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Frelander 2. Manual - part 482

Low and high beam bi-xenon headlamp

High beam halogen headlamp

Side marker reflex (NAS only)

Turn signal indicator

Manual beam adjusters

Cover

High beam halogen bulb

High beam bulb holder

Bi-xenon D1S bulb electrical connector

Bi-xenon D1S bulb

Cover

Turn signal indicator bulb

Turn signal indicator bulb holder

Side lamp bulb holder

Side lamp bulb

The xenon headlamp uses a complex surface reflector for the halogen fill-in high beam only unit. This uses the same
halogen H7 55W bulb as used on the halogen headlamp. A bi-xenon projector module is fitted for the low beam headlamp
but also operates as a high beam unit.

Safety Precautions

The following safety precautions must be followed when working on the xenon headlamp system:

DO NOT attempt any procedures on the xenon headlamps when the lights are switched on
Handling of the D1S Xenon bulb must be performed using suitable protective equipment, e.g. gloves and goggles
The glass part of the bulb must not be touched
Xenon bulbs must be disposed of as hazardous waste
Only operate the lamp in a mounted condition in the reflector.

WARNING: The Xenon system generates up to 28000 volts and contact with this voltage could lead to fatality.

Make sure that the headlamps are switched off before working on the system.

Headlamp Construction and Functionality

The xenon lamp or High Intensity Discharge (HID) lamp as they are sometimes called, comprises an ellipsoidal lens with a
solenoid controlled shutter to change the beam output from low to high beam.

• NOTE: If the light control module rotary switch is in the OFF position, the xenon lamps do not operate when the high
beam 'flash' function is operated. If the rotary switch is in the headlamps position or AUTO position with the low beam
lamps active, the xenon low beam will remain on when the high beam 'flash' function is operated.

The xenon headlamp system is controlled by the CJB using a control module for each headlamp and an igniter. The control
modules and the igniters provide the regulated power supply required to illuminate the xenon bulbs through their start-up
phases of operation.

The xenon headlamp is a self contained unit located within the headlamp assembly. The unit comprises a reflector, the
lens, a shutter controller and the xenon bulb, which as an assembly is known as the projector module.

The reflector provides the mounting for the xenon bulb which is an integral part of the igniter. The igniter locates in an
aperture at the rear of the reflector and is secured with 2 Torx screws to ensure correct alignment in the reflector.

A shutter is used to change the beam projection from low beam to high beam and visa versa. The shutter controller is a
solenoid which operates the shutter mechanism via a lever. When the shutter is in the low beam position, it masks some
of the light emitted from the reflector, providing a defined low beam cut-off.

A tourist lever mechanism is located on the right hand side of the projector module. This mechanism moves a flap to blank
off a portion of the beam spread to enable the vehicle to be driven in opposite drive hand markets without applying
blanking decals to the headlamp lens. The beam is changed by removing the cover at the rear of the lamp assembly and
moving a small lever located at the side of the projector module.

The xenon bulb illuminates when an arc of electrical current is established between two electrodes within the bulb. The
xenon gas sealed in the bulb reacts to the electrical excitation and the heat generated by the current flow to produce the
blue/white light.

To operate at full efficiency, the xenon bulb goes through three stages of operation before full output for continuous
operation is achieved. The three phases are; start-up phase, warm-up phase and continuous phase.

In the start-up phase, the bulb requires an initial high voltage starting pulse of up to 30000 volts to establish the arc. This
is produced by the igniters. The warm-up phase begins once the arc is established. The xenon control modules regulate
the supply to the bulbs to 2.6A which gives a lamp output of 75W. During this phase, the xenon gas begins to illuminate
brightly and the environment within the bulb stabilises ensuring a continual current flow between the electrodes. W hen the
warm-up phase is complete, the xenon control modules change to continuous phase. The supply voltage to the bulb is
reduced and the operating power required for continual operation is reduced to 35W . The process from start-up to
continuous phase is completed in a very short time.

The xenon system is controlled by the CJB, the two xenon control modules and the two igniters. The xenon control
modules (one per headlamp) receive an operating voltage from the CJB when the headlamps are switched on. The modules
regulate the power supply required through the phases of start-up.

The igniters (one per headlamp) generate the initial high voltage required to establish the arc. The igniters have integral
coils which generate high voltage pulses required for start-up. Once the xenon bulbs are operating, the igniters provide a
closed circuit for regulated power supply from the control modules.

ADAPTIVE FRONT LIGHTING SYSTEM (AFS)

The system operates by the AFS control module receiving inputs from the engine control module for engine running signal,
the ABS module for steering angle and vehicle speed and a reverse gear input from the transmission.

