Component Testing — Mercury Milan I (2005-2010)

Introduction

Component testing procedures are provided to determine whether a component is good or bad.

Testing information for each component includes a schematic, a view of the terminal locations and step-by-step test procedures. Terminal locations are identified by numbers or letters that may be on the component or next to it.

Scheme 3

Scheme 3: Introduction

The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under the column "Circuit to test". If you wish to test the complete component, perform all tests.

Connect the tester to the terminals shown in the second column and operate the component as shown in the third column.

Scheme 4

Scheme 4: Schematic

Scheme 5

Scheme 5: Terminals

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Washer switch circuit	10 and 15	On	Closed circuit
Washer switch circuit	10 and 15	Rest	Open circuit
Wiper switch circuit	9 and 15	Off	Open circuit
		High	Closed circuit
		Low	Open circuit
	11 and 15	Off	Open circuit
		High	Open circuit
		Low	Open circuit
	12 and 15	Off	Open circuit
		High	Closed circuit
		Low	Closed circuit
	15 and 16	Off	Open circuit
		High	Closed circuit
		Low	Closed circuit
Intermittent wiper circuit	15 and 16	Interval 1	Open circuit
		Interval 2	Open circuit
		Interval 3	Open circuit
		Interval 4	Closed circuit
		Interval 5	Closed circuit
	11 and 15	Interval 1	Open circuit
		Interval 2	Closed circuit
		Interval 3	Closed circuit
		Interval 4	Closed circuit
		Interval 5	Open circuit
	12 and 15	Interval 1	Closed circuit
		Interval 2	Closed circuit
		Interval 3	Open circuit
		Interval 4	Open circuit
		Interval 5	Open circuit

MULTIFUNCTION SWITCH, WIPER/WASHER PORTION - COMPONENT TESTING

Scheme 6

Scheme 6: Schematic

Scheme 7

Scheme 7: Terminals

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Turn signal	2 and 8	Left turn	Closed circuit
Turn signal	3 and 8	Right turn	Closed circuit
Flash-to-pass	6 and 8	Pull and hold lever stalk toward steering wheel	Open circuit
Flash-to-pass	4 and 8	Pull and hold lever stalk toward steering wheel	Closed circuit
High beam/Low beam	6 and 8	Lever stalk in detent toward steering wheel	Closed circuit
High beam/Low beam	4 and 8	Lever stalk in detent toward steering wheel	Closed circuit

MULTIFUNCTION SWITCH - COMPONENT TESTING

Scheme 8

Scheme 8: Schematic

Scheme 9

Scheme 9: Terminals

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Headlamp circuit	1 and 8	Off	Open circuit
		Park	Open circuit
		Head	Closed circuit
		Auto	Open circuit
Autolamp Circuit	1 and 9	Off	Open circuit
		Park	Open circuit
		Head	Open circuit
		Auto	Closed circuit
Parking Lamps	1 and 3	Off	Open circuit
Parking Lamps	1 and 3	Park	Closed circuit
		Head	Open circuit
		Auto	Open circuit
Fog lamps	1 and 6	Off	Open circuit
		Fog lamps	Closed circuit

MAIN LIGHT SWITCH - COMPONENT TESTING

Scheme 10

Scheme 10: Schematic

Scheme 11

Scheme 11: Terminals

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Interior lamps Circuit	4 and 2	Interior lamps	Closed circuit
Interior lamps Circuit	4 and 2	Off	Open circuit
Illumination dimmer resistor	4 and 1	Rotate knob clockwise	Ohmmeter will show smoothly increasing resistance

ILLUMINATION DIMMER SWITCH - COMPONENT TESTING

Scheme 12

Scheme 12: Schematic

Scheme 13

Scheme 13: Terminal locations

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Starter relay circuit	4 and 7	Off	Open circuit
		Acc	Open circuit
		Run	Open circuit
		Start	Closed circuit
Run/Start power circuit	4 and 1	Off	Open circuit
		Acc	Open circuit
		Run	Closed circuit
		Start	Closed circuit
Run/Acc power circuit	4 and 6	Off	Open circuit
		Acc	Closed circuit
		Run	Closed circuit
		Start	Open circuit
Key reminder circuit	4 and 5	Key In	Closed circuit
		Key Out	Open circuit
Key removal inhibit circuit	4 and 3		65-75ohms

