30S06T0 nvh principle and diagnosis 2007

Noise, Vibration and Harshness Diagnosis Student Guide FCS14598REF FCS-14598-REF Course Code: 30S06T0 April, 2007 Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing the asbestos dust can cause asbestosis and cancer Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2006 Ford Motor Company Produced and Coordinated by Technical Service Support Operations Ford Customer Service Division April, 2007 M CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time, on time Complete servicing my vehicle in a timely and professional manner Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied Be responsive to questions or concerns that I bring to your attention Expectation #3 “Fix It Right the First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix it Right the First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model — Web-Based — Web-Based — Instructor Led — Instructor Led The Benefits The successful implementation of expectations means: — Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” NVH TABLE OF CONTENTS INTRODUCTION INTRO - Noise, Vibration and Harshness Diagnosis Intro - Course Description Intro - Worksheets Intro - Course Requirements Intro - Course Objectives Intro - Course Agenda Intro - PREREQUISITE REVIEW - LESSON ONE DEMONSTRATIONS - 17 MTS 4000 OPERATION - 18 BALANCING A DRIVESHAFT USING THE MTS 4000 - 19 MTS 4000 REVIEW QUESTIONS - 20 MEASURING PULLEY DIAMETERS - 21 LESSON ONE WORKSTATIONS WORKSTATION 1: VIBRATION CONCERN DIAGNOSIS WORKSTATION 2: VIBRATION CONCERN DIAGNOSIS USING CMT WORKSTATION 3: VIBRATION CONCERN DIAGNOSIS WORKSTATION PART 1: PULLEY RATIO AND FREQUENCY CALCULATIONS WORKSTATION PART 2: TIRE SPEED CALCULATION - 23 - 24 - 27 - 30 - 33 - 35 LESSON TWO DEMONSTRATIONS - WHEEL RUNOUT - CHASSISEAR SET-UP - LESSON TWO WORKSTATIONS - WORKSTATION 1: NOISE CONCERN DIAGNOSIS - WORKSTATION 2: VIBRATION CONCERN DIAGNOSIS USING CMT - WORKSTATION 3: VIBRATION CONCERN DIAGNOSIS - 10 WORKSTATION 4: MEASURING RUNOUT - 12 APPENDIX APPENDIX - Calculations: Quick Reference Guide APPENDIX - Calculations: Step-by-Step Process APPENDIX - Write-up Job Aid APPENDIX - Noise, Vibration and Harshness TOC - i April, 2007 NVH Noise, Vibration and Harshness TABLE OF CONTENTS TOC - ii April, 2007 NOISE, VIBRATION AND HARSHNESS INTRODUCTION INTRODUCTION Noise, Vibration and Harshness Diagnosis Intro - April, 2007 NOISE, VIBRATION AND HARSHNESS INTRODUCTION Noise, Vibration and Harshness Diagnosis Course Description Mastertech MTS 4000 NVH Analyzer This is a 2-day course facilitated by an instructor This course is designed to provide hands-on opportunities for you to learn and improve your skills using tools and equipment and to apply knowledge learned in previous curriculum courses Each day you will have multiple opportunities to practice selected skills The results of your work are recorded on worksheets Worksheets All classroom and hands-on activities are guided by worksheets When you are assigned to one of four workstations, you will be given 30 to 45 minutes to complete the tasks and questions required by the worksheet for that workstation Every 30 to 45 minutes, you will move to another workstation and complete another worksheet until all four worksheets are complete Noise, Vibration and Harshness Diagnosis Intro - April, 2007 NOISE, VIBRATION AND HARSHNESS INTRODUCTION Course Requirements Each technician attending this course is required to pass a combination of hands-on and written evaluations These are administered on the afternoon of the second day z The hands-on evaluation is a pass/fail type It is