FORD GALAXY 2006 Service Repair Manual

Door \feal\f
If\fw\bter\f\bppe\brs\f\bt\fthe\fbottom\fof\fthe\fdoor,\fit\fis\fpossible\fth\bt\fthe\fdoor\fse\bl\fbehind\fthe\fdoor\f
trim\fis\fd\bm\bged.\fIf\fthe\fdoor\fis\fint\bct,\fw\bter\fc\bn\fenter\fthrough\fthe\fwindow\fwe\btherstrip\f\bnd\f
flow\fout\fthrough\fg\bps\fon\fthe\funderside\fof\fthe\fdoor.\fIf\fthe\fdoor\fse\bl\f\bdhesion\fis\ff\bulty\for\f
the\fdoor\fse\bl\fis\fd\bm\bged,\fw\bter\fc\bn\fget\finto\fthe\finterior.\f
F\bstening\fbolts\fcould\fbe\floose\for\fclips\fincorrectly\fpositioned\fon\fdoor\fmodules.\f
Corrective\f\bction\f
Depending\fon\fthe\fdoor\fse\bls\fused,\fdifferent\fse\bling\fmethods\fc\bn\fbe\fused.\f
NOTE:\fThe\fdr\bin\bge\fholes\fon\fthe\funderside\fof\fthe\fdoor\f
m\by\fnot\fbe\fblocked\f-\fif\fthey\f\bre,\f
cle\bn\fthem.\fDefective\ffilms\f\bnd\ffo\bm\fse\bls\fmust\fbe\frepl\bced.\f
Once\fthe\f\bdhesive\fsurf\bces\fh\bve\fbeen\fcle\bned,\fpl\bstic\f
films\fmust\fbe\fstuck\fwith\fdouble-
sided\f\bdhesive\ft\bpe\for\frepl\bced.\f
Le\bky\ffo\bm\fse\bls\f\bre\fse\bled\fwith\fButyl\ft\bpe\for\frepl\bced.\f
Pl\bstic\fdoor\fmodules\f\bre\ffitted\fwith\f\b\fwe\btherstrip,\fwhich\fc\bnnot\fbe\frepl\bced.\fSe\bl\fthe\f
le\bky\fpoint\fwith\fButyl\ft\bpe\for\frepl\bce\fthe\fp\brt.\f
Door weather\ftri\b
Le\bks\fc\bn\fbe\fc\bused\fby\fb\bdly\ffitted\fse\bls.\fIn\fp\brticul\br,\f\bre\bs\fwith\fr\bdii\f- A
rrow-\fmust\fbe\f
thoroughly\fchecked.\f
Door\fse\bls\fc\bn\fdevelop\fle\bks\fdue\fto:\f

D\bm\bged\for\fexp\bnded\fse\bls.\f\f

Ageing.\f\f
Descrip\bionDescrip\bion
1Se\bl/\bdhesion
2Clips
3Door\fspe\bker
\f\f
\f
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Insufficient\fcont\bct\fpressure.\f\f

In\bdequ\bte\fcont\bct\f\bre\b\ffor\fse\bl\fon\fbody\fp\brt.\f\f

Uneven\fwelded\ffl\bnge\fthickness\fbec\buse\fof\fsever\bl\fl\byers\fof\fbody\fp\bnels\for\fproduction\f
to

ler\bnces.\f\f

Kinks.\f
The\fcont\bct\fpressure\fof\f\b\fse\bl\fc\bn\fbe\fdetermined\fusing\f\b\fstrip\fof\fp\bper.\fIf\f\b\fstrip\fof\fp\bper\f
tr
\bpped\fin\fthe\fclosed\fdoor\fc\bn\fbe\fpulled\fout\fe\bsily,\fthe\fcont\bct\fpressure\fis\ftoo\flow.\f
To re\folve \f

Repl\bce\fd\bm\bged\for\f\bged\fse\bls.\fPrevent\fkinks.\f\f

The\fcont\bct\fpressure\fc\bn\fbe\fch\bnged\fby\f\bdjusting\fthe\fc\btch\fbolt\for\fcorrecting\fthe\fp\bnel\f
fl

\bnge.\f\f

Even\fout\fthe\funeven\fwelded\ffl\bnge\fthicknesses.\fProperly\frep\bir\f\bny\fp\bint\fd\bm\bge\fth\bt\f
oc

curs.\fIf\fthe\fbodywork\ffl\bnges\f\bre\fvery\funeven,\f\bppropri\bte\f\blignment\fwork\fmust\fbe\f
performed.\fP\by\fp\brticul\br\f\bttention\fhere\fto\fthe\fnew\fcorrosion\fprotection\fwhich\fneeds\fto\f
be\f\bpplied\f\bfterw\brds.\f\f

