Windstar 2003

2003 Windstar Workshop Manual Page 1 of 17
SECTION 501-16: Wipers and Washers 2003 Windstar Workshop Manual

DIAGNOSIS AND TESTING Procedure revision date: 07/06/2005
Wipers and Washers Printable View (426 KB)
Refer to Wiring Diagrams Cell 81, Interval Wiper/Washer for schematic and connector information.
Special Tool(s)
73III Automotive Meter
105-R0057 or equivalent
Alternator, Regulator, Battery and Starter Tester (ARBST)

010-00725 or equivalent
Worldwide Diagnostic System (WDS)

418-F224,
New Generation STAR (NGS) Tester

418-F052, or equivalent diagnostic tool with appropriate adapter cable
Principles of Operation
The front wipers and washer are controlled by the front electronic module (FEM). The front washer/wiper portion of the multifunction switch is hardwired to the FEM. When the switch is
moved to the desired position, the FEM processes this information and outputs the appropriate command(s) to one of several hardwired relays which control the front wiper motor speeds or
front washer pump actuation. Fault management of the front wiper provides limited front wiper functionality in the event of a failure of the front wiper/washer switch or an ignition switch
failure transmitted by the instrument cluster module.
The front washer pump is hardwired to the FEM which will actuate the pump when the front wiper/washer portion of the multifunction switch is moved to the wash position.
The rear wiper and washer are controlled by the FEM. The rear wiper/washer portion of the multifunction switch is hardwired to the FEM. When the switch is moved to the desired position,
the FEM processes this information and outputs the appropriate command(s) to a hardwired relay which controls the rear wiper motor speeds, and rear washer pump actuation.
Inspection and Verification
1. Verify the customer concern by operating the wiper and washer.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Visual Inspection Chart

Mechanical Electrical
Windshield wiper blade Battery junction box (BJB) fuse(s):
Wiper arm and pivot shaft 2 (10A)
Rear wiper motor 6 (30A)
Windshield washer reservoir 7 (25A)
Washer hoses Windshield wiper motor
Rear wiper motor
Windshield washer pump
Rear washer pump
Connectors
Multifunction switch
Rear wiper/washer switch
3. If the diagnostic tool does not power up, refer to the diagnostic tool manual.
4. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
SCP or ISO; all electronic control units, no response/not equipped, refer to Section 418-00.
No response/not equipped for FEM, GO to Pinpoint Test A.
System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the FEM.
5. If the DTCs retrieved are related to the concern, go to Front Electronic Module (FEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics.
6. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
Front Electronic Module (FEM) Diagnostic Trouble Code (DTC) Index

DTC Description Source Action
B1241 Wiper Washer Rear Pump Relay Circuit Short to Battery FEM GO to Pinpoint Test E.
B1244 Wiper Rear Motor Run Relay Circuit Failure FEM GO to Pinpoint Test B.
B1245 Wiper Rear Motor Run Relay Circuit Short to Battery FEM GO to Pinpoint Test B.
B1431 Wiper Brake/Run Relay Circuit Failure FEM GO to Pinpoint Test A.
B1432 Wiper Brake/Run Relay Circuit Short to Battery FEM GO to Pinpoint Test A.
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B1436 Wiper High/Low Speed Relay Coil Circuit Short to Battery FEM GO to Pinpoint Test G.
B1438 Wiper Mode Select Switch Circuit Failure FEM GO to Pinpoint Test A.
B1446 Wiper Park Sense Circuit Failure FEM GO to Pinpoint Test D.
B1448 Wiper Park Sense Circuit Short to Battery FEM GO to Pinpoint Test D.
B1450 Wiper Wash/Delay Switch Circuit Failure FEM GO to Pinpoint Test A.
B1460 Wiper Washer Pump Motor Relay Coil Circuit Short to Battery FEM GO to Pinpoint Test E.
B1482 Wiper Washer Fluid Level Sensor Circuit Short to Ground FEM REFER to Section 413-01.
B1611 Wiper Rear Mode Select Switch Circuit Failure FEM GO to Pinpoint Test B.
Symptom Chart
Symptom Chart
Condition Possible Sources Action
No communication with the module — front electronic module (FEM) Battery junction box (BJB) fuse(s). REFER to Section 419-
2 (10A). 10.
Circuitry.
FEM.
The wipers are inoperative — front wipers Battery junction box (BJB) fuse 6 GO to Pinpoint Test A.
(30A).
Relay(s).
Switch.
Circuitry.
Wiper motor.
Front electronic module (FEM).
The wipers are inoperative — rear wipers Battery junction box (BJB) fuse 7 GO to Pinpoint Test B.
(25A).
Relay(s).
Switch.
Circuitry.
Wiper motor.
The wipers stay on continuously — front or rear Relay. GO to Pinpoint Test C.
Switch.
Circuitry.
The intermittent wiper speed does not operate correctly Switch. GO to Pinpoint Test D.
Circuitry.
The washer pump is inoperative — front and rear Battery junction box (BJB) fuse(s). GO to Pinpoint Test E.
6 (30A).
7 (25A).
Switch.
Circuitry.
Motor.
The washer pump is inoperative — front and rear washers stay on Switch. GO to Pinpoint Test F.
continuously Circuitry.
The high/low wiper speeds do not operate correctly Switch. GO to Pinpoint Test G.
Circuitry.
Pinpoint Tests
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE — FRONT WIPERS
Test Step Result / Action to Take

