This 2004 Suzuki Forenza came in with the complaint that the headlights do not work except for the flash to pass feature. I checked the fuses and the headlight relay in the underhood fuse box and they were okay. I then turned my attention to the 201 splice pack that is located behind the instrument cluster assembly.
To remove the instrument cluster bezel there are two phillip’s headed screws along the upper wedge of the bezel.
The lower edge is held in place by spring clips. The clips can be seen in the following picture. The lower edge of the bezel has to be pulled towards the driver’s seat in order for the clips to disengage.
Once the bezel is out of the way, there are three screws that hold the instrument cluster in place; two along the lower edge and one above the center upper edge.
With the cluster loose it can be maneuvered to access the harness connectors along the top rear edge. The latches are a little difficult to depress so take your time.
There are two splice packs located behind the instrument cluster. The 201 splice pack is located to the left. Pretty obvious there is a problem here. Lots of melted plastic and discolored wires.
A closer look showed that someone has been here before. Two of the wires had already been cut out of the splice pack and joined together.
The two blue wires were the ones that I needed to fix to correct the headlight problem on this car but I decided to remove the splice pack completely.
The inside of the melted splice pack assembly.
In the end there were three different splices. Three purple wires, two blue wires and the remaining light green wires.
Just to be absolutely clear all wires of the same color will be crimped together in one connector. You will wind up with three separate splice connections. You may need to remove some tape from the harness to actually tell the wire color. Many times all the wires will appear to be the same burnt brown color near the original splice pack.
I know this is a bit old, but I need to ask a question. I’m going to do this myself and want to make sure it’s right. All the purple wires, all the green and all the blue go together? It looks like that in the picture but I wanted to make sure, TY.
You need to put the dimmer switch in the high beam position and not use the flash to pass detent, just to be sure the fuse does not blow on high beam. Assuming the fuse does not blow on high beam, you will then need to remove the instrument cluster and check the integrity of the three purple wires in the splice pack. If there is nothing shorted externally, separate the three wires and check to see of the fuse blows on low beams. If it does not locate the purple wire from the splice pack that has power on it, while the low beam headlights are turned on. Connect it to one of the other wires and see what happens when you turn the low beams on. If the fuse blows replace it and touch the powered purple wire to the other wire and see what happens. Let me know the results.
As soon as you turn on the low beam switch on it blows. But if you put the dimmer switch to parking lights you can pull the light switch to you and the high beams will turn on and it will not blow.
You stated that the fuse blows when the low beams are on. Does the fuse blow when the dimmer switch is in the high beam position and then the headlight switch is turned on?