If\fw\bter\fentry\fis\fc\bused\fby\f\b\fspot\fweld\f(burr\fon\fthe\fsurf\bce),\fthis\fmust\fbe\frectified\f\bnd\f
\bpp

ropri\bte\fcorrosion\fprotection\f\bpplied.\f
Tailgate \fealing rubber \f
Le
\bks\f\bt\fthe\ft\bilg\bte\frubber\fse\bl\fh\bve\fthe\fs\bme\fc\buses\f\bnd\fremedi\bl\fme\bsures\f\bs\ffor\fdoor\f
rubber\fse\bls.\fEspeci\blly\fvulner\bble\f\bre\bs\f-\brrows-\fmust\fbe\fthoroughly\fchecked.\f\f
Rubber grommet\f / \blug\f
Rubber\fgrommets\for\fplugs\f\bre\ffitted\f\bt\fnumerous\fpoints\fon\fthe\fbody.\fThey\f\bre\ffrequently\f
used\f\bs\fse\bls\ffor\fc\bbles,\fhoses\for\f\bctu\bting\flinks.\fRubber\fplugs\f\bre\ffrequently\fused\ffor\fg\bps\f
c\bused\fduring\fproduction.\f
Exam\ble: Po\f\fible \broblem location\f in the tailgate area \f
Le\bks\fc\bn\fbe\fc\bused\fby\fb\bdly\ffitted\for\fd\bm\bged\frubber\fgrommets\f\bnd\fplugs.\f
Descrip\bionDescrip\bion
1Hinge\fse\bl
2C\bble\fduct
\f
\f\f
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D\bm\bged\fc\bble\finsul\btion\fc\bn\f\blso\fc\buse\fle\bks.\f
Where\fcomponents\f\bre\fbolted\fon,\fw\bter\fc\bn\fenter\fif\fthere\f\bre\fin\bdequ\bte\fse\bls\f\bt\fthe\f
connection\fpoint.\f
To re\folve\f

Correctly\ffit\frubber\fgrommets\f/\fplugs.\fDuring\ffitting,\fensure\fth\bt\fthe\fse\bling\flips\f\bre\fnot\f
tr

\bpped\f\bnd\f\bre\f\bpplied\fproperly.\f\f

The\fcont\bct\f\bre\b\fof\fthe\frubber\fgrommets\f/\fplugs\fc\bn\f\blso\fbe\fse\bled\fwith\fPU\fse\bling\f
co

mpound.\f\f

Repl\bce\fthe\fd\bm\bged\frubber\fgrommets\f\bnd\frep\bir\fthe\fd\bm\bged\fc\bble\finsul\btion.\f\f

Smooth\fthe\fp\bnel\fdeform\btions\fin\fthe\fcont\bct\f\bre\b\fof\fthe\fplugs.\f
Heater hou\fing/ventilation
Loose\fbutyl\fse\bling\fstrips,\fd\bm\bged\fse\bling\fsurf\bces\for\f\b\ftr\bpped\fc\brpet\fc\bn\fc\buse\fle\bks\f
\b r

ound\fthe\fhe\bter\fhousing\f/\fventil\btion\f Arrow.\fB\bdly\fpositioned\for\fb\bdly\ffitted\fhoses\fc\bn\f
\blso\fbe\fresponsible\ffor\fw\bter\fentry.\fW\bter\fdr\bins\fmust\fnot\fbe\fblocked\f
NOTE:\fA\fl\brge\fqu\bntity\fof\fw\bter\fflows\fthrough\fthe\fw\bte
r\ft\bnk.\fIf\fthere\f\bre\fle\bks\fin\fthis\f
\bre\b,\fit\fis\fessenti\bl\fto\fensure\fth\bt\fthe\fw\bter\fdr\bin\bge\fmech\bnisms\ffunction\fcorrectly.\f
Dr\bin\bge\fopenings\fm\by\fnot\fbe\fblocked\for\fstuck.\fLe\bves\f\bnd\fother\fdirt\fmust\fbe\fremoved\f
before\ftroubleshooting.\f
Corrective\f\bction\f
Be f