A1 USE THE RECORDED RESULTS FROM THE FEM SELF-TEST
Use the recorded results from the FEM self-test. Yes
Are any DTCs recorded? If DTC B1431, GO to A2 .
If DTC B1432, GO to A4 .
No
GO to A12.
A2 CHECK THE WIPER ON/OFF RELAY — USE THE FEM ACTIVE COMAND WIPER RLY
Enter the following diagnostic mode on the scan tool: FEM active command WIPER RLY. Yes
Disconnect: Windshield Wiper ON/OFF Relay. INSTALL a new windshield wiper
Trigger the FEM active command WIPER RLY to ON. ON/OFF relay. REPEAT the FEM self-
Measure the resistance between windshield wiper ON/OFF relay pin 2, circuit 1318 (DG/WH), harness side and ground. test. CLEAR the DTCs.
No
GO to A3.
Is the resistance less than 5 ohms?

A3 CHECK CIRCUIT 1318 (DG/WH) FOR OPEN
Disconnect: FEM C201b. Yes
Measure the resistance between FEM C201b pin 1, circuit 1318 (DG/WH), harness side and windshield wiper ON/OFF relay pin INSTALL a new FEM. REFER to Section
2, circuit 1318 (DG/WH), harness side. 419-10. REPEAT the FEM self-test.
CLEAR the DTCs.
No
REPAIR the circuit. REPEAT the FEM
self-test. CLEAR the DTCs.

A4 CHECK THE WIPER ON/OFF RELAY
Disconnect: Windshield Wiper ON/OFF Relay. Yes
Measure the voltage between windshield wiper ON/OFF relay pin 2, circuit 1318 (DG/WH), harness side and ground. GO to A5.
No
INSTALL a new wiper ON/OFF relay.
REPEAT the FEM self-test. CLEAR the
DTCs.
Is the voltage greater than 10 volts?

A5 CHECK CIRCUIT 1318 (DG/WH) FOR SHORT TO VOLTAGE
Disconnect: Windshield Wiper ON/OFF Relay. REPAIR the circuit. REPEAT the FEM
Measure the voltage between windshield wiper ON/OFF relay pin 2, circuit 1318 (DG/WH), harness side and ground. self-test. CLEAR the DTCs.
No
INSTALL a new FEM. REFER to Section
419-10.

A6 CHECK FOR MULTIPLE DTCS
Is DTC B1450 also present? GO to A9.
No
GO to A7.
A7 CHECK THE MULTIFUNCTION SWITCH
Disconnect: Multifunction Switch C202. Yes
Carry out the multifunction switch component test. GO to A8.
Refer to Wiring Diagrams Cell 149, Interval Wiper/Washer for component testing. No
INSTALL a new multifunction switch.
REFER to Section 211-05. REPEAT the
Is the multifunction switch OK? FEM self-test. CLEAR the DTCs.
A8 CHECK CIRCUIT 1301 (YE) FOR OPENS
Measure the resistance between FEM C201d pin 2, circuit 1301 (YE), harness side and multifunction switch C202 pin 5, circuit Yes
1301 (YE), harness side. INSTALL a new FEM. REFER to Section
419-10. REPEAT the FEM self-test.
CLEAR the DTCs.
No


A9 CHECK THE MULTIFUNCTION SWITCH FOR CORRECT OPERATION
Carry out the multifunction switch component test. GO to A10.
A10 CHECK CIRCUIT 1302 (WH/LG) FOR OPEN
Disconnect: FEM C201d. Yes
Measure the resistance between the FEM C201d pin 14, circuit 1302 (WH/LG), harness side and multifunction switch C202 pin 3, GO to A11.
circuit 1302 (WH/LG), harness side.
No