IGNITION SWITCH - COMPONENT TESTING

Scheme 14

Scheme 14: Schematic

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Forward/Rearward circuit	5 and 4	Forward	Closed circuit
	5 and 4	Rest/Rearward	Open circuit
	5 and 9	Rest/Forward	Open circuit
	5 and 9	Rearward	Closed circuit
Front up/down circuit	5 and 2	Up	Closed circuit
	5 and 2	Rest/Down	Open circuit
	5 and 6	Rest/Up	Open circuit
	5 and 6	Down	Closed circuit
Rear up/down circuit	5 and 1	Up	Closed circuit
	5 and 1	Rest/Down	Open circuit
	5 and 12	Rest/Up	Open circuit
	5 and 12	Down	Closed circuit
Forward/Rearward Recliner Circuit	5 and 8	Rest/Forward	Open circuit
	5 and 8	Rearward	Closed circuit
	5 and 3	Forward	Closed circuit
	5 and 3	Rest/Rearward	Open circuit

POWER SEAT SWITCH, 8-WAY POWER SEAT - COMPONENT TESTING

Scheme 15

Scheme 15: Terminals

Scheme 16

Scheme 16: Schematic

Scheme 17

Scheme 17: Terminals

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Forward/Rearward circuit	4 and 3	Forward	Closed circuit
	6 and 2	Forward	Closed circuit
	4 and 6	Rearward	Closed circuit
	3 and 2	Rearward	Closed circuit
Front up/down circuit	4 and 1	Up	Closed circuit
	8 and 2	Up	Closed circuit
	4 and 8	Down	Closed circuit
	1 and 2	Down	Closed circuit
Rear up/down circuit	4 and 5	Up	Closed circuit
	7 and 2	Up	Closed circuit
	7 and 4	Down	Closed circuit
	5 and 2	Down	Closed circuit

POWER SEAT SWITCH, 6-WAY POWER SEAT - COMPONENT TESTING

Scheme 18

Scheme 18: Schematic

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Switch lock	2, C504a and 2, C504b	Unlock	Closed circuit
Switch lock	2, C504a and 2, C504b	Lock	Open circuit
Left front window circuit	2, C504a and 5, C504a	Up	Closed circuit
Right front window circuit	2, C504a and 3, C504a	Down	Closed circuit
Right front window circuit	2, C504a and 8, C504a	Up	Closed circuit
	7, C504b and 8, C504a 7, C504b and 3, C504a	Rest	Closed circuit
Left rear window circuit	2, C504a and 1, C504b	Up	Closed circuit
	2, C504a and 6, C504b	Down	Closed circuit
	7, C504b and 1, C504b 7, C504b and 6, C504b	Rest	Closed circuit
Right rear window circuit	2, C504a and 8, C504b	Up	Closed circuit
	2, C504a and 4, C504b	Down	Closed circuit
	7, C504b and 8, C504b 7, C504b, and 4, C504b	Rest	Closed circuit

MASTER WINDOW ADJUST SWITCH - FUSION / MILAN - COMPONENT TESTING

Scheme 19

Scheme 19: Terminals

Scheme 20

Scheme 20: Schematic

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Switch lock	3, C535b and 4, C535b	Lock On	Closed circuit
Switch lock	3, C535b and 4, C535b	Lock Off	Open circuit
Left front window circuit	3, C535a and 4, C535a	Up	Closed circuit
	3, C535a and 7, C535a	Down	Closed circuit
	3, C535a and 8, C535a	One-Touch Up/Down	Closed circuit
Right front window circuit	3, C535a and 5, C535a	Up	Closed circuit
	3, C535a and 2, C535a	Down	Closed circuit
	3, C535a and 1, C535a	One-Touch Up/Down	Closed circuit
Left rear window circuit	3, C535b and 2, C535b	Up	Closed circuit
Left rear window circuit	3, C535b and 1, C535b	Down	Closed circuit
Right rear window circuit	3, C535b and 8, C535b	Up	Closed circuit
Right rear window circuit	3, C535a and 7, C535b	Down	Closed circuit