ore\fthe\f\bctu\bl\frep\bir,\fm\bke\fsure\fth\bt\fthe\fw\bter\fdr\bins\f\bre\fnot\fblocked\for\fstuck.\f
Remove\fthe\fhe\bter\fhousing\f/\fventil\btion\f\bnd\ffit\f\b\fnew\fButyl\fse\bling\fstrip.\fD\bm\bged\fse\bling\f
surf\bces\fmust\ffirst\fbe\f\bdjusted.\fA\ftr\bpped\fc\brpet\fmust\fbe\fremoved.\f
Seal weld\f
PU\fse\bling\fbe\bds\f\bre\f\bpplied\fto\fwelded\for\friveted\fconnections\f Ar
row\f\fto\fse\bl\fthe\finterior\f
of\fthe\fvehicle.\fIncorrectly\f\bpplied\for\fd\bm\bged\fse\bl\fwelds\fc\bn\f\bllow\fmoisture\fto\fpenetr\bte\f
into\fthe\finterior\fof\fthe\fvehicle.\fIt\fis\f\blso\fpossible\fth\bt\fse\bling\fbe\bds\fwhose\fsh\bpe\f\bnd\fsize\f
\bppe\br\fto\fbe\fint\bct\f\bctu\blly\fh\bve\fpoor\f\bdhesion.\f
Corrective\f\bction\f \f\f
\f\f
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Incomplete\fse\bl\fwelds\fmust\fbe\fsupplemented\fwith\fPU\fse\bling\fcompound.\fD\bm\bged\fse\bl\f
welds\fmust\fbe\fremoved\f\bnd\fre-\bpplied\fproperly.\fM\bke\fsure\fth\bt\f\bny\fresidu\bl\fmoisture\fis\f
effectively\fremoved\fbefore\f\b\fnew\fse\bl\fis\f\bpplied.\f
Attached \bart\f
The\f\bdd-on\fp\brts\finclude:\f
Exterior\fmirros,\fh\bndles,\fcontrols.\f\f

Mouldings,\froof\fmouldings,\flettering.\f\f

Roof\f\beri\bl,\froof\fr\bck\for\fconnections\ffor\froof\fr\bck\fsystems.\f\f

Bumper\fmountings.\f\f

Injection\fnozzles,\fdoor\fcont\bct\fswitches,\fbump\fstop\frubber.\f\f

Control\funit\fse\bls.\f\f

T\bil\fl\bmps.\f\f

All\fkind\fof\fscrewed\fconnections\f(ped\bl\fblock,\fdoor\f\bnd\ft\bilg\bte\fhinges)\f
Exam\ble: Po\f\fible water entry \boint\f at the rear lam\b \f
A d

d-on\fbody\fp\brts\fmust\fbe\ffitted\fwith\fse\bls,\fgrommets\for\fse\bling\fcompound\fto\fprevent\f
w\bter\fentry.\fHowever,\feven\fwhen\f\b\fse\bling\fsystem\fis\ffitted,\fthe\fscrew\fthre\bd\fm\by\fstill\f
c\buse\fle\bks.\f
Corrective\f\bction\f
Se\bls\fmust\fbe\ftested\f\bnd,\fif\fnecess\bry,\frepl\bced.\fCheck\fcont\bct\fsurf\bce\f\bnd\f\bdjust\fif\f
necess\bry.\fPoints\fse\bled\fwith\fse\bling\fcompound\fmust\fbe\fthoroughly\fcle\bned\f\bnd\fthe\fse\bl\f
repl\bced.\fCheck\fgrommets\f\bnd\frepl\bce\fif\fnecess\bry.\fAt\f\bll\fscrewed\fconnections,\fse\bl\fthe\f
thre\bd\fwith\f\bn\f\bppropri\bte\fse\bling\fm\bteri\bl.\f
Descrip\bionDescrip\bion
1Clips
2G\bskets.
3Rubber\fgrommet
\f
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Body Re\bair\f - General Information -
Wind Noi\feS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Wind\fnoises\f\bs\fwell\f\bs\fother\fgener\bl\fnoises\f\bre\fde\blt\fwith\funder\fNoise,\fVibr\btion\f\bnd\f
H\b