The AFS control module processes these signals and provides an output to the headlamp leveling motors to adjust the
headlamp horizontal aim according to vehicle speed and steering angle.

• NOTE: In markets with Daytime Running Lamps (DRL), the AFS system will not operate when the DRL are active.

The AFS control module is connected on the high speed CAN bus to receive information from other vehicle systems. The
control module is connected to the AFS power module on a dedicated Local Interconnect Network (LIN) bus. The AFS
control module calculates, using input data from other systems, the required position of the horizontal adjustment of the
projector modules. The position information is then output on the LIN bus to the AFS power module located on each
headlamp assembly. This module then outputs the appropriate signals to power the AFS stepper motors in the headlamp
to the appropriate position.

The horizontal position of the projector modules is dependant on a number of input variables. The position is determined
by vehicle speed and steering angle. When reverse gear is elected, the projector modules are moved to the straight ahead
position to avoid glare to other road users.

The angles of each projector module differ to give the correct spread of light, for example, when turning left, the left hand
projector module will have a greater swivelling angle than the right hand projector module.

In the event of a failure of the AFS system, a warning indicator in the instrument cluster flashes to warn the driver. The
AFS warning indicator illuminates when the ignition switch is in power mode 6 and will flash continuously until the fault is
rectified.

Illumination of the AFS warning indicator does not necessarily mean that there is a fault with the AFS system. The fault
may be caused by a failure of another system such as steering angle sensor or the vehicle speed signal missing,
preventing the AFS system operating correctly.

HEADLAMP LEVELING

Headlamp leveling provides for the adjustment of the vertical aim of the headlamps to minimize glare to other road users
when the vehicle attitude changes due to vehicle loading.

Two types of headlamp leveling are available dependant on the type of headlamps fitted to the vehicle:

Manual headlamp leveling - Halogen headlamps only (ROW vehicles only)
Automatic headlamp leveling - Xenon headlamps only.

Manual Headlamp Leveling - ROW Halogen Headlamps Only

Manual headlamp levelling is only available on ROW vehicles with halogen headlamps.

• NOTE: Headlamp levelling is not available on NAS vehicles with halogen headlamps.

The manual system comprises the following components:

Two headlamp levelling motors
Headlamp leveling rheostat rotary control.

When the ignition is in ignition power mode 6, power is supplied to the light control module via the ignition relay in the
BJB and a fuse in the CJB. Power is also supplied via the ignition relay in the BJB to the headlamp leveling motor in each
headlamp assembly.

Movement of the leveling rotary control produces a variable voltage output, which is sensed by the motors. The motors
react to the supplied voltage and move the headlamp to the requested position which relates to the supplied voltage from
the leveling rotary control. The headlamps can only be lowered from their unladen position to compensate for changes in
vehicle attitude due to loading.

The manual headlamp leveling rotary control has no defined positions which relate to the vehicle loading. The approximate
rotary thumbwheel control position for a given loading is shown in the following table:

Rotary Control Rotation

Vehicle Load

Driver only or Driver and front seat passenger

1/4

Driver and passengers in all seats

Maximum gross vehicle weight

Full

Maximum rear axle load

Automatic Headlamp Leveling - Xenon Headlamps Only

Automatic headlamp leveling is only available on vehicles with xenon headlamps. The system is not a Dynamic headlamp
levelling system and changes in vehicle inclination due to positive and negative acceleration are not compensated.

Automatic headlamp leveling provides for the static, periodic adjustment of the vertical aim of the headlamps to minimise
glare to other road users when the vehicle attitude changes due to loading.

Automatic headlamp leveling is controlled by a headlamp leveling module which is located on the bulkhead, adjacent to
the instrument panel on the passenger side 'A' pillar.

• NOTE: On vehicles with the AFS system, the headlamp leveling software is incorporated into the AFS control module and
the module is known as the AFS control module.

The headlamp leveling system comprises the following components and information from other vehicle systems:

Front and rear vehicle height sensors
Two headlamp leveling, vertical adjustment motors

Headlamp leveling module (or AFS control module if vehicle is fitted with AFS)
Ignition in power mode 6.

When the ignition is in power mode 6, power is supplied, via the ignition relay in the BJB, to the light control module, the
headlamp leveling motors (or AFS motors if fitted) and to the headlamp leveling module (or AFS control module if fitted).

When the light control module rotary switch is moved to the side lamp or headlamp position, a Local Interconnect Network
(LIN) bus message is passed from the light control module to the CJB for the selected function. The CJB then issues a
'lights on' message on the high speed CAN bus to the headlamp leveling module (or AFS control module if fitted).

