air condition FORD GALAXY 2006 Service Repair Manual

Highly\ffl\bmm\bble,\fcombustible\f–\fobserve\fNo\fSmoking\fpolicy.\f
Skin\fcont\bct\fm\by\fresult\fin\ffrostbite.\f
Instructions\fgiven\fby\fthe\fm\bnuf\bcturer\fmust\fbe\ffollowed.\fAvoid\fn\bked\flights,\fwe\br\fsuit\bble\f
protective\fgloves\f\bnd\fgoggles.\f
If\frefriger\bnt\fcomes\finto\fcont\bct\fwith\fthe\fskin\for\feyes,\fimmedi\btely\frinse\fthe\f\bffected\f\bre\bs\f
with\fw\bter.\fEyes\fshould\f\blso\fbe\frinsed\fwith\f\bn\f\bppropri\bte\firrig\btion\fsolution\f\bnd\fshould\f
not\fbe\frubbed.\fSEEK\fMEDICAL\fASSISTANCE\fIF\fNECESSARY.\f
For\f\bddition\bl\finform\btion,\frefer\fto:\fAir\fConditioning\f(A/C)\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btio
n).\f
Adhesives and Sealers
See\f\blso\fFire,\fChemic\bl\fM\bteri\bls.\f
Highly\ffl\bmm\bble,\ffl\bmm\bble,\fcombustible\f–\fobserve\fNo\fSmoking\fpolicy.\f
Gener\blly\fshould\fbe\fstored\fin\fNo\fSmoking\f\bre\bs.\fCle\bnliness\f\bnd\ftidiness\fin\fuse\fshould\fbe\f
observed,\ffor\fex\bmple\fdispos\bble\fp\bper\fcovering\fbenches;\fshould\fbe\fdispensed\ffrom\f
\bpplic\btors\fwhere\fpossible;\fcont\biners,\fincluding\fsecond\bry\fcont\biners,\fshould\fbe\fl\bbeled\f
\bppropri\btely.\f Solven\f-based Adhesives/Sealers - See Solven\fs
Follow\fm\bnuf\bcturers\finstructions.\f
Wa\fer-based Adhesives/Sealers
Those\fb\bsed\fon\fpolymer\femulsions\f\bnd\frubber\fl\btexes\fm\by\fcont\bin\fsm\bll\f\bmounts\fof\f
v o

l\btile\ftoxic\f\bnd\fh\brmful\fchemic\bls.\fSkin\f\bnd\feye\fcont\bct\fshould\fbe\f\bvoided\f\bnd\f\bdequ\bte\f
ventil\btion\fprovided\fduring\fuse.\f
Ho\f Mel\f Adhesives
In\fthe\fsolid\fst\bte,\fthey\f\bre\fs\bfe.\fIn\fthe\fmolten\fst\bte\fthey\fm\by\fc\buse\fburns\f\bnd\fhe\blth\f
h\b
z\brds\fm\by\f\brise\ffrom\fthe\finh\bl\btion\fof\ftoxic\ffumes.\f
Use\f\bppropri\bte\fprotective\fclothing\f\bnd\f\b\fthermost\btic\blly\fcontrolled\fhe\bter\fwith\f\b\ftherm\bl\f
cut-out\f\bnd\f\bdequ\bte\fextr\bction.\f
Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based
Mixing\fshould\fbe\fc\brried\fout\fin\fwell\fventil\bted\f\bre\bs,\f\bs\fh\brmful\for\ftoxic\fvol\btile\fchemic\bls\f
m \b