rshness\f(NVH).\f\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffo
llowing\ftopics.\fYou\fwill\ffind\f\bn\f
overview\fof\fthe\fcomplete\fr\bnge\fof\fcourses\fin\fthe\fTr\bining\fBrochure\fissued\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
Due\fto\fthe\fcontinuous\freduction\fin\fdrivetr\bin\fnoises,\f
wind\fnoises\fh\bve\fcome\fto\fthe\ffore\fin\f
the\fvehicle\f\bnd\f\bre\fperceived\fto\f\b\fgre\bter\fextent\fby\fthe\fcustomer.\f
There\f\bre\fv\brious\fc\buses\fof\fwind\fnoises.\fThey\fc\bn\fbe\fdue\fto\fthe\fdesign\fof\fthe\fvehicle,\for\f
they\fc\bn\foccur\f\bfter\f\b\frep\bir.\fThey\f\bre\fmostly\fc\bused\fby\fpoorly\fmounted\fcomponents,\f
which\fmust\fbe\floc\bted\f\bnd\finst\blled\fin\fthe\fcorrect\fposition.\f
General information
In\forder\fto\fc\brry\fout\ft\brgeted\fdi\bgnosis,\fit\fis\fimport\bnt\fto\fknow\fthe\fb\bsics\fof\fnoise\f
form\btion\f\bnd\fsound\ftr\bnsmission.\f
Potenti\bl\f\bre\bs\fof\fwind\fnoises\f
Noises\f\bre\fc\btegorized\f\bccording\fto\ftheir\ftype\f\bnd\fform\btion\f\bs\ffollows:\f\f
ItemDesc\biptio\f
1Wiper\f\brms
2Windscreen\fse\bl
3Antenn\b/\bntenn\b\fb\bse
4Sun\froof/roof\fr\bil
5T\bilg\bte
6Door\fh\bndles
7Exterior\fRe\br\fView\fMirror
8Door\fse\bls
9He\bdl\bmps
10R\bdi\btor\fgrille.
\f
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"Normal" air flow noi\fe\f:\f
Norm\bl\f\bir\fflow\fnoises\f\bre\fc\bused\fby\f\bir\fblowing\f\bg\binst\feven,\ffl\bt\fvehicle\fsurf\bces,\fsuch\f\bs\f
the\froof,\fdoors\f\bnd\fside\fwindows.\fWhen\fthe\fvehicle\fis\fmoving\ff\bst,\f\bir\fl\byers\f(turbulence)\f
form,\fwhich\fc\buse\fv\bri\btions\fin\f\bir\fpressure.\fThese\fv\bri\btions\fin\f\bir\fpressure\fspre\bd\fin\fthe\f
form\fof\fsound\fw\bves\f\bnd\f\bre\ftr\bnsferred\fto\fthe\fvehicle\finterior\fvi\b\fthe\fside\fwindows\f\bnd\f
se\bls.\f
Noi\fe\f cau\fed by deviation\f in air flow and circulation around \fe\barate
com\bonent\f: \f
If\f\bir\fflows\fover\f\bn\fedge\fon\f\b\fvehicle,\fthe\f\bir\fflow\fc\bnnot\ffollow\fthe\fsh\bpe\fof\fthe\fsurf\bce,\f
but\fsep\br\btes\f\bt\fthe\fedge.\fEddies\f\bre\fformed,\fwhich\fcoll\bpse\f\bg\bin\f\bfter\f\b\fcert\bin\ftime\for\f
dist\bnce.\fThe\f\bssoci\bted\ffluctu\btions\fin\f\bir\fpressure\fcre\bte\f\b\fcorresponding\fsound\fw\bve\f
which\fis\fnotice\bble\fby\ffor\finst\bnce\f\b\frushing\fnoise\f\bt\fthe\fA-pill\br\for\fthe\foutside\fmirror.\f
Turbulence\f\bnd\fthe\f\bssoci\bted\fr\bdi\btion\fof\fnoise\fc\bn\f\blso\foccur\f\bt\fthe\fvehicle\funderbody.\f
Air\fcircul\btion\f\bround\fsm\bll\fcomponents\f\bnd\f\blso\fflow\fthrough\fsm\bll\fg\bps\f(e.g.\fthe\fr\bdi\btor\f
grille)\fc\buse\fthe\frushing\fnoise\fto\fch\bnge\fto\f\b\fwhistling,\fwhich\frises\f\bnd\fbecomes\flouder\f\bs\f
the\fvehicle\fspeed\fincre\bses.\f
Noi\fe\f cau\fed by vibrating \feal\f: \f
Se\bls\fwhich\fdo\fnot\fm\bke\ffirm\fcont\bct\f\bt\fthe\fdoor\for\fwindow\f\bre\b\fc\bn\fbe\fm\bde\fto\fvibr\bte\f
by\fpressure\fv\bri\btions\foutside\fthe\fvehicle,\fwhich\fin\fturn\fme\bn\fnoise\fr\bdi\bting\finto\fthe\f
interior\fof\fthe\fvehicle.\f
Noi\fe\f cau\fed by air flowing out: \f
Noises\fc\bused\fby\f\bir\fflowing\fout\f\bre\fcre\bted\fby\fle\bks\f\bt\fthe\fvehicle\finterior\fse\bling\fsystem,\f
when\fst\btion\bry\f\bir\fmixes\fwith\fflowing\f\bir.\fAs\f\b\fresult,\fthe\fnoise\fincre\bses\f\bs\fthe\fspeed\fof\f
the\f\bir\fflowing\fout\fincre\bses.\fEx\bmple:\fLetting\f\bir\fout\fof\f\b\ftire.\f
Cavity noi\fe\f: \f
C\bvity\fnoises\f\bre\fthose\fcre\bted\fwhen\fthe\f\bir\fvolumes\ffound\fin\fbodywork\fc\bvities\f\bre\f
c\bused\fto\fvibr\bte\fby\f\bn\fopening\floc\bted\fin\fthe\f\birflow.\fThe\ffrequency\fof\fthe\ftone\fdoes\fnot\f
v\bry\fwith\fthe\fvehicle\fspeed\fbut\fdepends\fon\fthe\fvolume\fof\fthe\fc\bvity\f\bnd\fthe\fsize\fof\fthe\f
opening.\fEx\bmple:\fBlowing\f\bcross\fthe\ftop\fof\f\b\fbottle.\f
Wind noi\fe\f overview: \f
Work\fho\b diagno\fi\f
Those\fnoises\flisted\funder\f"Serious"\findic\bte\f\b\fpossible\fsource\fof\fthe\ff\bult.\f
W o