A11 CHECK CIRCUIT 1300 (VT) FOR OPEN
Measure the resistance between the FEM C201d pin 13, circuit 1300 (VT), harness side and multifunction switch C202 pin 4, Yes
circuit 1300 (VT), harness side. INSTALL a new multifunction switch.
FEM self-test. CLEAR the DTCs.
No

A12 CHECK WIPER MULTIFUNCTION SWITCH — MONITOR THE FEM PID WPMODE
Ignition OFF. Yes
Connect the scan tool. GO to A16.
Ignition ON.
Enter the following diagnostic mode on the scan tool: FEM PID WPMODE, while rotating the windshield wiper switch through No
each of its wiper and washer positions. GO to A13.
Do the PIDs agree with the switch positions?
A13 CARRY OUT MULTIFUNCTION SWITCH COMPONENT TEST
Check the multifunction switch for correct operation. GO to A14.
A14 CHECK CIRCUITS 1300 (VT), 1301 (YE), AND 1302 (WH/LG) FOR OPENS
Measure the resistance between FEM C201d pin 13, circuit 1300 (VT), harness side and multifunction switch C202 pin 4, circuit GO to A15.
1300 (VT), harness side; and between FEM C201d pin 2, circuit 1301 (YE), harness side and multifunction switch C202 pin 5,
circuit 1301 (YE), harness side; and between FEM C201d pin 14, circuit 1302 (WH/LG), harness side and multifunction switch No
C202 pin 3, circuit 1302 (WH/LG), harness side. REPAIR the circuit as necessary.
DTCs.
Are the resistances less than 5 ohms?

A15 CHECK CIRCUITS 1300 (VT), 1301 (YE), AND 1302 (WH/LG) FOR SHORTS TO VOLTAGE
Measure the voltage between FEM C201d pin 13, circuit 1300 (VT), harness side and ground; and between FEM C201d pin 2, Yes
circuit 1301 (YE), harness side and ground; and between FEM C201d pin 14, circuit 1302 (WH/LG), harness side and ground. REPAIR the circuit as necessary.
DTCs.
No
INSTALL a new FEM. REFER to Section
CLEAR the DTCs.
Is any voltage indicated?

A16 CHECK FOR CORRECT WIPER OPERATION — USING FEM ACTIVE COMMANDS
Enter the following diagnostic mode on the scan tool: FEM active command WIPER RLY ON. Yes
Do the wipers operate? INSTALL a new FEM. REFER to Section
CLEAR the DTCs.
No
GO to A17.
A17 CHECK CIRCUIT BJB FOR OPEN
Disconnect: BJB Fuse 5 (30A). Yes
Measure the voltage between BJB fuse 6 (30A) input side and ground. REINSTALL BJB fuse 6 (30A), GO to
A18 .
No
REPAIR the BJB. REPEAT the FEM

A18 CHECK WIPER ON/OFF RELAY
Disconnect: Wiper ON/OFF Relay. Yes
Check the wiper ON/OFF relay for correct operation. GO to A19.
INSTALL a new wiper ON/OFF relay.
Is the wiper ON/OFF relay OK? DTCs.
A19 CHECK CIRCUIT 65 (DG) FOR VOLTAGE
Measure the voltage between the wiper ON/OFF relay pin 1, circuit 65 (DG), harness side and ground. Yes
GO to A20.
No

A20 CHECK CIRCUIT 65 (DG) FOR OPEN
Disconnect: Windshield Wiper Motor C125. Yes
Measure the resistance between the wiper ON/OFF relay pin 4, circuit 65 (DG), harness side and windshield wiper motor C125 GO to A21.
pin 2, circuit 65 (DG), harness side.
No

A21 CHECK CIRCUIT 28 (BK/VT) FOR SHORT TO VOLTAGE
Measure the voltage between wiper ON/OFF relay pin 4, circuit 28 (BK/VT), harness side and ground. Yes
No
GO to A22.

A22 CHECK WIPER MOTOR GROUND CIRCUIT 1205 (BK) FOR OPEN
Measure the resistance between windshield wiper motor C125 pin 3, circuit 1205 (BK), harness side and ground. Yes
GO to A23.
No

A23 CHECK CIRCUIT 640 (RD/YE) FOR SHORT TO VOLTAGE
Measure the voltage between FEM C201d pin 3, circuit 640 (RD/YE), harness side and ground. REPAIR the circuit. REPEAT the FEM
No
GO to A24.