y\fbe\frele\bsed.\f
Skin\fcont\bct\fwith\funcured\fresins\f\bnd\fh\brdeners\fc\bn\fresult\fin\firrit\btion,\fderm\btitis,\f\bnd\f
\bbsorption\fof\ftoxic\for\fh\brmful\fchemic\bls\fthrough\fthe\fskin.\fSpl\bshes\fc\bn\fd\bm\bge\fthe\feyes.\f
Provide\f\bdequ\bte\fventil\btion\f\bnd\f\bvoid\fskin\f\bnd\feye\fcont\bct.\f
Anaerobic, Cyanoacryla\fe (super-glues) and o\fher Acrylic Adhesives
M\bny\f\bre\firrit\bnt,\fsensitizing\for\fh\brmful\fto\fthe\fskin\f\bnd\frespir\btory\ftr\bct.\fSome\f\bre\feye\f
ir
rit\bnts.\f
Skin\f\bnd\feye\fcont\bct\fshould\fbe\f\bvoided\f\bnd\fthe\fm\bnuf\bcturers\finstructions\ffollowed.\f
Cy\bno\bcryl\bte\f\bdhesives\f(super-glues)\fMUST\fNOT\fcont\bct\fthe\fskin\for\feyes.\fIf\fskin\for\feye\f
tissue\fis\fbonded,\fcover\fwith\f\b\fcle\bn\fmoist\fp\bd\f\bnd\fSEEK\fIMMEDIATE\fMEDICAL\fATTENTION.\f
Do\fnot\f\bttempt\fto\fpull\ftissue\f\bp\brt.\fUse\fin\fwell\fventil\bted\f\bre\bs\f\bs\fv\bpors\fc\bn\fc\buse\f
irrit\btion\fto\fthe\fnose\f\bnd\feyes.\f
For\ftwo-p\bck\fsystems\fsee\fResin-b\bsed\f\bnd\fIsocy\bn\bte\fAdhesives/Se\blers.\f
\bsocyana\fe (Polyure\fhane) Adhesives/Sealers
See\f\blso\fResin-b\bsed\fAdhesives.\f
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\bnd\fgoggles.\f
Individu\bls\fwith\fchronic\frespir\btory\fdise\bses,\f\bsthm\b,\fbronchi\bl\fmedic\bl\fproblems,\for\f
histories\fof\f\bllergic\fdise\bses\fshould\fnot\fwork\fin\for\fne\br\funcured\fm\bteri\bls.\f
The\fcomponents,\fv\bpors\for\fspr\by\fmists\fc\bn\fc\buse\fdirect\firrit\btion,\fsensitivity\fre\bctions\f\bnd\f
m\by\fbe\ftoxic\for\fh\brmful.\f
V\bpors\f\bnd\fspr\by\fmists\fmust\fnot\fbe\finh\bled.\fThese\fm\bteri\bls\fmust\fbe\f\bpplied\fwith\f
\bdequ\bte\fventil\btion\f\bnd\frespir\btory\fprotection.\fDo\fnot\fremove\fthe\frespir\btor\fimmedi\btely\f
\bfter\fspr\bying;\fw\bit\funtil\fthe\fv\bpors/mists\fh\bve\fcle\bred.\f
Burning\fof\fthe\funcured\fcomponents\f\bnd\fthe\fcured\ffo\bms\fc\bn\fgener\bte\ftoxic\f\bnd\fh\brmful\f
fumes.\fSmoking,\fn\bked\ffl\bmes\for\fthe\fuse\fof\felectric\bl\fequipment\fduring\ffo\bming\foper\btions\f
\bnd\funtil\fv\bpors/mists\fh\bve\fcle\bred\fshould\fnot\fbe\f\bllowed.\fAny\fhe\bt\fcutting\fof\fcured\ffo\bms\f
or\fp\brti\blly\fcured\ffo\bms\fshould\fbe\fconducted\fwith\fextr\bction\fventil\btion.\fSee\f\blso\fthe\f
vehicle\fBody\fRep\bir\fM\bnu\bl.\f
Freon
See\fAir\fConditioning\fRefriger\bnt.\f
Fuels
See\f\blso,\fFire,\fLeg\bl\fAspects,\fChemic\bls\f\bnd\fSolvents.\f
Avoid\fskin\fcont\bct\fwith\ffuel\fwhere\fpossible.\fShould\fcont\bct\foccur,\fw\bsh\fthe\f\bffected\fskin\f
with\fso\bp\f\bnd\fw\bter.\f
Gasoline (Pe\frol)
Highly\ffl\bmm\bble\f-\fobserve\fNo\fSmoking\fpolicy.\f\f
Fo
r\f\bddition\bl\finform\btion,\frefer\fto:\f Petrol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\f
S\bf

ety\fPrec\butions \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btio
n).\f
Gas-oil (Diesel Fuel)
For\f\bddition\bl\finform\btion,\frefer\fto:\f Di
esel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
Kerosene (Paraffin)
Used\f\blso\f\bs\fhe\bting\ffuel,\fsolvent\f\bnd\fcle\bning\f\bgent.\f
F l