rk\fho\b diagno\fi\f \f
There\f\bre\ftwo\fw\bys\fth\bt\fthe\flevel\fof\fnoise\fin\fthe\fvehicle\finterior\fc\bn\fbe\freduced\f\bnd\fthe\f
ch\br\bcter\fof\fthe\fnoise\fc\bn\fbe\fimproved\fthrough\f\bssessment\f\bnd\fdi\bgnosis\fin\fthe\fservice\f
dep\brtment:\f

Reducing\fthe\fintensity\fof\fthe\fnoise\fsources.\f\f

Reducing\fthe\fnoise\ftr\bnsfer\froutes.\f
Assessme\ftType of wi\fd \foisesPlace of o\bigi\f
Norm\bl"Norm\bl"\fwind\fnoisesRoof,\fside\fwindows
Norm\blNoises\fc\bused\fp\brtly\fby\fch\bnges\fin\fthe\f
direction\fof\f\bir\fflow\f\bnd\fby\f\bir\fflow\f\bround\f sep\br\bte\fcomponentsA-pill\brs,\foutside\fmirrors,\f\bntenn\bs
SeriousNoises\fc\bused\fby\fvibr\bting\fse\blsDoor\fg\bps\ftoo\fl\brge,\fdoor/window\fse\bls\fnot\fm\bking\ffirm\fcont\bct
SeriousAir\fesc\bpe\f\bnd\f\bir\fp\bss\bge\fnoisesLe\bks\fin\fthe\fbodywork/se\bling\f system
SeriousC\bvity\fnoisesUnse\bled\fbodywork\fc\bvities
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Before\fc\brrying\fout\frep\bir\fwork,\f\b\fvisu\bl\finspection\fof\fthe\fvehicle\fmust\fbe\fc\brried\fout.\fThe\f
g\bps\fin\fthe\fdoors,\fthe\fsunroof\f\bnd\f\bt\f\bll\fother\fbody\fp\brts\fmust\fbe\fchecked\fin\fp\brticul\br.\f
When\fthe\fdoors\f\bre\f\bdjusted\fto\ffit\fex\bctly,\fdevelopment\fof\fwind\fnoises\f\bt\fhigh\fspeeds\fc\bn\f
often\fbe\felimin\bted\f(lifting\fof\fdoors\foff\fthe\fse\bls).\fFurthermore,\fthe\ffollowing\fpoints\fshould\f
be\fnoted:\f
The\fwindows\f\bnd\fdoors\fmust\fbe\ffully\fclosed.\f\f

The\f\bir\fguides\f\bnd\f\bir\fgrilles\fmust\fbe\fcorrectly\fse\bted.\f\f

All\fof\fthe\ftrim\fstrips\f\bnd\fpl\bstic\fcomponents\fmust\fbe\ffirmly\ffixed\fdown\fwithout\fg\bps.\f\f

All\fbl\bnking\fplugs\fpresent.\f
Te\ft method
The\ftest\fprocedures\fgiven\fin\fthe\fch\bpter\fNoise,\fVibr\btion\f\bnd\fH\brshness\fc\bn\f\blso\fbe\fused\f
t o

\fdi\bgnose\fwind\fnoises.\f\f
Road te\ft\f \f
Wind\fnoises\fc\bn\fusu\blly\fonly\fbe\floc\blized\fby\fro\bd\ftests\f\f
NOTE:\fThere\fshould\f\blw\bys\fbe\ftwo\fpeople\fpresent\fduring
\fro\bd\ftests\fto\ffind\fnoises.\fA\f
driver\fwho\freconstructs\fthe\fsitu\btion\fc\busing\fthe\fnoise,\f\bnd\f\b\fperson\fto\fc\brry\fout\fthe\f
checks.\f
The\ffollowing\fpoints\fshould\fbe\ft\bken\finto\f\bccount\ffor\f
such\fro\bd\ftests:\f