conducted with exercises in noise, vibration and harshness diagnosis, and will cover: – Noise, vibration and harshness diagnosis – MTS 4000 usage – ChassisEAR usage In order to pass the course, you must demonstrate mastery of the skills covered at the evaluated hands-on exercise AND you must answer at least 80% of the written post-test questions correctly Course Objectives Upon successful completion of this course, you will be able to: z Diagnose engine, driveline and wheel/tire vibration concerns using a Mastertech MTS 4000 NVH Analyzer z Calculate engine frequencies, engine accessory frequencies, driveshaft frequencies, and wheel and tire frequencies Properly measure engine accessory pulleys and tires to perform frequency calculations z Diagnose a noise concern using the ChassisEAR z Diagnose a tire vibration using a simulated Road Force® Balancer z Measure wheel/tire/hub runout using a dial indicator and a runout gauge Course Agenda LESSON ONE: z Introductions, Prerequisite Review, Instructor-led Demonstrations, Lesson Workstations (Vibration Concern Diagnosis, Vibration Concern Diagnosis using CMT, Vibration Concern Diagnosis, Pulley Ratio and Frequency Calculations and Tire Speed Calculations) LESSON TWO: z Instructor-led Demonstrations, Lesson Workstation Reviews, Lesson Workstations (Noise Concern Diagnosis, Vibration Concern Diagnosis using CMT, Vibration Concern Diagnosis, Measuring Runout), Final Review, Post-Test Noise, Vibration and Harshness Diagnosis Intro - April, 2007 NOISE, VIBRATION AND HARSHNESS INTRODUCTION NOTES: Noise, Vibration and Harshness Diagnosis Intro - April, 2007 LESSON TWO WORKSTATION WORKSTATION VIBRATION CONCERN DIAGNOSIS USING COMPUTER-BASED SCENARIOS DIRECTIONS: Complete Workstation at the computer station SUMMARY: In this activity complete one computer-based scenario, Scenario During the scenario you will be directed to answer questions in your workbook The questions are listed below Password for scenario: Enter the vehicle and customer concern below Vehicle: Concern: If a vibration occurs during a road test, fill in the engine RPM and vehicle speed on the table accordingly Road Tests Engine RPM Vehicle Speed Slow Acceleration Heavy Acceleration Neutral Coast Down Downshift Speed Neutral Engine Run-up What type of concern is this? A Vehicle speed-related B Engine speed-related C Torque-related Noise, Vibration and Harshness Diagnosis 2-8 April, 2007 LESSON TWO WORKSTATION Based on the MTS 4000, fill in the graphic below What was the cause of the concern? _ What repair solved the concern? _ Noise, Vibration and Harshness Diagnosis 2-9 April, 2007 LESSON TWO WORKSTATION WORKSTATION VIBRATION CONCERN DIAGNOSIS DIRECTIONS: Complete Workstation at the vehicle workstation Duplicate the customer concern and use the MTS 4000 to diagnose the concern SUMMARY: In this activity verify the concern and use the MTS 4000 data to determine the cause of the concern What is the customer concern? _ What test would be performed to verify that this is an engine speed-related vibration? _ _ Where you feel or see the vibration? _ _ z Connect the MTS 4000 to the vehicle data link connector (DLC) Choose [1 Vehicle Selection] and then choose [1 Select new vehicle] Record the pulley diameters in the chart below Calculate the pulley ratios and enter them in the chart below Diameter Ratio Crankshaft pulley A/C compressor pulley Power steering pump pulley Generator pulley z Enter the pulley ratios in the MTS 4000 z When the vibration is most evident, use the SAVE button on the MTS 4000 to capture the data Answer the questions on the following page Noise, Vibration