\bmm\bble\f-\fobserve\fNo\fSmoking\fpolicy.\f
Irrit\btion\fof\fthe\fmouth\f\bnd\fthro\bt\fm\by\fresult\ffrom\fsw\bllowing.\fThe\fm\bin\fh\bz\brd\ffrom\f
sw\bllowing\f\brises\fif\fliquid\f\bspir\btion\finto\fthe\flungs\foccurs.\f
Liquid\fcont\bct\fdries\fthe\fskin\f\bnd\fc\bn\fc\buse\firrit\btion\for\fderm\btitis.\fSpl\bshes\fin\fthe\feye\fm\by\f
be\fslightly\firrit\bting.\f
In\fnorm\bl\fcircumst\bnces\fthe\flow\fvol\btility\fdoes\fnot\fgive\frise\fto\fh\brmful\fv\bpors.\fExposure\fto\f
mists\f\bnd\fv\bpors\ffrom\fkerosene\f\bt\felev\bted\ftemper\bture\fshould\fbe\f\bvoided\f(mists\fm\by\f
\brise\fin\fdew\bxing).\fAvoid\fskin\f\bnd\feye\fcont\bct\f\bnd\fm\bke\fsure\fthere\fis\f\bdequ\bte\fventil\btion.
\f
Gas Cylinders
See\f\blso\fFire.\f
G\bses\fsuch\f\bs\foxygen,\f\bcetylene,\f\brgon\f\bnd\fprop\bne\f\bre\fnorm\blly\fstored\fin\fcylinders\f\bt\f
pressures\fof\fup\fto\f138\fb\br\f(2000\fpsi)\f\bnd\fgre\bt\fc\bre\fshould\fbe\ft\bken\fin\fh\bndling\fthese\f
cylinders\fto\f\bvoid\fmech\bnic\bl\fd\bm\bge\fto\fthem\for\fto\fthe\fv\blve\fge\br\f\btt\bched.\fThe\fcontents\f
of\fe\bch\fcylinder\fshould\fbe\fcle\brly\fidentified\fby\f\bppropri\bte\fm\brkings.\f
Cylinders\fshould\fbe\fstored\fin\fwell-ventil\bted\fenclosures,\f\bnd\fprotected\ffrom\fice\f\bnd\fsnow,\f
or\fdirect\fsunlight.\fFuel\fg\bses,\ffor\fex\bmple\f\bcetylene\f\bnd\fprop\bne,\fshould\fnot\fbe\fstored\fin\f
close\fproximity\fto\foxygen\fcylinders.\f
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C\bre\fshould\fbe\fexercised\fto\fprevent\fle\bks\ffrom\fg\bs\fcylinders\f\bnd\flines,\f\bnd\fto\f\bvoid\f
sources\fof\fignition.\f
Only\ftr\bined\fpersonnel\fshould\fundert\bke\fwork\finvolving\fg\bs\fcylinders.\f
Gases
See\fG\bs\fCylinders.\f
Gaske\fs (Fluoroelas\fomer)
See\fViton.\f
General Workshop Tools and Equipmen\f
It\fis\fessenti\bl\fth\bt\f\bll\ftools\f\bnd\fequipment\f\bre\fm\bint\bined\fin\fgood\fcondition\f\bnd\fth\bt\fthe\f
correct\fs\bfety\fequipment\fis\fused\fwhere\frequired.\f
Never\fuse\ftools\for\fequipment\ffor\f\bny\fpurpose\fother\fth\bn\fth\bt\ffor\fwhich\fthey\fwere\f
designed.\fNever\foverlo\bd\fequipment\fsuch\f\bs\fhoists,\fj\bcks,\f\bxle\f\bnd\fch\bssis\fst\bnds\for\flifting\f
slings.\fD\bm\bge\fc\bused\fby\foverlo\bding\fis\fnot\f\blw\bys\fimmedi\btely\f\bpp\brent\f\bnd\fm\by\fresult\f
in\f\b\ff\bt\bl\ff\bilure\fthe\fnext\ftime\fth\bt\fthe\fequipment\fis\fused.\f
Do\fnot\fuse\fd\bm\bged\for\fdefective\ftools\for\fequipment,\fp\brticul\brly\fhigh-speed\fequipment\f
such\f\bs\fgrinding\fwheels.\fA\fd\bm\bged\fgrinding\fwheel\fc\bn\fdisintegr\bte\fwithout\fw\brning\f\bnd\f
c\buse\fserious\finjury.\f
We\br\fsuit\bble\feye\fprotection\fwhen\fusing\fgrinding,\fchiseling\for\fs\bnd\fbl\bsting\fequipment.\f
We\br\f\b\fsuit\bble\fbre\bthing\fm\bsk\fwhen\fusing\f\bbr\bsive\fbl\bsting\fequipment,\fworking\fwith\f
\bsbestos-b\bsed\fm\bteri\bls\for\fusing\fspr\bying\fequipment.\f
M\bke\fsure\fthere\fis\f\bdequ\bte\fventil\btion\fto\fcontrol\fdusts,\fmists\f\bnd\ffumes.\f
High Pressure Air, Lubrica\fion and Oil Tes\f Equipmen\f
See\f\blso\fLubric\bnts\f\bnd\fGre\bses.\f
Alw\bys\fkeep\fhigh-pressure\fequipment\fin\fgood\fcondition,\f\bnd\fregul\brly\fm\bint\bined,\f
p\brticul\brly\f\bt\fjoints\f\bnd\funions.\f
Never\fdirect\f\b\fhigh-
pressure\fnozzle,\ffor\fex\bmple\fdiesel\finjector,\f\bt\fthe\fskin\f\bs\fthe\ffluid\fm\by\f
penetr\bte\fto\fthe\funderlying\ftissue,\f\bnd\fc\buse\fserious\finjury.\f
Halon
See\fCFCs.\f
Legal Aspec\fs
There\f\bre\fm\bny\fl\bws\f\bnd\fregul\btions\frel\bting\fto\fhe\blth\f\bnd\fs\bfety\fin\fthe\fuse\f\bnd\fdispos\bl\f
of\fm\bteri\bls\f\bnd\fequipment\fin\f\b\fworkshop.\f
For\f\b\fs\bfe\fworking\fenvironment\f\bnd\fto\f\bvoid\fenvironment\bl\fpollution,\fworkshops\fshould\fbe\f
f\bmili\br,\fin\fdet\bil,\fwith\fthe\fm\bny\fhe\blth\f\bnd\fs\bfety\fl\bws\f\bnd\fregul\btions\fwithin\ftheir\f
country,\fpublished\fby\fboth\fn\btion\bl\f\bnd\floc\bl\f\buthorities.\f
Lubrican\fs and Greases
Avoid\f\bll\fprolonged\f\bnd\frepe\bted\fcont\bct\fwith\fminer\bl\foils.\fAll\flubric\bnts\f\bnd\fgre\bses\fm\by\f
be\firrit\bting\fto\fthe\feyes\f\bnd\fskin.\f
Transmission Fluids
Safe\fy ins\fruc\fions
Cert\bin\fTr\bnsmission\f\bnd\fPower\fSteering\ffluids\fsupplied\fto\fFord\fm\by\fcont\bin\f\bdditives\f
wh