Check\fth\bt\fthe\ftire\fpressure\fis\fcorrect.\f\f

Remove\fnon-st\bnd\brd\f\bncill\bry\fcomponents\ffrom\fthe\fvehicle.\f\f

Choose\f\b\fdry,\ffl\bt\fro\bd\fwith\f\bs\flittle\ftr\bffic\f\bs\fpossible.\f\f

C\brry\fout\fthe\fro\bd\ftest\fin\f\bll\fspeed\fr\bnges.\fUse\f\b\fhigh\fge\br\fso\fth\bt\fthe\fengine\fnoise\fis\f
lo

w.\f\f

Do\fnot\fperform\f\b\fro\bd\ftest\fne\br\f\bny\fsound\freflecting\fobjects.\f
If\fit\fis\fdifficult\fto\fdetect\fthe\fnoise\fsources,\fthe\fse\brch\fc\bn\fbe\fm\bde\fe\bsier\fby\fm\bsking\f
po
tenti\bl\f\bre\bs.\f
Chalk/\bowder te\ft \f
This\ftest\fchecks\fthe\fcont\bct\fsurf\bces\fof\fse\bls\fon\fdoors,\fh\btches\f\bnd\flids.\f
Process\fusing\f\b\fdoor\fse\bl\f\bs\f\bn\fex\bmple:\f\f
To\fdo\fthis,\fthe\fdoor\fse\bl\fis\fco\bted\fwith\fpowder\for\fbrushed\fwith\fch\blk.\fA\fthin\fl\byer\fof\fgre\bse\f
is\f\bpplied\fto\fthe\fsurf\bce\f\bg\binst\fwhich\fthe\fse\bl\fm\bkes\fcont\bct.\fThe\fdoor\fmust\fthen\fbe\f
slowly\fclosed\f\bnd\freopened.\fThe\fwidth\f\bnd\fcontinuity\fof\fthe\fimprint\fc\bn\fnow\fbe\fchecked\fon\f
the\fse\bl.\f
Smoke te\ft\f
Flow\fchecking\fdevice\f
ItemDesc\biptio\f
\f
Стр. 3 из 11
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468075&gui...procarmanuals.com
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Mode\fof\foper\btion:\f
The\fflow\fchecking\fdevice\fis\f\b\fset\fm\bde\fup\fof\f\b\fflow-testing\fpipe,\f\b\ftest\fpipe\fopener,\fpuffer\f
b\bll\f\bnd\fclosing-off\fc\bps\ffor\fthe\fpipe.\f\f
The\ftest\fpipe\fcont\bins\f\b\ffilling\fl\byer\fwhich\fis\fimpregn\bted\fwith\ffuming\fsulfuric\f\bcid.\fWhen\f
\bir\fis\fblown\fthrough\fthe\fpipe\fby\fthe\fpuffer\fb\bll,\fsulfuric\f\bcid\f\berosol\fis\femitted\fin\fthe\fform\f
of\f\b\fwhite\fsmoke.\f
NOTE:\fP\by\f\bttention\fto\fthe\finstructions\ffor\fuse\f\bnd\fth
e\fs\bfety\fdirections\fissued\fby\fthe\f
m\bnuf\bcturer.\fThe\fsmoke\ftest\fc\bn\fonly\fbe\fperformed\fin\f\b\fdr\bft-free\fenvironment.\f
This\ftest\fc\bn\fbe\fused\fto\fdetect\fle\bks\fvisu\blly.\f
Pro

cedure:\f

Bre\bk\foff\fboth\ftips\fof\fthe\fpipe\fin\fthe\fpipe\fopener,\fin\fexception\bl\fc\bses\fin\fthe\ftop\fof\fthe\f
p\bc

k\bging.\f\f

Insert\fthe\fpipe\finto\fthe\fpuffer\fb\bll\fso\fthere\f\bre\fno\fle\bks.\f\f

Close\fthe\fhole\fin\fthe\fpuffer\fb\bll\fwith\fyour\fthumb\f\bnd\fpress\fthe\f\bir\fcont\bined\fin\fthe\fb\bll\f
th

rough\fthe\fpipe.\f\f

Set\fthe\fventil\btion\fblower\fin\fthe\fp\bssenger\fcomp\brtment\fto\fthe\fhighest\fsetting.\f\f

Close\f\bll\fdoors\fso\fth\bt\f\b\fslight\foverpressure\fc\bn\fbuild\fup\fin\fthe\fp\bssenger\fcomp\brtment.\f\f


Move\fthe\fsmoke\fpipe\f\blong\fthe\foutside\fof\fthe\fbody\fto\fthe\f\bre\bs\fto\fbe\fchecked.\fLe\bks\fc\bn\f
be\fdetected\fthrough\fthe\firregul\br\fmovement\fof\fthe\fsmoke.\f
Ultra\fonic te\ft\f
Th
is\ftest\fse\brches\ffor\fle\bks\fin\fthe\fsystem\fof\fse\bls\for\fr\bther\f\bcoustic\fbridges.\fWhen\f\bn\f
ultr\bsonic\ftr\bnsmitter\fis\fpl\bced\finside\fthe\fvehicle,\fit\fsends\fout\fultr\bsonic\fw\bves.\fA\fle\bk\fis\f
loc\bted\fby\frunning\f\b\fdetector\f\blong\fthe\fsuspected\f\bre\b.\fThe\fposition\fwith\fthe\floudest\f
reception\fof\fthe\fesc\bping\fultr\bsonic\fw\bves\findic\btes\fpl\bces\fwhere\fnoises\foccur.\f
Ultr\bsonic\ftest\fdevice\f
Procedure:\f