MASTER WINDOW ADJUST SWITCH - M Z - COMPONENT TESTING

Scheme 21

Scheme 21: Terminals

Scheme 22

Scheme 22: Window switch - Schematic

Scheme 23

Scheme 23: Terminals

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
One-Touch Up/Down	4 and 6	One-Touch Up/Down	Closed circuit
One-Touch Up/Down	4 and 6	Neutral	Open circuit
Right front window circuit	2 and 3	Up	Closed circuit
Right front window circuit	5 and 2	Down	Closed circuit

WINDOW ADJUST SWITCH, PASSENGER SIDE - M Z - COMPONENT TESTING

Scheme 24

Scheme 24: Schematic

Scheme 25

Scheme 25: Terminals

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Window adjust switches	2 and 3, 5 and 6	Up	Closed circuit
	1 and 2, 3 and 5	Down	Closed circuit
	6 and 5	Rest	Closed circuit
	1 and 2	Rest	Closed circuit

WINDOW ADJUST SWITCHES - COMPONENT TESTING

Scheme 26

Scheme 26: Schematic

Scheme 27

Scheme 27: Terminal locations

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Left mirror		Selector switch Left
Up	6 and 3 1 and 5	Up	Closed circuit
Down	3 and 5 6 and 1	Down	Closed circuit
Left	6 and 3 5 and 4	Left	Closed circuit
Right	6 and 1 3 and 8	Right	Closed circuit
Right mirror		Selector switch Right
Up	6 and 3 2 and 1	Up	Closed circuit
Down	3 and 2 6 and 1	Down	Closed circuit
Left	6 and 3 7 and 1	Left	Closed circuit
Right	3 and 7 6 and 1	Right	Closed circuit

EXTERIOR REAR VIEW MIRROR SWITCH - COMPONENT TESTING

Scheme 28

Scheme 28: Schematic

Scheme 29

Scheme 29: Terminal locations

Circuit to test	Connect self-powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Lock/unlock circuit	3 and 4	Rest	Open circuit
		Lock	Open circuit
		Unlock	Closed circuit
	1 and 4	Rest	Open circuit
		Lock	Closed circuit
		Unlock	Open circuit

POWER DOOR LOCK SWITCH - COMPONENT TESTING

Scheme 30

Scheme 30: Schematic

Scheme 31

Scheme 31: Terminals

Circuit to test	Connect self powered test light or ohmmeter to terminals	Move switch to these positions	A good switch will indicate
Tilt	4 and 2	Tilt	Closed circuit
Slide	4 and 7	Close	Closed circuit
	4 and 3	Open	Closed circuit
	4 and 2	Auto open	Closed circuit

ROOF OPENING PANEL SWITCH - COMPONENT TESTING

Scheme 32

Scheme 32: Schematic

Scheme 33

Scheme 33: Terminals

Circuit to test	Connect ohmmeter to terminals	A good relay will indicate
Coil	85 and 86	50-100ohms
Contact	30 and 87a	Closed circuit
Contact	30 and 87	Open circuit
Coil - Contact	86 and 30	Open circuit
	86 and 87a	Open circuit
	86 and 87	Open circuit

RELAY - MINI ISO - COMPONENT TESTING (NO VOLTAGE APPLIED)

Disconnect the ohmmeter; connect pins 30 and 85 to 12V DC power and pin 86 to ground. Measure voltage between pin 87 and pin 86. If the voltage is 12V, continue with the test. If not, replace the relay. Disconnect power from pin 85 and measure voltage between pin 87a and pin 86. If the voltage is 12V, the relay is okay. If not, replace the relay.

Scheme 34

Scheme 34: Schematic

Scheme 35

Scheme 35: Terminals

Circuit to test	Connect ohmmeter to terminals	A good relay will indicate
Coil	1 and 2	100-150ohms
Contact	3 and 4	Closed circuit
Contact	3 and 5	Open circuit
Coil - Contact	1 and 3	Open circuit
	1 and 4	Open circuit
	1 and 5	Open circuit

RELAY - MICRO ISO - COMPONENT TESTING (NO VOLTAGE APPLIED)

Disconnect the ohmmeter; connect pins 2 and 3 to 12V DC power and pin 1 to ground. Measure voltage between pin 5 and pin 1. If the voltage is 12V, the relay is okay. If not, replace the relay.

Component Testing Mercury Milan I