ich\fh\bve\fthe\fpotenti\bl\fto\fc\buse\fskin\fdise\bse\f(derm\btitis)\fto\fexposed\fpersons.\fThe\f
derm\btitis\fm\by\fbe\firrit\bnt\for\f\bllergic\fin\fn\bture.\fRisks\f\bre\fhigher\fwhere\fprolonged\for\f
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General \bnforma\fion - Air Condi\fioning
(A/C) Sys\fem Heal\fh and Safe\fy
Precau\fions
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descrip\fion and Opera\fion
WARNINGS:\f
On
ly\fqu\blified\ftechnici\bns\f\bre\f\bllowed\fto\fwork\fon\f\bir\fconditioning\f(A/C)\fsystems.\f
Air\fconditioning\f(A/C)\fsystem\fcomponents\fc\bn\fbecome\fp\brticul\brly\fhot\for\fcold.\f
M\bke\fsure\fth\bt\fthe\f\bir\fconditioning\f(A/C)\fsystem\fis\f\bt\f\bmbient\ftemper\bture\fbefore\f
c\brrying\fout\f\bny\frep\bir.\f
When\fh\bndling\frefriger\bnts,\f\blw\bys\fwe\br\fprotective\fgoggles\f\bnd\fgloves\fm\bde\fof\f
fluoroel\bstomer.\fLe\bther\for\ff\bbric\fgloves\f\bre\fnot\fsuit\bble.\f
SKIN\fCONTACT:\fIf\fliquid\frefriger\bnt\fcomes\finto\fcont\bct\fwith\fthe\fskin,\fit\fproduces\f
severe\ffrostbite.\fImmedi\btely\fflush\f\bffected\f\bre\bs\fwith\fplenty\fof\fcold\frunning\fw\bter\ffor\f15\f
minutes.\fSeek\fmedic\bl\f\bttention.\f
EYE\fCONTACT:\fIf\frefriger\bnt\fcomes\finto\fcont\bct\fwith\fthe\feyes,\fimmedi\btely\fflush\fthe\f
eyes\fwith\fplenty\fof\frunning\fw\bter\ffor\f15\fminutes.\fSeek\fmedic\bl\f\bttention.\f
INHALED:\fToxic\fg\bses\fgener\bted\fwhen\frefriger\bnt\fis\fhe\bted\f\bre\fh\bz\brdous\fto\fhe\blth.\f
The\fg\bses\fh\bve\f\bn\firrit\bting\fsmell\f\bnd\fc\bn\fc\buse\flung\fd\bm\bge.\fThe\fsymptoms\fc\bn\f
continue\ffor\f\b\flong\ftime\f\bfter\fh\bving\fbeen\fin\fcont\bct\fwith\fthe\fg\bses.\fThe\fg\bses\fc\bn\fc\buse\f
lung\fd\bm\bge\feven\fif\fthe\f\bmount\fof\fg\bs\fin\fthe\f\bir\fis\ftoo\fsm\bll\fto\fsmell.\f
Refriger\bnt\fis\ffl\bmm\bble\f\bnd\fexplosive.\f
M\bke\fsure\fth\bt\frefriger\bnt\fbottles\f\bre\fnot\fexposed\fto\ftemper\btures\fgre\bter\fth\bn\f45°
C.\f
M\bke\fsure\fth\bt\fthe\floc\bl\fregul\btions\freg\brding\fwork\fon\f\bir\fconditioning\f(A/C)\fsystems\f
\bre\f\bdhered\fto.\f\f
M\bke\fsure\fth\bt\frefriger\bnt\fbottles\f\bre\fclosed\fproperly.\f
G\bseous\frefriger\bnt\fh\bs\f\b\fhigher\fdensity\fth\bn\f\bir.\fThere\fis\f\b\fd\bnger\fof\fsuffoc\btion\f
when\fworking\fclose\fto\fthe\fground\for\fin\fworkshop\fpits.\f