A24 Component Test
Carry out the component test for the windshield wiper motor in this section. Yes
Is the wiper motor OK? The system is operating correctly at this
time. Concern may have been caused by
a loose or corroded connector. CLEAR
the DTCs. REPEAT the selt-test.
No
INSTALL a new windshield wiper motor.
REFER to Motor — Windshield Wiper in
this section.
PINPOINT TEST B: THE WIPERS ARE INOPERATIVE — REAR WIPERS

B1 USE THE RECORDED DTCS FROM THE FEM SELF-TEST
Are any DTCs recorded? If DTC B1244, GO to B2 .
If DTC B1245, GO to B5 .
If DTC B1611, GO to B7 .
No
GO to B9.
B2 CHECK THE REAR WIPER RELAY
Disconnect: Rear Wiper Relay. Yes
Check the rear wiper relay for correct operation. GO to B3.
INSTALL a new rear wiper relay. REPEAT the FEM self-test.
CLEAR the DTCs.
Is the rear wiper relay OK?
B3 CHECK CIRCUIT 1359 (DG/VT) FOR SHORT TO GROUND
NOTE: Make sure that the rear wiper is turned OFF. Yes
GO to B4.
Measure the resistance between rear wiper relay pin 1, circuit 1359 (DG/VT), harness side and ground.
No
REPAIR the circuit. REPEAT the FEM self-test. CLEAR the
DTCs.
Is the resistance greater than 10,000 ohms?

B4 CHECK CIRCUIT 1359 (DG/VT) FOR OPEN
Disconnect: FEM C201a. Yes
Measure the resistance between FEM C201a pin 4, circuit 1359 (DG/VT), harness side and rear wiper relay INSTALL a new FEM. REFER to Section 419-10. REPEAT the
pin 1, circuit 1359 (DG/VT), harness side. FEM self-test. CLEAR the DTCs.
No
DTCs.

B5 CHECK REAR WIPER RELAY FOR CORRECT OPERATION
Check the rear wiper relay for correct operation. Yes
GO to B6.
Refer to Wiring Diagrams Cell 149, Interval Wiper/Washer for component testing.
No
Is the rear wiper relay OK? CLEAR the DTCs.
B6 CHECK CIRCUIT 1359 (DG/VT) FOR SHORT TO VOLTAGE
Measure the voltage between FEM C201a pin 4, circuit 1359 (DG/VT), harness side and ground. Yes
DTCs.
No
INSTALL a new FEM. REFER to Section 419-10. REPEAT the

B7 CHECK THE MULTIFUNCTION SWITCH FOR CORRECT OPERATION
Check the multifunction switch for correct operation. GO to B8.
INSTALL a new multifunction switch. REFER to Section 211-
05. REPEAT the FEM self-test. CLEAR the DTCs.
Is the multifunction switch OK?
B8 CHECK CIRCUIT 1413 (VT/LB) FOR OPEN
Disconnect: FEM C201e. Yes
Measure the resistance between FEM C201e pin 5, circuit 1413 (VT/LB), harness side and multifunction INSTALL a new FEM. REFER to Section 419-10. REPEAT the
switch C202 pin 2, circuit 1413 (VT/LB), harness side. FEM self-test. CLEAR the DTCs.
No
DTCs.

B9 CHECK THE FEM PID R_WPRUN
Enter the following diagnostic mode on the scan tool: FEM PID R_WPRUN. Yes
Does the FEM PID R_WPRUN indicate ON? REPAIR the circuit. REPEAT the FEM self-test. CLEAR the
DTCs.
No
GO to B10.
B10 CHECK WIPER OPERATION — USE FEM ACTIVE COMMAND WIPER RLY
Activate and deactivate the rear wiper using the FEM active command WIPER RLY. Yes
Did the rear wiper operate correctly? INSTALL a new FEM. REFER to Section 419-10. REPEAT the
No
GO to B11.
B11 CHECK BJB FOR OPEN
Measure the voltage between BJB fuse 7 (25A) input side and ground. REINSTALL BJB Fuse 7. GO to B12 .
No
REPAIR the BJB. REPEAT the FEM self-test. CLEAR the
DTCs.

B12 CHECK THE REAR WIPER RELAY FOR CORRECT OPERATION
Disconnect: Rear Wiper Relay. Yes
Check the rear wiper relay for correct operation. GO to B13.
CLEAR the DTCs.
B13 CHECK CIRCUIT 406 (BN/WH) FOR OPEN
Measure the voltage between rear wiper relay pin 5, circuit 406 (BN/WH), harness side and ground. Yes
GO to B14.
No
DTCs.

B14 CHECK CIRCUIT 406 (BN/WH) FOR OPEN
Disconnect: Rear Wiper Motor C476. Yes
Measure the voltage between rear wiper motor C476 pin 3, circuit 406 (BN/WH), harness side and ground. GO to B15.
No
DTCs.