and Harshness Diagnosis - 10 April, 2007 LESSON TWO WORKSTATION Based on the MTS 4000 data, fill in the graphic below Highlight the most dominant vibration and press ENTER What are the probable causes of the concern? _ _ _ _ _ Noise, Vibration and Harshness Diagnosis - 11 April, 2007 LESSON TWO WORKSTATION WORKSTATION MEASURING RUNOUT DIRECTIONS: Complete Workstation at the bench workstation using the Service Information, dial indicator, and wheel runout gauge SUMMARY: In this activity measure tire, wheel and hub runout Determine whether the tire, wheel and hub are within specifications Perform the runout measurements listed below Specification Actual TIRE RUNOUT: Radial 0.045” (1.14 mm) Lateral 0.045” (1.14 mm) Radial 0.045” (1.14 mm) Lateral 0.045” (1.14 mm) Hub Face 0.010” (0.25 mm) Wheel Bolt 0.015” (0.38 mm) Drum/Rotor Pilot 0.006” (0.15 mm) WHEEL RUNOUT: HUB RUNOUT: Is there an excessive runout condition? If so, what would be the proper repair? _ _ _ What is the proper torque for the lug nuts on this wheel and tire assembly? _ _ _ List some possible symptoms of improperly torqued lug nuts _ _ _ Noise, Vibration and Harshness Diagnosis - 12 April, 2007 LESSON TWO WORKSTATION Four, five, and eight lugnut style wheels are depicted below Place a number by each lugnut to indicate the tightening sequence of the lugnuts 2006 Focus 2006 Ranger 2006 F-250 Noise, Vibration and Harshness Diagnosis - 13 April, 2007 LESSON TWO Noise, Vibration and Harshness Diagnosis WORKSTATION - 14 April, 2007 NVH DIAGNOSIS APPENDIX APPENDIX Noise, Vibration and Harshness Diagnosis APPENDIX - April, 2007 NVH DIAGNOSIS Noise, Vibration and Harshness Diagnosis APPENDIX APPENDIX - April, 2007 NVH DIAGNOSIS APPENDIX CALCULATIONS - QUICK REFERENCE Use the Tire Speed and Frequency Chart to find the wheel speed in RPM: z Measure the diameter of the tire from side to side z Using the chart, select the RPM @ MPH (or km/h) that corresponds to the diameter of the tire z Multiply the RPM @ MPH (or km/h) value by the vehicle speed at which the vibration occurs Tire Size (mm) Tire Size (Inches) Tire RPM @ MPH Tire RPM @ KM/H 560 22 15.8 9.88 585 23 15.1 9.44 610 24 14.5 9.06 635 25 13.9 8.69 660 26 13.4 8.38 685 27 12.9 8.06 710 28 12.4 7.75 735 29 11.9 7.44 760 30 11.5 7.19 785 31 11.1 6.94 810 32 10.8 6.75 835 33 10.5 6.56 864 34 10.2 6.38 Quick Reference Formulas: z Driveshaft speed (RPM) = Tire/wheel speed x Axle ratio z Engine firing frequency = 1/2 the number of cylinders x Engine RPM z Accessory ratio = Crankshaft pulley diameter ÷ Accessory pulley diameter z Accessory speed = Engine speed x Accessory ratio z Hertz = RPM ÷ 60 z RPM = Hertz x 60 Noise, Vibration and Harshness Diagnosis APPENDIX - April, 2007 NVH DIAGNOSIS Noise, Vibration and Harshness Diagnosis APPENDIX APPENDIX - April, 2007 NVH DIAGNOSIS APPENDIX CALCULATIONS - STEP-BY-STEP PROCESS Tire/wheel RPM and frequency calculation using MPH: z A vehicle with 28 inch (710 mm) diameter tires is experiencing a vibration at 43 MPH z Using the chart below for 28 inch tires, you multiply 12.4 (Tire RPM @1 mph) by 43 MPH (Vehicle speed where vibration was felt) z Calculation: 12.4 X 43 = 533.2 RPM @ 43 MPH z Divide 533.2 RPM by 60 to determine the tire frequency in Hertz Typically, it is best to round up or down to get a whole number This tire frequency would be rounded up to Hz z Calculation: 533.2 RPM ÷ 60 = 8.88 Hz (9 Hz rounded) Tire/wheel RPM and frequency calculation using km/h: z A vehicle with 28 inch (710 mm) diameter tires is experiencing a vibration at 70 km/h z Using the chart below for 28 inch tires, you multiply 7.75 (Tire RPM @1 km/h) by 70 km/h (Vehicle speed where vibration was felt) z Calculation: 7.75 X 70 = 542.5 RPM @ 70 km/h z Divide 542.5 RPM by 60 to determine the tire frequency in Hertz Typically, it is best to round up or down to get a whole number This tire frequency would be rounded to Hz z Calculation: 542.5 RPM ÷ 60 = 9.04 Hz (9 Hz rounded) Tire Size (mm) Tire Size (Inches) Tire RPM @ MPH Tire RPM @ KM/H 560 22 15.8 9.88 585 23 15.1 9.44 610 24 14.5 9.06 635 25 13.9 8.69 660 26 13.4 8.38 685 27 12.9 8.06 710 28 12.4 7.75 735 29 11.9 7.44 760 30 11.5 7.19 785 31 11.1 6.94 810 32 10.8 6.75 835 33 10.5 6.56 864 34 10.2 6.38 Noise, Vibration and Harshness Diagnosis APPENDIX - April, 2007 NVH DIAGNOSIS APPENDIX Driveshaft Frequency calculation: z Obtain the axle ratio of the vehicle Suppose the vehicle you are diagnosing has a rear axle ratio of 3.08:1 z Multiply the tire/wheel frequency of 8.88 Hz (calculated in previous example) with the rear axle ratio of 3.08:1 This results in a driveshaft frequency of 27.3 Hz at a vehicle speed of 43 mph (69 km/h) z Calculation: 8.8 Hz X 3.08 = 27.3 Hz @ 43 MPH z Note: The calculated frequency of 27.3 Hz is the first order driveshaft frequency The second order frequency of the driveshaft is twice this number, or 54.6 Hz First-Order Engine Frequency calculation: z If an engine vibration is felt at 2400 RPM, you would divide this number by 60 (the number of seconds in a minute) to determine the first-order engine frequency in Hertz z Calculation: 2400 RPM ÷ 60 = 40 Hz Engine Firing Frequency calculation: z An automobile with a six-cylinder engine experiences a vibration concern at 2400 RPM z The engine is firing the cylinders at 7200 times per minute (Half the number of cylinders x 2400 = 7200) z Divide this number by 60 (the number of seconds in a minute) to obtain the engine firing frequency z Calculation: 2400 x (Half the number of cylinders) ÷ 60 = 120 Hz Engine Accessory Frequency calculation: z An engine vibration is felt at 2250 RPM If the crankshaft pulley measures 3/8 inches, you would convert the fractional measurement to the decimal equivalent of 6.37 inches (see chart below) z If an accessory pulley measured ½ inches you would convert the fractional measurement to the decimal equivalent of 3.50 inches (see chart below) z Calculation: 6.37 in ÷ 3.5 in = 1.82 Pulley Ratio Engine Pulley RPM calculation (continuation from previous step): Take the engine RPM where the vibration was felt and multiply this by the pulley ratio z Calculation: 2250 RPM x 1.82 = 4095 RPM (Pulley RPM) z Calculation: 4095 ÷ 60 = 68.2 Hz (Pulley Frequency) Fraction Decimal Equiv Fraction Decimal Equiv 1/16 06 9/16 56 1/8 12 5/8 62 3/16 18 11/16 68 1/4 25 3/4 75 5/16 31 13/16 81 3/8 37 7/8 87 7/16 43 15/16 93 1/2 50 1.00 Noise, Vibration and Harshness Diagnosis APPENDIX - April, 2007 NVH DIAGNOSIS Noise, Vibration and Harshness Diagnosis APPENDIX APPENDIX - April, 2007 NVH DIAGNOSIS Noise, Vibration and Harshness Diagnosis APPENDIX APPENDIX - April, 2007 ... Vibration and Harshness TOC - i April, 2007 NVH Noise, Vibration and Harshness TABLE OF CONTENTS TOC - ii April, 2007 NOISE, VIBRATION AND HARSHNESS INTRODUCTION INTRODUCTION Noise, Vibration and Harshness... Vibration and Harshness Diagnosis Intro - April, 2007 NOISE, VIBRATION AND HARSHNESS INTRODUCTION Noise, Vibration and Harshness Diagnosis Course Description Mastertech MTS 4000 NVH Analyzer This is... Vibration Concern Diagnosis using CMT, Vibration Concern Diagnosis, Measuring Runout), Final Review, Post-Test Noise, Vibration and Harshness Diagnosis Intro - April, 2007 NOISE, VIBRATION AND HARSHNESS