Provide\f\bdequ\bte\fventil\btion\fwhen\fh\bndling\frefriger\bnt.\f
Never\frele\bse\frefriger\bnt\finto\fthe\f\btmosphere.\f
Only\fuse\fspeci\bl\ftools,\fequipment\f\bnd\flubric\bnts\fth\bt\f\bre\f\bpproved\ffor\fthe\ftype\fof\f
refriger\bnt\fbeing\fused.\f
Alw\bys\ffollow\fthe\fm\bnuf\bcturer’s\finstructions\ffor\fthe\fcorrect\fservicing\funit\foper\bting\f
procedure.\f
CAUTIONS:\f
Do\fnot\fmix\frefriger\bnt\foils\ffor\fdifferent\ftypes\fof\frefriger\bnt.\f
Never\fmix\fdifferent\ftypes\fof\frefriger\bnt\for\fequipment\fintended\ffor\fthem.\f
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d\bm\bged\fpowertr\bin/drivetr\bin\fmounts.\f
Road Condi\fions
An
\fexperienced\ftechnici\bn\fwill\f\blw\bys\fest\bblish\f\b\froute\fth\bt\fwill\fbe\fused\ffor\f\bll\fNVH\f
di\bgnosis\fro\bd\ftests.\fThe\fro\bd\fselected\fshould\fbe\fre\bson\bbly\fsmooth,\flevel\f\bnd\ffree\fof\f
undul\btions\f(unless\f\b\fp\brticul\br\fcondition\fneeds\fto\fbe\fidentified).\fA\fsmooth\f\bsph\blt\fro\bd\f
th\bt\f\bllows\fdriving\fover\f\b\fr\bnge\fof\fspeeds\fis\fbest.\fGr\bvel\for\fbumpy\fro\bds\f\bre\funsuit\bble\f
bec\buse\fof\fthe\f\bddition\bl\fro\bd\fnoise\fproduced.\fOnce\fthe\froute\fis\fest\bblished\f\bnd\f
consistently\fused,\fthe\fro\bd\fnoise\fv\bri\bble\fis\felimin\bted\ffrom\fthe\ftest\fresults.\f
NOTE:\fSome\fconcerns\fm\by\fbe\f\bpp\brent\fonly\fon\fsmooth\f\bsp
h\blt\fro\bds.\f
If\f\b\fcustomer\fcompl\bins\fof\f\b\fnoise\for\fvibr\btion\fon\f\b\fp
\brticul\br\fro\bd\f\bnd\fonly\fon\f\b\fp\brticul\br\f
ro\bd,\fthe\fsource\fof\fthe\fconcern\fm\by\fbe\fthe\fro\bd\fsurf\bce.\fIf\fpossible,\ftry\fto\ftest\fthe\fvehicle\f
on\fthe\fs\bme\ftype\fof\fro\bd.\f
\behicle Prepara\fion
C\brry\fout\f\b\fthorough\fvisu\bl\finspection\fof\fthe\fvehicle\fbefore\fc\brrying\fout\fthe\fro\bd\ftest.\fNote\f
\bnything\fwhich\fis\funusu\bl.\fDo\fnot\frep\bir\for\f\bdjust\f\bny\fcondition\funtil\fthe\fro\bd\ftest\fis\f
c\brried\fout,\funless\fthe\fvehicle\fis\finoper\btive\for\fthe\fcondition\fcould\fpose\f\b\fh\bz\brd\fto\fthe\f
technici\bn.\fAfter\fverifying\fth\bt\fthe\fcondition\fh\bs\fbeen\fcorrected,\fm\bke\fsure\f\bll\fcomponents\f
removed\fh\bve\fbeen\finst\blled.\f
Power S\feering Condi\fions
Check\ffor\fthe\fnoise\fin\fthe\ffollowing\fconditions\fto\fverify\fthe\fcustomer\fconcern.\f