B15 CHECK CIRCUIT 63 (RD) FOR OPEN
Yes
Measure the resistance between rear wiper relay pin 3, circuit 63 (RD), harness side and rear wiper motor GO to B16.
C476 pin 2, circuit 63 (RD), harness side.
No
DTCs.

B16 CHECK CIRCUIT 1205 (BK) FOR OPEN
Measure the resistance between rear wiper motor C476 pin 1, circuit 1205 (BK), harness side and ground. Yes
INSTALL a new rear wiper motor. REFER to Motor — Rear
Wiper in this section.
No
DTCs.
PINPOINT TEST C: THE WIPERS STAY ON CONTINUOUSLY — FRONT OR REAR

C1 USE THE RESULTS FROM THE FEM SELF-TEST
Use the recorded results from FEM self-test. Yes
Are any DTCs recorded? REFER to the Front Electronic Module (FEM) Diagnostic Trouble Code (DTC)
Index.
No
For front wiper concerns, GO to C2 .
For rear wiper concerns, GO to C6 .

C2 CHECK WIPER ON/OFF RELAY
Check the wiper ON/OFF relay for correct operation. GO to C3.
INSTALL a new wiper ON/OFF relay. REPEAT the FEM self-test. CLEAR the
DTCs.
Is the wiper ON/OFF relay OK?
C3 CHECK CIRCUIT 1318 (DG/WH) FOR SHORT TO GROUND
NOTE: Make sure that the front wiper switch is in the OFF position. Yes
GO to C4.
Measure the resistance between wiper ON/OFF relay pin 2, circuit 1318 (DG/WH), harness
side and ground. No
REPAIR the circuit. REPEAT the FEM self-test. CLEAR the DTCs.

C4 CHECK THE MULTIFUNCTION SWITCH
Check the multifunction switch for correct operation. GO to C5.
INSTALL a new multifunction switch. REFER to Section 211-05. REPEAT the
C5 CHECK CIRCUIT 1301 (YE) FOR SHORT TO GROUND
Measure the resistance between multifunctuon switch C202 pin 5, circuit 1301 (YE), harness Yes
side and ground. INSTALL a new FEM. REFER to Section 419-10. REPEAT the FEM self-test.
CLEAR the DTCs.
No

C6 CHECK REAR WIPER RELAY FOR CORRECT OPERATION
Check the rear wiper relay for correct operation. Yes
GO to C7.
No
INSTALL a new rear wiper switch. REFER to Section 211-05.
C7 CHECK CIRCUIT 1359 (DG/VT) FOR OPEN
Measure the resistance between rear wiper relay pin 1, circuit 1359 (DG/VT), harness side Yes
and ground. GO to C8.
No

C8 CHECK THE MULTIFUNCTION SWITCH
Check the multifunction switch for correct operation. GO to C9.
INSTALL a new multifunction switch. REFER to Section 211-05. REPEAT the
C9 CHECK CIRCUIT 1413 (VT/LB) FOR SHORT TO GROUND
Measure the resistance between multifunction switch C202 pin 2, circuit 1413 (VT/LB), Yes
harness side and ground. INSTALL a new FEM. REFER to Section 419-10. REPEAT the FEM self-test.
CLEAR the DTCs.
No
PINPOINT TEST D: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY

D1 USE THE RESULTS FROM THE FEM SELF-TEST
Are any DTCs recorded? If DTC B1446, GO to D2 .
If DTC B1448, GO to D4 .
No
GO to D6.
D2 CHECK WIPER ON/OFF RELAY FOR CORRECT OPERATION
Check the wiper ON/OFF relay for correct operation. GO to D3.
INSTALL a new wiper ON/OFF relay. REPEAT the FEM self-test.
CLEAR the DTCs.
D3 CHECK CIRCUIT 28 (BK/VT) FOR OPEN
Measure the resistance between FEM C201b pin 13, circuit 28 (BK/VT), harness side and wiper ON/OFF INSTALL a new FEM. REFER to Section 419-10. REPEAT the
relay pin 4, circuit 28 (BK/VT), harness side. FEM self-test. CLEAR the DTCs.
No
DTCs.

