steering and suspension D D electronic steering and suspension student guide and self-study COURSE CODE: 33S09T0 ORDER NUMBER: FCS-14356-REF Updated January, 2006 DELIVER 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 © 2001 Ford Motor Company Produced and Coordinated by Technical Service Support Operations Ford Customer Service Division February, 2001 SERVICE STANDARDS Mission Statement: All dealership personnel will treat every customer as a potential lifetime purchaser, communicating a professional image which embraces honesty and concern for customer wants and needs Dealer-to-Customer Service Standards: Appointment available within one day of the customer’s requested service day Write-up begins within four minutes of arrival Service needs courteously identified, accurately recorded on Repair Order, and verified with customer Vehicles serviced right on the first visit Service status provided within one minute of inquiry Vehicle ready at agreed upon time Thorough explanation of work done, coverages and changes These seven service standards provide a process and product value that are compelling reasons for owners to purchase and repurchase Ford or Lincoln-Mercury products These standards also help to attract new owners through favorable testimonials and improved owner satisfaction Standard “Fix It Right the First Time, on Time.” The technician is the most important player when it comes to Standard #4 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 — Self Study — Self Study — Ford Multimedia Training (FMT) — Instructor Led — Instructor Led The Benefits The successful implementation of standards means — Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” TABLE OF CONTENTS INTRODUCTION Steering and Suspension Curriculum Intro-1 Electronic Steering and Suspension Classroom Course Intro-2 DAY ONE Prerequisite Review Questions Day One-1 Worksheet A (At Workstation 1) Air Suspension (On Vehicle) Day One-5 Student’s Answer Sheet .Day One-5 Worksheet B (At Workstation 2) Diagnose Electronic Steering (On Vehicle) .Day One-7 Student’s Answer Sheet .Day One-7 Worksheet C (At Workstation 3) Component Diagnosis (On Bench) Day One-9 Student’s Answer Sheet .Day One-9 Worksheet D (At Workstation 4) Navigate EVTMs (Tabletop) Day One-11 Student’s Answer Sheet .Day One-11 DAY TWO Worksheet E (At Workstation 1) Diagnose Air Suspension Pneumatics (On Vehicle) Day Two-1 Student’s Answer Sheet Day Two-1 Worksheet F (At Workstation 2) Diagnose a Suspension Concern (On Vehicle) Day Two-3 Student’s Answer Sheet Day Two-3 Worksheet G (At Workstation 3) Component Testing (On Bench) Day Two-5 Student’s Answer Sheet Day Two-5 Worksheet H (At Workstation 4) Diagnose Suspension Mock-Up (On Bench) Day Two-9 Student’s Answer Sheet Day Two-9 SELF STUDY INTRODUCTION Intro-1 Introduction Intro-1 Course Description for Self-Study Learners Intro-2 Technician Course Objectives Intro-2 Steering and Suspension Curriculum Intro-3 Review of Base Steering and Suspension Systems Intro-6 LESSON 1: ELECTRONIC STEERING SYSTEM OPERATION 1-1 Objectives 1-1 Contents 1-1 Electronic Steering System Operation 1-2 Review Questions 1-7 Electronic Steering & Suspension Classroom February, 2001 i TABLE OF CONTENTS LESSON 2: ELECTRONIC STEERING SYSTEM COMPONENTS AND FUNCTION 2-1 Objectives 2-1 Contents 2-1 Input Components 2-2 Output Components 2-5 Modules 2-9 Detailed System Operation 2-10 Review Questions 2-19 LESSON 3: ELECTRONIC SUSPENSION SYSTEM OPERATION OVERVIEW 3-1 Objectives 3-1 Contents 3-1 Rear Load-Leveling Suspension Systems 3-2 4-Wheel Air Suspension Systems 3-3 Ride Control Suspension Systems 3-4 Review Questions 3-7 LESSON 4: ELECTRONIC SUSPENSION SYSTEM COMPONENTS AND FUNCTION 4-1 Objectives 4-1 Contents 4-1 System Hardware 4-2 Input Components 4-6 Output Components 4-14 Modules 4-22 Typical System Operation 4-24 Review Questions 4-33 LESSON 5: DIAGNOSIS AND TESTING PROCEDURES 5-1 Objectives 5-1 Contents 5-1 Diagnostic Strategies 5-2 Electronic Steering and Suspension System Malfunctions 5-10 Diagnostic Process 5-14 Review Questions 5-17 CONCLUSION Conclusion-1 Conclusion Conclusion-1 ANSWERS TO REVIEW QUESTIONS Answers-1 Lesson 1: Electronic Steering System Operation Answers-1 Lesson 2: Electronic Steering System Components and Functions Answers-3 Lesson 3: Electronic Suspension System Operation Overview Answers-5 Lesson 4: Electronic Suspension System Components and Functions Answers-7 Lesson 5: Diagnosis and Testing Procedures Answers-9 ii February, 2001 Electronic Steering & Suspension Classroom INTRODUCTION STEERING AND SUSPENSION CURRICULUM STEERING & SUSPENSION CURRICULUM PATH Base Steering & Suspension – SS Base Steering & Suspension – FMT Steering & Suspension System Alignment – Fordstar Prerequisites – Electrical Part – Electrical Part – Electrical Part – Electronics Part – Electronics Part – Electronics Part – Networks + Multiplexing Part – Networks + Multiplexing Part – Noise, Vibration & Harshness Base Steering & Suspension – Classroom Electronic Steering & Suspension – SS Electronic Steering & Suspension – FMT Multiplexed Steering & Suspension Systems – Fordstar Electronic Steering & Suspension – Classroom Legend = Self Study (SS) = Ford Multimedia Training (FMT) = Fordstar = Instructor Led – Classroom Planned Training Pathway Ford Motor Company has identified the skills and knowledge necessary to meet the curriculum goals in the Steering and Suspension Specialty The Planned Training Pathway is a series of courses designed to provide you with these skills and knowledge Description The STST Steering and Suspension Curriculum consists of eight courses The self-study courses and FMT courses are self-paced training programs The Distance Learning (FORDSTAR) courses are instructor-led broadcasts This course is hands-on and is facilitated by an instructor The information in the self-study, FMT, and FORDSTAR courses are designed to prepare you to successfully complete the instructor-led course You are currently in course eight of the steering and suspension curriculum: Electronic Steering and Suspension Classroom Electronic Steering & Suspension Classroom February, 2001 Intro-1 INTRODUCTION ELECTRONIC STEERING AND SUSPENSION CLASSROOM COURSE Course Description This is a two-day hands-on course The course is designed to provide you with maximum practice and application of diagnostic and service skills The first day, you will practice these skills on four different worksheets The morning of the second day, you will receive four more opportunities to practice Before the end of the course, you will have had eight opportunities to practice your diagnostic and service skills The results of your work will be recorded on worksheets Worksheets All hands-on activities will be guided by worksheets When you are assigned to a workstation, you will be given 30 to 40 minutes to complete the worksheet Every 30 to 40 minutes, you will move to the next workstation and complete another worksheet You will have minutes to move from one workstation to another Course Requirements To meet the requirements of this course, you must satisfactorily complete a final exam that will be administered on the afternoon of the second day The final exam includes a combination of hands-on and written exercises Course Objectives The purpose and the objectives of this course are to enable you to: l Perform diagnostic routines associated with electronic steering and suspension concerns l Use special tools and service equipment associated with electronic steering and suspension diagnosis and repair l Perform diagnostic test procedures l Perform repair and adjustment procedures EVALUATION STRATEGY This course will allow you to perform Electronic Steering and Suspension diagnostic skills Your evaluation will be based on score of 80% or higher on a written final examination and the ability to pass a hands-on post-test Intro-2 February, 2001 Electronic Steering & Suspension Classroom DAY ONE PREREQUISITE REVIEW QUESTIONS Briefly explain the purpose of the air suspension system Briefly explain the purpose of the ride control system Briefly explain the purpose of the electronic steering system Name the major input and output devices associated with an air suspension system Inputs Outputs Name some major inputs and outputs associated with the two different types of ride control systems Driver input ride control system Inputs Outputs Road input ride control system Inputs Electronic Steering & Suspension Classroom Outputs February, 2001 Day One-1 DAY ONE PREREQUISITE REVIEW QUESTIONS (Continued) Name some inputs and outputs associated with the electronic steering systems EVO System Inputs Outputs VAPS I System (Original VAPS) Inputs Outputs VAPS II and III Systems Inputs Outputs Explain how “networking” of these electronic control systems can aid in diagnosis Explain some of the safety issues involved with air suspension systems What are some of the customer concerns that might be associated with the electronically controlled suspension and steering systems? Air Suspension Malfunctions Day One-2 Ride Control Malfunctions February, 2001 Steering System Malfunctions Electronic Steering & Suspension Classroom LESSON 5: DIAGNOSIS AND TESTING PROCEDURES NOTES 5-16 February, 2001 Electronic Steering and Suspension LESSON 5: DIAGNOSIS AND TESTING PROCEDURES REVIEW QUESTIONS Why should self-tests be run after electrical repairs? The PID mode of the NGS allows you to see signals as they are interpreted by the _ Using the active command mode of NGS allows the technician to bypass the _ normal operating strategies and command it to operate the control components of steering and suspension systems What happens when a module detects a missing or invalid input signal? Electronic Steering and Suspension February, 2001 5-17 LESSON 5: DIAGNOSIS AND TESTING PROCEDURES NOTES 5-18 February, 2001 Electronic Steering and Suspension CONCLUSION CONCLUSION This concludes the Electronic Steering and Suspension Self-Study course The next course in the Steering and Suspension Curriculum is the Electronic