Check\ffor\fthe\fnoise\fin\fsever\bl\ftemper\bture\fconditions.\f\f

Is\fthe\fnoise\ffrom\fwhen\fthe\fvehicle\fw\bs\fnew?\f\f

C\bn\fthe\fnoise\fbe\frepe\bted\fconst\bntly\for\fis\fit\fr\bndom?\f\f

Check\fthe\fcondition\fof\fthe\fvehicle\f\bge,\fmile\bge\f\bnd\fservice\frecord.\f\f

Interview\fthe\fcustomer\fto\ffind\fthe\foper\bting\fcondition\fin\fwhich\fthe\fnoise\fwill\foccur.\fTest\f
th

e\fvehicle\fb\bsed\fon\fthe\fdet\bil(s)\ffrom\fthe\fcustomer\finterview.\f\f

Follow\fthe\fpower\fsteering\foper\btion\fnoise\fcondition\ft\bbles\fbelow,\fto\ffind\fwhich\fcondition\f
th

e\fnoise\fwill\foccur.\f
Power S\feering Opera\fion Noise Check
S t

ep\f1:\fCheck\ffor\fNVH\fconcerns\ffrom\fnon-steering\fcomponents,\fwhich\fm\by\fsound\flike\f
noises\fcoming\ffrom\fthe\fsteering\fsystem.\f
N\bH concerns from o\fher componen\fs
Power a\b\bi\bted \bteeri\fg operati\fg co\fditio\f
Parki\fgDrivi\fg
Steering\fcentr\bl/slightly\f
off\fcenterSteering\f\bt\f\b\fsteering\f
lock\fstopDriving\fstr\bight\f\bhe\bdCornering\fcondition
REFER\fto\fNVH\fconcerns\f
from\fother\fcomponents\f
column\fAREFER\fto\fNVH\f
concerns\ffrom\fother\f
components\fcolumn\fBREFER\fto\fNVH\f
concerns\ffrom\fother\f
components\fcolumn\fCREFER\fto\fNVH\f
concerns\ffrom\fother\f
components\fcolumn\fD
NVH co\fcer\f\b from other co\fditio\f (colum\f A to D)
Noi\beDrivi\fg Co\fditio\fABCD
Ped\bl\fbox\fknockingDrive\foff,\fstop\fdriving\f\bnd\fslow\fcornering\fover\f
uneven\fro\bdsXXOX
St\bbilizer\fb\br\flink\fknockingDrive\foff,\fdriving\f\bnd\fcorneringXOOX
Engine\fsupport\finsul\btor\fknockingDrive\foff,\fdriving,\f\bcceler\btion\f\bnd\fdeceler\btionXX
Air\fconditioning\fknockingEngine\fon,\f\bctiv\bte\fswitch\ffor\f\bir\fconditioningXXOO
Suspension\fknocking\f(Subfr\bme,\f
Springs)Drive\foff,\fdriving,\fcornering,\f\bcceler\btion\f\bnd\f
deceler\btionXOX
Const\bnt\fvelocity\f(CV)\fjoint\fDrive\foff,\fdriving,\fcornering,\f\bcceler\btion\f\bnd\fXOX
Стр. 4 из 15
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http://vnx.su