D4 CHECK WIPER ON/OFF RELAY FOR CORRECT OPERATION
Check the wiper ON/OFF relay for correct operation. GO to D5.
INSTALL a new wiper ON/OFF relay. REPEAT the FEM self-test.
CLEAR the DTCs.
D5 CHECK CIRCUIT 28 (BK/VT) FOR SHORT TO VOLTAGE
Measure the voltage between wiper ON/OFF relay pin 4, circuit 28 (BK/VT), harness side and ground. REPAIR the circuit. REPEAT the FEM self-test. CLEAR the
DTCs.
No

D6 CHECK THE MULTIFUNCTION SWITCH
Check the multifunction switch for correct operation. GO to D7.
INSTALL a new multifunction switch. REFER to Section 211-05.
REPEAT the FEM self-test. CLEAR the DTCs.
D7 CHECK CIRCUIT 640 (RD/YE) FOR SHORT TO VOLTAGE
Measure the voltage between FEM C201d pin 3, circuit 640 (RD/YE), harness side and ground. REPAIR the circuit. REPEAT the FEM self-test. CLEAR the
DTCs.
No
PINPOINT TEST E: THE WASHER PUMP IS INOPERATIVE — FRONT AND REAR

E1 USE THE RECORDED RESULTS FROM THE FEM SELF-TEST
Are any DTCs recorded? If B1241, GO to E2 .
If B1460, GO to E3 .
No
If the front washer is inoperative, GO to E4 .
If the rear washer is inoperative, GO to E7 .

E2 CHECK CIRCUIT 1333 (LB/WH) FOR SHORT TO VOLTAGE
Measure the voltage between FEM C201b pin 5, circuit 1333 (LB/WH), harness side and ground. REPAIR the circuit. REPEAT the FEM self-test. CLEAR the DTCs.
No
INSTALL a new FEM. REFER to Section 419-10. REPEAT the FEM

E3 CHECK CIRCUIT 1321 (TN/BK) FOR SHORT TO VOLTAGE
Measure the voltage between FEM C201b pin 14, circuit 1321 (TN/BK), harness side and ground. Yes
No
INSTALL a new FEM. REFER to Section 419-10. REPEAT the FEM

E4 CHECK THE MULTIFUNCTION SWITCH
Check the multifunction switch for correct operation. GO to E5.
E5 CHECK CIRCUIT 1321 (TN/BK) FOR OPEN
Disconnect: Front Washer Pump C137. GO to E6.
Measure the resistance between FEM C201b pin 14, circuit 1321 (TN/BK), harness side and front
washer pump C137 pin 2, circuit 1321 (TN/BK), harness side. No
REPAIR the circuit. INSTALL a new multifunction switch. REFER to
Section 211-05. REPEAT the FEM self-test. CLEAR the DTCs.

E6 CHECK FRONT WASHER PUMP
Connect: Front Washer Pump C137. Yes
Connect a fused (10A) jumper wire between FEM C201b pin 14, circuit 1321 (TN/BK), harness side INSTALL a new FEM. REFER to Section 419-10. REPEAT the FEM
and ground. self-test. CLEAR the DTCs.
Does the front washer pump operate correctly?
No
INSTALL a new front washer pump. REFER to Washer Pump and
Reservoir in this section. REPEAT the FEM self-test. CLEAR the
DTCs.
E7 CHECK THE BJB FOR OPEN
Measure the voltage between BJB fuse 7 (25A) input side and ground. GO to E8.
No
REPAIR the BJB. REPEAT the FEM self-test. CLEAR the DTCs.

E8 CHECK CIRCUIT 406 (BN/WH) FOR OPEN
Connect: Rear Washer Pump C1097. Yes
Measure the voltage between rear washer C1097 pin 1, circuit 406 (BN/WH), harness side and GO to E9.
ground.
No

E9 CHECK REAR WASHER PUMP
Connect: Rear Washer Pump C1097. Yes
Connect a fused (10A) jumper wire between FEM C201b pin 5, circuit 1333 (LB/WH), harness side GO to E10.
and ground.
Did the rear washer pump operate correctly? No
INSTALL a new rear washer pump. REFER to Washer Pump and
Reservoir in this section. REPEAT the FEM self-test. CLEAR the
DTCs.
E10 CHECK CIRCUIT 1333 (LB/WH) FOR OPEN
Measure the resistance between FEM C201b pin 5, circuit 1333 (LB/WH), harness side and rear Yes
washer pump C1097 pin 2, circuit 1333 (LB/WH), harness side. GO to E11.
No

E11 CHECK THE MULTIFUNCTION SWITCH
Check the multifunction switch for correct operation. REPAIR the circuit. REPEAT the FEM self-test. CLEAR the DTCs.
PINPOINT TEST F: THE WASHER PUMP IS INOPERATIVE — FRONT AND REAR WASHERS STAY ON CONTINUOUSLY.