The headlamp leveling module (or AFS control module if fitted) uses signals from the front and rear height sensors to
periodically re-align the vertical aim of the headlamps to their optimum position.

DAYTIME RUNNING LAMPS (DRL)

DRL are a market requirement in certain countries.
For additional information, refer to:

Daytime Running Lamps (DRL)

(417-04 Daytime Running Lamps (DRL), Description and

Operation).

FRONT FOG LAMP

Item

Part Number

Description

Bulb and holder

Harness connector

Attachment hole (4 off)

Beam alignment adjuster

Front fog lamps are available as an option or standard fitment on vehicles fitted with HID headlamps and headlamp
powerwash.

Two front fog lamps are located in apertures in the front bumper. Each lamp is secured in the bumper with 3 Torx screws
which are covered with a removable finisher. The fog lamp has an adjuster which is used to set the fog lamp to the correct
alignment.

The fog lamp uses a 55W halogen H11 bulb which is located in an integral holder. The holder is located in a hole in the
rear of the fog lamp housing and is turned to lock in position.

The front fog lamps are controlled by the CJB. W hen the ignition switch is in ignition power mode 6 and the light control
module rotary switch is in the side lamp or headlamp position, the front fog lamp button can be pressed to activate the
front fog lamps. A front fog lamp warning indicator is illuminated in the instrument cluster when the front fog lamps are
active.

Front Fog Lamp Functionality (NAS and Canadian Markets Only)

The front fog lamps operate as described previously but with the following differences which cover local laws governing
lamp usage.

If the low beam headlamps and the front fog lamps are on at the same time, when the high beam headlamps are switched
on, the front fog lamps will be automatically switched off. W hen the high beam headlamps are subsequently switched off,
the front fog lamps will be switched on automatically.

• NOTE: The front fog lamps will also be switched off if the high beam 'flash' function is operated.

REAR LAMP ASSEMBLY

Item

Part Number

Description

Stop/tail lamp

Reversing lamp

Side marker lamp (NAS only)

Rear fog lamp

Turn signal indicator lamp

Stop/tail lamp bulb holder

Turn signal indicator lamp bulb holder

Side marker bulb holder (NAS only)

Reversing lamp bulb holder

Rear fog lamp bulb holder

Connector plug

The rear lamp assembly is a one piece unit which contains a stop/tail lamp, a turn signal indicator lamp, a reversing lamp
and a fog lamp. Five bayonet fitting bulbs are used (six on NAS vehicles with the addition of a side marker lamp). These
are located in holders which fit into the applicable hole in the lamp housing and are locked by rotating. Each bulb holder is
connected by wires to a connector on the rear of the lamp housing.

The rear lamp assembly is located in a recess in the vehicle body. Two studs on the outer edge of the lamp housing locate
in plastic clips the vehicle body. The lamp is secured with two screws which are located on the inner edge of the lamp
housing, near the tailgate aperture.

Rear Stop/Tail Lamp

The upper lamp is a combined stop and tail lamp and uses a 21W/5W bayonet fitting bulb. The stop lamp uses the 21W
bulb filament and the side lamp uses the 5W bulb filament.

The stop lamp is activated when the ignition is in the ignition power mode 6 and the brake pedal switch is active (by
depressing the brake pedal). The high mounted stop lamp will also be activated when the brake pedal is pressed. The stop
lamps can also be activated by the Anti-lock Brake system (ABS) when Hill Descent Control (HDC) is active. The ABS
module send a high speed CAN bus message to the CJB which supplies power to the stop lamps and high mounted stop
lamp.

The side lamps are operated by selecting side lamps or headlamps on the light switch module. The side lamps are
operational at all times and are not dependant on the ignition power mode 6. The side lamps will also be illuminated when
the light switch module is in the AUTO position and a 'lights on' signal is received by the CJB from the rain/light sensor.

Turn Signal Indicator Lamp

The turn signal indicator lamp is located below the stop/tail lamp and uses a orange colored, 21W bayonet fitting bulb. On
vehicles from 2009MY a 'Silvervision' bulb is used.

The turn signal indicator lamps are operated by the left hand steering column multifunction switch or by the hazard flasher
switch. The steering column multifunction switch is only active with the ignition in the ignition power mode 6, the hazard
flasher switch is active at all times. W hen active, the turn signal indicator lamps will flash at a frequency cycle of 360ms
on and 360ms off.

Content .. 480 481 482 483 ..