Steering and Suspension Ford Multimedia Training (FMT) course The final evaluation questions for this self-study will appear at the beginning of the FMT course as a pretest You must pass the pretest before beginning the FMT course The principles and concepts presented in this course are the building blocks of knowledge to help you progress throughout the rest of the Steering and Suspension curriculum The next courses you will encounter apply this information to practical symptom-to-cause relationships Electronic Steering and Suspension February, 2001 Conclusion-1 CONCLUSION NOTES Conclusion-2 February, 2001 Electronic Steering and Suspension ANSWERS TO REVIEW QUESTIONS LESSON 1: ELECTRONIC STEERING SYSTEM OPERATION Electronically controlled steering systems provide the driver with increased steering assist at _ speed LOW With the EVO steering system, steering assist level is determined by looking at _ and vehicle speed steering wheel rotation rate _ vehicle speed The VAPS system will only vary steering assist based on _ Electronic Steering and Suspension February, 2001 Answers-1 ANSWER TO REVIEW QUESTIONS NOTES Answers-2 February, 2001 Electronic Steering and Suspension ANSWERS TO REVIEW QUESTIONS LESSON 2: ELECTRONIC STEERING SYSTEM COMPONENTS AND FUNCTION What are the three (3) ways in which the Electronic Power Steering Control Module can receive the Vehicle Speed Signal (VSS)? Hard-wired from vehicle speed sensor Hard-wired from another module From the multiplex network EVO actuator The is controlled by the electronic power steering control module and regulates the power steering fluid flow from the power steering pump in an EVO steering system On the VAPSII actuator assembly, a current controlled solenoid is used to vary the position of the spool valve If there is an electrical malfunction in the EVO steering system, the EVO system provides maximum assist by shutting off the power to the actuator If the actuator assembly is de-energized in the VAPSII steering system, the system provides minimum assist Electronic Steering and Suspension February, 2001 Answers-3 ANSWER TO REVIEW QUESTIONS NOTES Answers-4 February, 2001 Electronic Steering and Suspension ANSWERS TO REVIEW QUESTIONS LESSON 3: ELECTRONIC SUSPENSION SYSTEM OPERATION OVERVIEW List some of the benefits of electronically controlled suspension systems Load leveling capabilities Variable damping rate Ground clearance increase when required In a ride control system, what situations cause the system to switch to hard damping? Hard braking, hard acceleration, high vehicle speed, heavy road undulation, lateral acceleration, body sway Electronic Steering and Suspension February, 2001 Answers-5 ANSWER TO REVIEW QUESTIONS NOTES Answers-6 February, 2001 Electronic Steering and Suspension ANSWERS TO REVIEW QUESTIONS LESSON 4: ELECTRONIC SUSPENSION SYSTEM COMPONENTS AND FUNCTION air drier The compressor pumps pressurized air through the _ to remove moisture from the air active When the ignition is switched to the RUN position, the air suspension module is ride height On air suspension systems, the height sensors are used for information On some suspension movement to determine the need ride control systems, the height sensors are used to sense _ for hard damping control air flow Air solenoids are placed in the air lines to _ to and from the air springs and/or shocks control ride height The air suspension control module strategy is used to control shock dampening The ride control module strategy is used to _ What are the two types of ride control suspension systems? Driver input Road conditions input Electronic Steering and Suspension February, 2001 Answers-7 ANSWER TO REVIEW QUESTIONS NOTES Answers-8 February, 2001 Electronic Steering and Suspension ANSWERS TO REVIEW QUESTIONS LESSON 5: DIAGNOSIS AND TESTING PROCEDURES Why should self-tests be run after electrical repairs? To verify the repair was successful control module The PID mode of the NGS allows you to see signals as they are interpreted by the _ module Using the active command mode of NGS allows the technician to bypass the _ normal operating strategies and command it to operate the control components of steering and suspension systems What happens when a module detects a missing or invalid input signal? System will stop working, DTC is set and a malfunction indicator lamp may flash Electronic Steering and Suspension February, 2001 Answers-9 ... Classroom INTRODUCTION STEERING AND SUSPENSION CURRICULUM STEERING & SUSPENSION CURRICULUM PATH Base Steering & Suspension – SS Base Steering & Suspension – FMT Steering & Suspension System Alignment... the steering and suspension curriculum: Electronic Steering and Suspension Classroom Electronic Steering & Suspension Classroom February, 2001 Intro-1 INTRODUCTION ELECTRONIC STEERING AND SUSPENSION. .. Base Steering & Suspension – Classroom Electronic Steering & Suspension – SS Electronic Steering & Suspension – FMT Multiplexed Steering & Suspension Systems – Fordstar Electronic Steering & Suspension