F1 USE THE RESULTS FROM FEM SELF-TEST
Are any DTCs recorded? REFER to Front Electronic Module (FEM) Diagnostic Trouble Code (DTC) Index.
No
GO to F2.
F2 CHECK THE MULTIFUNCTION SWITCH
Check the multifunction switch for correct operation. If the front washer pump is ON continuously, GO to F3 .
Refer to Wiring Diagrams Cell 149, Interval Wiper/Washer for component testing. If the rear washer pump is ON continuously, GO to F4 .
No
Is the multifunction switch OK? INSTALL a new multifunction switch. REFER to Section 211-05. REPEAT the FEM
F3 CHECK CIRCUIT 1321 (TN/BK) FOR SHORT TO GROUND
Measure the resistance between FEM C201b pin 14, circuit 1321 (TN/BK), harness INSTALL a new FEM. REFER to Section 419-10. REPEAT the FEM self-test.
side and ground. CLEAR the DTCs.
No

F4 CHECK CIRCUIT 1333 (LB/WH) FOR SHORT TO GROUND
Measure the resistance between FEM C201b pin 5, circuit 1333 (LB/WH), harness side INSTALL a new FEM. REFER to Section 419-10. REPEAT the FEM self-test.
and ground. CLEAR the DTCs.
No
PINPOINT TEST G: THE HIGH/LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY

G1 USE THE RESULTS FROM FEM SELF-TEST
Are any DTCs recorded? If DTC B1436, GO to G2 .
No
GO to G4.
G2 CHECK WIPER HIGH/LOW RELAY
Disconnect: Wiper HIGH/LOW Relay. Yes
Check the wiper HIGH/LOW relay for correct operation. With the wiper HIGH/LOW relay disconnected,
GO to G3 .
No
INSTALL a new wiper HIGH/LOW relay. REPEAT
Is the wiper HIGH/LOW relay OK? the FEM self-test. CLEAR the DTCs.
G3 CHECK CIRCUIT 1319 (VT/WH) FOR SHORT TO VOLTAGE
Measure the voltage between FEM C201b pin 3, circuit 1319 (VT/WH), harness side and ground. REPAIR the circuit. REPEAT the FEM self-test.
CLEAR the DTCs.
No
INSTALL a new FEM. REFER to Section 419-10.

G4 CHECK WIPER HI /LOW RELAY — USE ACTIVE COMMAND SPEED RLY
Enter the following diagnostic mode on the scan tool: FEM active command SPEED RLY to ON. Yes
Does the HIGH/LOW relay energize? GO to G5.
No
INSTALL a new FEM. REFER to Section 419-10.
G5 CHECK WIPER HIGH/LOW RELAY
Disconnect: Wiper HIGH/LOW Relay. Yes
Check the wiper HIGH/LOW relay for correct operation. GO to G6.
INSTALL a new wiper HIGH/LOW relay. REPEAT
the FEM self-test. CLEAR the DTCs.
Is the wiper HIGH/LOW relay OK?
G6 CHECK THE CIRCUIT 1319 (VT/WH) FOR SHORT TO GROUND
Measure the resistance between FEM C201b pin 3, circuit 1319 (VT/WH), harness side and ground. GO to G7.
No
REPAIR the circuit. REPEAT the FEM self-test.
CLEAR the DTCs.

G7 CHECK THE CIRCUIT 1319 (VT/WH) FOR OPEN
Measure the resistance between FEM C201b pin 3, circuit 1319 (VT/WH), harness side and wiper HIGH/LOW relay pin Yes
2, circuit 1319 (VT/WH), harness side. GO to G8.
No
CLEAR the DTCs.

G8 CHECK CIRCUIT 65 (DG) FOR OPEN
Connect: FEM C201b. Yes
Measure the voltage between wiper HIGH/LOW relay pin 1, circuit 65 (DG), harness side and ground. GO to G9.
No
CLEAR the DTCs.

G9 CHECK CIRCUIT 589 (OG) FOR OPEN
Measure the resistance between wiper HIGH/LOW relay pin 3, circuit 589 (OG), harness side and wiper ON/OFF relay REINSTALL ON/OFF relay, GO to G10 .
circuit 589 (OG), harness side.
No
CLEAR the DTCs.

G10 CHECK CIRCUIT 56 (DB/OG) AND 58 (WH) FOR SHORT TO GROUND
Disconnect: Front Wiper Motor C125. Yes
Measure the resistance between wiper HIGH/LOW relay pin 5, circuit 56 (DB/OG), harness side and ground; and GO to G11.
between wiper HIGH/LOW relay pin 4, circuit 58 (WH), harness side and ground.
No
REPAIR Circuit 58 (WH) or circuit 56 (DB/OG), as
necessary. REPEAT the FEM self-test. CLEAR
the DTCs.

