeding both headlamps, so if neither move, could be the control or the bu/rd core is o/c somewhere. if only one moves, then could be the wiring to the other or the headlamp motor is defective.

Wind the control  up to the highest position, then use manual adjustment on the individual headlamp units to get it correct.

New Headlights from Ford ?

My headlight was brand new unit off eBay and aftermarket brand instead Ford. 
 

edit; I had mentioned the switch control panel isn’t faulty since I tested other focus mk2 that had functional manual levelling, my switch was tested to seen working okay.

would nice if you had photo of wiring?

6 hours ago, TomsFocus said:

Can you post a picture of the fusebox diagram from your car?  Levelling fuse is separate from bulbs fuse.  The pictograms may not be immediately obvious.

I check bulbs and headlight fuses it’s seen okay because I had meant to the headlight are all working beside manual levelling is inoperable.

Sorry I can't be any help but following as I have the exact issue on a focus 61 I'd really like an answer too as tried everything!! 

On a Fiesta 2004 and on a Focus 2011 my thoughts would be water ingress to the GEM, and/or corrosion of the connectors to the GEM

@unofix yes quite possibly or the wiring but no sign of water damage/ corrosion on mine apart from slight corrosion on headlight connecter right side. Could an relay potentially cause this issue as (had fault code B10E7 and B1C84 flag up?) It would be interesting if any faults flag up on @Tomush car that match mine. 

15 hours ago, Tomush said:

would nice if you had photo of wiring?

Only have a Haynes manual, but pin 1 on switch for pot wiper, and 10 for ground.  Unplug the headlights, and see if voltage changes on pin 5 on the free connector when the control is varied.

No connction to GEM shown in either Fiesta or Fusion Manual

I was confused, but obviously a Focus unit and Fiesta unit are identical part numbers.

23 hours ago, Tomush said:

tested other Focus Mk2 with same switch

 

If you look on CATCAR, there are numerous different switches listed for Focus, and Fiesta,  Unless the two units have the same part number, there may be a subtle difference.

Focus Haynes also shows the use of a GEM, so this might also suggest that there are differences somewhere.

22 hours ago, bea91 said:

@unofix yes quite possibly or the wiring but no sign of water damage/ corrosion on mine apart from slight corrosion on headlight connecter right side. Could an relay potentially cause this issue as (had fault code B10E7 and B1C84 flag up?) It would be interesting if any faults flag up on @Tomush car that match mine. 

Only levelling manually are broken. I don’t think my GEM are broken?

10 hours ago, Paulkp said:

If you look on CATCAR, there are numerous different switches listed for Focus, and Fiesta,  Unless the two units have the same part number, there may be a subtle difference.

Focus Haynes also shows the use of a GEM, so this might also suggest that there are differences somewhere.

I thought focus and fiesta had same? I meant that focus mk2 had same switch as mine and it’s doesn’t had speedometer brightness?

also what you mean pot wiper? I’m bit lost that.

Apologies, I should have explained it better.

The levelling control in the switch is a POTentiometer, with one end at 12V and 0V at the other.  A contact (the wiper) travels the length of the resistance, thus outputting a voltage ranging between 12V to 0V depending on the position.  This voltage is fed to a motor control circuit, (in the headlamp) which adjusts another pot physically connected to the levelling motor, until the voltages are equal, and the motor stops.  (A nice simple analogue bridge circuit, none of this digital rubbish!)

So if you lose the 0V to the pot in the switch, the output to the lamp unit will remain at about 12V, and neither headlamp will adjust.

My '07 Fiesta control has the manual levelling, and although your Focus may have manual levelling, the control on my '08 Focus is a dimmer for dash illumination. (it has automatic levelling which means every time you go over a bump, you dazzle oncoming drivers !)

I don't have any schematics for a 2006 Fiesta, but just as an example of the control here is the circuit from a 2008 Focus.

Fiesta circuit very similar.

Hi @Tomush do you think you could update your profile with the vehicle details please? 👍

It's confusing seeing 2004 when it's 2006 and no mention of the engine etc.

12 hours ago, Tomush said:

Only levelling manually are broken.

I still think it's the fuse.  Have you tested for 12v reaching the switch plug?

Fuse40/10A (Haynes) is the 12V supply to the light switch, but in my Fiesta it is 7.5A.

(OP should be able to check the decal is on the back of the glove box.)

This is used for both levelling, and fed to the multifunction (dip/main/flash) to energise the coils in the main and dip relays as required.

Levelling uses E17 as ground for the control pot, as does the horn.  So if the horn works, then that earth is probably OK.

If you still have your old headlamps, I'd be tempted to plug one back in, and see if it works.....

@TomsFocus @Paulkp, my horn currently are working, dip/main/side/indictor lights are functional. Old one are same plus old headlight binned because len are trashed.

@unofix all updated

Apologies, I'd misread the diagram, didn't realise the light switch was on the same fuse as the levelling switch.

(Edited - Deleted previous text, that was for a Mk2 Focus headlight plug, not Mk6 Fiesta)

On 9/13/2023 at 10:48 PM, Paulkp said:

Fiesta circuit very similar.

Could you check the pin numbers for the level motor on the light cluster plug in your Haynes, Paul?  Plugs are totally different shape on Mk2 Focus so I assume the pin numbers will also be different to those on Unofix's diagram.

Unfortunately, the Haynes manual contradicts itself ......

The control volts from the switch (Colours : Bu-LH,Bu/Rd-RH) go to pin 5.

The 12V supply for the levelling motor control is also the supply to the sidelight (Gn/Og-LH,Gn/Wh-RH) and goes to pin 2.

However, the part of the diagram that shows the internals of the headlight shows pin 2 feeding the sidelight and levelling motor control on the LH, and pin 5 feeding the sidelight and levelling motor control on the RH.....

The control voltage is thus also confused in the same way.......

My supposition is that the cabling/plug bit is correct, and the internals are incorrect.  I say this because the Haynes has separate diagrams for the bulb supplies and the levelling.

On the supplies diagram, pin 2 goes to the sdidelight bulb on both LH and RH.

(Been a long day, travelled by car to Gosport (30m), ferry to Portsmouth, paddle steamer to Ryde, hovercraft to Southsea then back to Ryde, then a train to Ryde pierhead, back to Pompey, then Gosport then home.  So petrol, diesel, steam, aviation fuel, and 750V electricity ! Plus ice cream and cake !)