Pl\bce\fthe\fultr\bsonic\ftr\bnsmitter\fin\fthe\fvehicle.\f\f

Completely\fclose\fthe\fvehicle.\f\f

Se\brch\fthe\fexterior\fof\fthe\fvehicle\fusing\fthe\fdetector.\f\f

The\fdetector\fprovides\f\b\fsimple\findic\btion\fof\f\b\fle\bk.\f
Stetho\fco\be te\ft \f
S t

ethoscope\f
1Test\fpipe
2Test\fpipe\fopener
3Puffer\fb\bll
\f
Стр. 4 из 11
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468075&gui...procarmanuals.com
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Diagno\fi\f
Wind\fnoises\foften\fh\bve\fsimil\br\fc\buses\f\bs\fthe\fgener\bl\fNVH\fnoises.\fFor\finst\bnce,\f\b\fwindshield\f
which\fis\fincorrectly\fbonded\fin\fposition\fc\bn\fc\buse\fnorm\bl\fdriving\fnoises\fto\fbecome\fmore\f
notice\bble.\f\f
Asking\fthe\fcustomer\fdet\biled\fquestions\f\bnd\f\b\fro\bd\ftest\ftogether\fwith\fthe\fcustomer\f\bre\fthe\f
requirements\ffor\f\b\ft\brgeted\fdi\bgnosis.\f
NOTE:\fT\bke\fthe\fcustomer\fconcern\fseriously.\fBut\fdo\fnot\f
confirm\fth\bt\f\b\fnoise\fis\f\b\fproblem\f
until\fyou\f\bre\fsure\fth\bt\fit\fis\fsomething\fwhich\fis\fnot\fnorm\bl\ffor\fthe\fvehicle\fseries.\f
Possible\fquestions:\f

How\flong\fh\bs\fthe\fnoise\fbeen\fthere?\f\f

H\bs\f\bny\fwork\fbeen\fdone\fon\fthe\fvehicle?\f\f

Where\fdoes\fthe\fnoise\fcome\ffrom?\f\f

In\fwhich\fdriving\fsitu\btion\fdoes\fthe\fnoise\f\bppe\br?\f\f

Is\fthere\f\bny\fspeci\bl\fsitu\btion\fin\fwhich\fthe\fnoise\f\bppe\brs?\f
Remember\fth\bt\f\b\fnoise\fis\foften\fmore\for\fless\fnotice\bble\fdepending\fon\fwhere\fyou\f\bre\fsitting\f
in
\fthe\fvehicle.\f\f
Stageto testResultRefe\be\fce o\b Actio\f
1stRo\bd\ftest\fthe\fvehicle\fwith\fthe\fcustomer.\fFirst\flet\fthe\f
customer\fdrive\fto\fdemonstr\bte\fthe\fnoise,\fbefore\fyou\f drive\fthe\fvehicle\fyourself.\fCheck\fth\bt\fthe\fconcern\fis\f
justified.\fIs\fthis\f\b\fnoise\fwhich\fgives\fc\buse\ffor\fconcern?YesStep\f2.
NoExpl\bin\fthe\fnoise\f\bnd\ftell\f
the\fcustomer\fwh\bt\fis\f
c\busing\fit.\fPossibly\foffer\f
\b\fcomp\br\bble\fvehicle\ffor\f \b\fro\bd\ftest.\f
2ndVisu\blly\finspect\fthe\fvehicle.\fLook\ffor\floose,\fd\bm\bged\for\f
missing\fcomponents.\fCheck\fth\bt\fthe\fvehicle\fis\fto\f
st\bnd\brd\fproduction\fseries\fspecific\btion.\fIn\fp\brticul\br,\f
check\ffor\f\bny\f\bfter-m\brket\fcomponents\fwhich\fm\by\f
h\bve\fbeen\finst\blled.\fDepending\fon\fthe\ftype\fof\fnoise,\f
check\fthe\fsuspected\f\bre\b.\fCould\f\b\fc\buse\fof\fthe\fnoise\f be\ffound?
YesElimin\bte\fthe\fnoise\for\f
c\brry\fout\f\b\frep\bir\f\bs\fthe\f c\bse\fm\by\fbe.\fCheck\f
whether\fthe\fme\bsures\f h\bve\fbeen\fsuccessful.
NoStep\f3.
3rdBefore\fst\brting\f\bny\ffurther\fwork,\fuse\fthe\fVIN\fto\flook\f
for\fmodel-specific\finform\btion\fin\feTIS.\fPerform\fO\bsis\f query\f\bnd\fcheck\fTSBs.\fC\bn\f\b\fc\buse\ffor\fthe\fnoise\fbe\f
determined\fb\bsed\fon\fthe\finform\btion\f\bv\bil\bble?\fYesT\bke\fthe\f\bction\fspecified\f
in\fthe\fO\bsis\for\fTSB\finform\btion.\fCheck\f
whether\fthe\fme\bsures\f h\bve\fbeen\fsuccessful.
NoStep\f4.
4thLoc\blize\fthe\fnoise.\fIn\fdoing\fso,\fcheck\fwhether\fit\fis\f\bn\f unusu\bl\fnoise\for\fif\fit\fis\f\b\fusu\bl\fdriving\fnoise\fth\bt\fis\f
more\fnotice\bble\fbec\buse\fof\fin\bdequ\bte\fse\bling.\fIs\fit\f\bn\f
YesStep\f5.
\f
Стр. 5 из 11
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468075&gui...procarmanuals.com
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Po\f\fible concern\f with corrective mea\fure\f
NOTE:\fInstructions\fon\fgener\bl\fnoise\f\bre\fsumm\brized\fsep
\br\btely\fin\fthe\fNoise,\fVibr\btion\f
\bnd\fH\brshness\fsection.\fThese\fc\bn\fbe\fuseful\fwhen\fse\brching\ffor\fthe\fc\buses\fof\fwind\fnoises.\f
There\ffollows\f\bn\foutline\fof\fthe\fpossible\fconcerns\frel\b
ting\fto\fwind\fnoises.\fSelected\fex\bmples\f
\bre\fgiven\fshowing\fthe\fc\buses\fof\fwind\fnoises\f\bnd\fthe\fw\bys\fin\fwhich\fthey\fc\bn\fbe\felimin\bted.\f
They\f\bre\fintended\fto\fprovide\ftroubleshooting\ftips\f\bnd\fsuggestions\ffor\fthe\fuser\fbut\fdo\fnot\f
represent\f\bn\fexh\bustive\ff\bults\flist.\fThe\ftopics\f\bre\fsubdivided\fby\fthe\fdifferent\fgroups\fof\f
components.\f\f
The\ftest\fprocedures\fdescribed\fin\fthe\fNoise,\fVibr\btion\f\bnd\fH\brshness\fsection\fc\bn\fbe\fused\f
when\ftroubleshooting.\f
Seal\f
In\fgener\bl,\fse\bls\f\bre\fvery\fimport\bnt\fwhen\felimin\bting\fwind\fnoises.\fSpeci\bl\f\bttention\fshould\f
\b l

w\bys\fbe\fp\bid\fhere\fto\fthe\fpossible\fc\buses\fof\fwind\fnoises.\f
unusu\bl\fnoise?
NoStep\f7.
5thDetermine\fthe\fsource\fof\fthe\fnoise.\fC\bn\fthe\fc\buse\fbe\f determined?YesElimin\bte\fthe\fnoise\for\f
c\brry\fout\f\b\frep\bir\f\bs\fthe\f c\bse\fm\by\fbe.\fCheck\f
whether\fthe\fme\bsures\f h\bve\fbeen\fsuccessful.
NoStep\f6.
6thDetermine\fthe\fp\bth\fof\fthe\fnoise\fusing\fthe\fstethoscope.\f
By\fw\by\fof\f\b\ftri\bl,\fm\bsk\fthe\fsuspected\f\bre\b\for\f
components\for\fremove\fthem.\fC\bn\fthe\fc\buse\fbe\f determined?
YesElimin\bte\fthe\fnoise\for\f
c\brry\fout\f\b\frep\bir\f\bs\fthe\f c\bse\fm\by\fbe.\fCheck\f
whether\fthe\fme\bsures\f h\bve\fbeen\fsuccessful.
NoStep\f7.
7thCheck\fthe\fvehicle\ffor\fin\bdequ\bte\for\fd\bm\bged\fse\bls.\fThe\f
se\bling\fof\f\b\fvehicle\fc\bn\fbe\fchecked\fusing\fthe\f
stethoscope,\fthe\fpowder\ftest,\fthe\fsmoke\ftest\f\bnd\fthe\f
ultr\bsonic\fdetector.\f(See\funder\ftest\fmethod.)\fCould\f\b\f le\bk\fbe\fdetected?
YesRenew\fthe\fse\bl\for\f
perform\fthe\f\bppropri\bte\f
rep\bir\f\bs\fnecess\bry.\fCheck\fwhether\fthe\f
me\bsures\fh\bve\fbeen\f successful.
NoStep\f8.
8thUnder\fcert\bin\fcircumst\bnces\fthere\fm\by\fbe\f\b\f
construction\bl\fproblem\fwhich\fis\fnot\fyet\fknown\f\bbout.\f Record\fthe\fproblem\fin\f\bn\fExpress\fService\fReport\f\bnd\f
send\fit\fon\fby\fthe\fusu\bl\fmethod.\f
Стр. 6 из 11
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468075&gui...procarmanuals.com
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