G11 CHECK CIRCUIT 56 (DB/OG) AND 58 (WH) FOR OPEN
Measure the resistance between wiper HIGH/LOW relay pin 5, circuit 56 (DB/OG), harness side and windshield wiper Yes
motor C125 pin 1, circuit 56 (DB/OG), harness side; and between wiper HIGH/LOW relay pin 4, circuit 58 (WH), harness GO to G12.
side and windshield wiper motor C125 pin 2, circuit 58 (WH), harness side.
No
REPAIR the circuit as necessary. REPEAT the

G12 CHECK CIRCUIT 56 (DB/OG) AND 58 (WH) FOR SHORT TO VOLTAGE
Measure the voltage between wiper HIGH/LOW relay pin 5, circuit 56 (DB/OG), harness side and ground; and between Yes
wiper HIGH/LOW relay pin 4, circuit 58 (WH), harness side and ground. REPAIR the circuit as necessary. REPEAT the
No
GO to G13.

G13 Component Test
Carry out the component test for the windshield wiper motor in this section. Yes
Is the wiper motor OK? The system is operating correctly at this time.
Concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT
the selt-test.
No
INSTALL a new windshield wiper motor. REFER
to Motor — Windshield Wiper in this section.
Component Test
Windshield Wiper Motor
CAUTION: Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and
will make the wiper motor inoperative. Rough handling of new wiper motors may also damage the motor magnets.
Use Alternator, Regulator, Battery and Starter Tester (ARBST) to test the wiper motor on the vehicle.
To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. For additional information, refer to Mounting Arm and Pivot Shaft in
this section.
Disconnect the wiper motor. Connect the (1) green lead from (2) ARBST to the battery negative (-) post. Connect the (3) red lead from ARBST to the wiper motor (4) common brush terminal
(terminal 3).
Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is
greater than 3.5 amperes, install a new wiper motor.
Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is
greater than 5.5 amperes, install a new wiper motor.

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2003 Windstar Workshop Manual Page 1 of 17

SECTION 501-16: Wipers and Washers 2003 Windstar Workshop Manual

Wipers and Washers Printable View (426 KB)

Alternator, Regulator, Battery and Starter Tester (ARBST)

Worldwide Diagnostic System (WDS)

New Generation STAR (NGS) Tester

Inspection and Verification

1. Verify the customer concern by operating the wiper and washer.

2. Visually inspect for obvious signs of mechanical and electrical damage.

Visual Inspection Chart

Front Electronic Module (FEM) Diagnostic Trouble Code (DTC) Index

PINPOINT TEST A: THE WIPERS ARE INOPERATIVE — FRONT WIPERS

Test Step Result / Action to Take

Is the resistance less than 5 ohms?

Is the resistance less than 5 ohms?

Is the voltage greater than 10 volts?

Is the voltage greater than 10 volts?

REPAIR the circuit. REPEAT the FEM

Is the resistance less than 5 ohms?

Is the resistance less than 5 ohms?

Is the resistance less than 5 ohms?

Are the resistances less than 5 ohms?

Is any voltage indicated?

Is the voltage greater than 10 volts?

Is the voltage greater than 10 volts?

Is the resistance less than 5 ohms?

Is the voltage greater than 10 volts?

Is the resistance less than 5 ohms?

Is any voltage indicated?

PINPOINT TEST B: THE WIPERS ARE INOPERATIVE — REAR WIPERS

Test Step Result / Action to Take

Is the resistance greater than 10,000 ohms?

Is the resistance less than 5 ohms?

Is the voltage greater than 10 volts?

Is the resistance less than 5 ohms?

Is the voltage greater than 10 volts?

Is the voltage greater than 10 volts?

Is the voltage greater than 10 volts?

Is the resistance less than 5 ohms?

Is the resistance less than 5 ohms?

PINPOINT TEST C: THE WIPERS STAY ON CONTINUOUSLY — FRONT OR REAR

Test Step Result / Action to Take

For rear wiper concerns, GO to C6 .

Is the resistance greater than 10,000 ohms?

Is the resistance greater than 10,000 ohms?

Is the resistance greater than 10,000 ohms?

Is the resistance greater than 10,000 ohms?

Test Step Result / Action to Take

Is the resistance less than 5 ohms?

Is any voltage indicated?

Is any voltage indicated?

PINPOINT TEST E: THE WASHER PUMP IS INOPERATIVE — FRONT AND REAR

Test Step Result / Action to Take

If the rear washer is inoperative, GO to E7 .

Is any voltage indicated?

Is any voltage indicated?

Is the resistance less than 5 ohms?

Is the voltage greater than 10 volts?

Is the voltage greater than 10 volts?

Is the resistance less than 5 ohms?

Test Step Result / Action to Take

Is the resistance greater than 10,000 ohms?

Is the resistance greater than 10,000 ohms?

PINPOINT TEST G: THE HIGH/LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY