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.
If I just turn the parking lights on fuse doesn’t blow. But as soon as I turn on the low beam lights fuse blows. Also now the DRL do not come on when I take off the emergency brake. Think I am going to have to take center console apart to see if maybe there is a short inside of there.
You will need to sacrifice a few fuses to narrow down the location. Install a new fuse and turn the headlights on. If the fuse blew, switch the position of the dimmer switch. Install another fuse and see if blows. Let me know what happens.
Sorry about that. It is the 25 amp fuse under the hood first location on the top left. The cover says headlight for fuse use.
Which fuse? There are six fuses involved in the headlight system. I need the location of the fuse box, the location of the fuse within the box, the designation of the fuse on the fuse box legend and the fuse size.
The splicing has been done by the dealership. But now the headlight fuse keeps blowing whenever I turn on the headlights. Any answer to why this could be happening?