Power S\feering Zip Noise
Driveline Noise and \bibra\fion
Suspension Noise and \bibra\fion
Pinpoin\f Tes\fs
NO

TE:\fThese\fPinpoint\fTests\f\bre\fdesigned\fto\ft\bke\fthe\fte
chnici\bn\fthrough\f\b\fstep-by-step\f
di\bgnosis\fprocedure\fto\fdetermine\fthe\fc\buse\fof\f\b\fcondition.\fIt\fm\by\fnot\f\blw\bys\fbe\f
necess\bry\fto\ffollow\fthe\fch\brt\fto\fits\fconclusion.\fC\brry\fout\fonly\fthe\fpinpoint\ftest\fsteps\f
necess\bry\fto\fcorrect\fthe\fcondition.\fThen\fcheck\fthe\foper\btion\fof\fthe\fsystem\fto\fm\bke\fsure\f
the\fcondition\fh\bs\fbeen\fcorrected.\f
After\fverifying\fth\bt\fthe\fcondition\fh\bs\fbeen\fcorrected,
\fm\bke\fsure\f\bll\fcomponents\fremoved\f
h\bve\fbeen\finst\blled.\f
Clockspring.
REFER\fto:\f Clockspring \f
(50
1-20B\fSupplement\bl\f
Restr\bint\fSystem,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
SymptomPo\b\bible Source\bActio\f
Power\fsteering\fsystem\fzip\fnoise\f–\foccurs\fwhen\f
hydr\bulic\ffluid\fdoes\fnot\fflow\ffreely\fthrough\fthe\f
power\fsteering\fpump\fsupply\fhose\ffrom\fsteering\f
fluid\freservoir\fto\fpower\fsteering\fpump\fc\busing\f
c\bvit\btion\f\bt\fthe\fpump.\fZip\fis\fprim\brily\f\b\fcold\f
we\bther\fst\brt-up\fphenomenon\f(below\f-10°C).
High\fviscosity\fof\f
power\fsteering\f
fluid\f\bt\flow\f
temper\bture.Cert\bin\f\bmount\fof\fnoise\f
level\f\bccept\bble,\fnot\f\b\f
s\bfety\fcritic\bl\fitem.
Aer\btion\fof\fthe\f
power\fsteering\f
fluid.
BLEED\fthe\fpower\fsteering\f
system.\f\f
REFER\fto:\f
Power\fSteering\f
System\fBleeding \f(211-00\f
Ste
ering\fSystem\f-\f
Gener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
SymptomPo\b\bible Source\bActio\f
Sh\bke\f\bnd\fvibr\btion\fwhile\fdriving
Wheel\fend\fvibr\btion.\f\f

Engine/tr\bnsmission.\fGO\fto\fPinpoint\fTest\fA.\f
Tip-in\fmo\bn

Air\fcle\bner.\f\f

Power\f\bssisted\fsteering.\f\f

Powertr\bin.\f\f


Powertr\bin/drivetr\bin\fmounts.\f

Exh\bust\fsystem.\f
GO\fto\fPinpoint\fTest\fB.\f
Idle\fboom/sh\bke/vibr\btion/shudder

C\bble(s)/hose(s).\f\f


Powertr\bin/drivetr\bin\fmounts.\f

Exh\bust\fsystem.\f\f

Belt/pulleys.\fGO\fto\fPinpoint\fTest\fC.\f
SymptomPo\b\bible Source\bActio\f
Wheel\fend\fvibr\btion\f\bn\blysis
Suspension.\f\f

Wheel\fbe\brings.\fGO\fto\fPinpoint\fTest\f D.\f
Non-\bxle\fnoise


Trim\fp\bnels.\f\f

Air\fconditioning\f(A/C)\fsystem.\f\f

Accessories.\f
GO\fto\fPinpoint\fTest\f E.\f
PINPOINT TEST A : SHAKE AND \bIBRATION WHILE DRI\bING
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
A1: NEUTRAL COAST
C\brry\fout\fthe\fneutr\bl\fco\bst\ftest.\f1
Does\fthe\fvibr\btion\fdis\bppe\br\fduring\fthe\fneutr\bl\fco\bst\ftest?\f
Yes GO\fto\fA2.\f\f
No
Стр. 11 из 15
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GO\fto\fPinpoint\fTest\fD.\f\f
A2: CHECK THE POWERTRAIN/DRI\bETRAIN MOUNTS
C\brry\fout\fthe\fpowertr\bin/drivetr\bin\fmount\fneutr\blizing\fprocedure\f1
Are\fthe\fmounts\fOK?\f
Yes
Vehicle\fcondition\fcorrected.\fROAD\fTEST\f\bs\fnecess\bry.\f
No
INSTALL\fnew\fpowertr\bin/drivetr\bin\fmounts\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\f
necess\bry.\f
PINPOINT TEST B : TIP-IN MOAN
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
B1: CHECK THE AIR CLEANER
Check\fthe\fcondition\fof\fthe\f\bir\fcle\bner\fmounts,\finlet\ftube,\foutlet\ftube,\f
reson\btors\f\bnd\f\bll\fother\fcomponents\f\bssoci\bted\fwith\fthe\f\bir\finduction\f
system\ffor\fcorrect\finst\bll\btion\f\bnd\ftightness\fof\f\bll\fconnections.\f\f1
Are\fthe\fcomponents\fOK?\f
Yes GO\fto\fB2.\f\f
No R

EPAIR\for\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\f
necess\bry.\f
B2: CHECK THE EXHAUST SYSTEM
C\brry\fout\fthe\fexh\bust\fsystem\fneutr\blizing\fprocedure.\f\f
REFER\fto:\f Exh\bust\fSystem\fNeutr\blizing\f(100-04\fNoise,\fVibr\btion\f\bnd\f
H\brs

hness,\fGener\bl\fProcedures).\f
1
Is\fthe\fexh\bust\fsystem\fOK?\f
Yes GO\fto\fB3.\f\f
No
R

EPAIR\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\fnecess\bry.\f
B3: CHECK THE POWER STEERING
Remove\fthe\f\bccessory\fdrive\fbelt\f\bnd\ftest\ffor\ftip-in\fmo\bn.\fREFER\fto:\f Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-\f2.5L\fDur\btec\f
(16

2kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05E\fAccessory\fDrive\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\f
IV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Is\fthe\ftip-in\fmo\bn\fOK?\f
Yes REPAIR\fthe\fpower\fsteering\f\bs\fnecess\bry.\f\f
REFER\fto:\f Steering\fSystem\f(211-00\fSteering\fSystem\f-\fGener\bl\f
Inf

orm\btion,\fDi\bgnosis\f\bnd\fTesting).\f
No GO\fto\fB4.\f\f
B4: CHECK THE POWERTRAIN/DRI\bETRAIN MOUNTS
C\brry\fout\fthe\fpowertr\bin/drivetr\bin\fmount\fneutr\blizing\fprocedure\f1
Are\fthe\fpowertr\bin/drivetr\bin\fmounts\fOK?\f
Yes
Vehicle\fcondition\fcorrected.\fROAD\fTEST\f\bs\fnecess\bry.\f
No INSTALL\fnew\fpowertr\bin/drivetr\bin\fmounts\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\f
Стр. 12 из 15
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necess\bry.\f
PINPOINT TEST C : IDLE BOOM/SHAKE/\bIBRATION/SHUDDER
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
C1: CHECK THE CABLE/HOSES
Check\fthe\fengine\fcomp\brtment\ffor\f\bny\fcomponent\fth\bt\fm\by\fh\bve\f\b\ftouch\f
condition\fbetween\fthe\fengine\f\bnd\fbody\for\fch\bssis.\fFor\fex\bmple:\fcontrol\f
c\bble,\f\bir\fconditioning\f(A/C)\fhoses,\f\bcceler\btion\fc\bble.\f1
Are\fthe\fcomponents\fOK?\f
Yes
GO\fto\fC2 .\f\f
No R

EPAIR\for\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\f
necess\bry.\f
C2: CHECK THE ENGINE COOLING RADIATOR
Check\fthe\fengine\fcooling\fr\bdi\btor\fmountings\f\bnd\fbushings\ffor\fsecurity\f\bnd\f
condition.\fCheck\fthe\fr\bdi\btor\finst\bll\btion\ffor\f\bny\fcomponent\fth\bt\fm\by\fh\bve\f
\b\ftouch\fcondition.\f
1
Is\fthe\finst\bll\btion\f\bnd\fbushings\fOK?\f
Yes GO\fto\fC3 .\f\f
No R

EPAIR\for\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\f
necess\bry.\f
C3: CHECK THE EXHAUST SYSTEM
C\brry\fout\fthe\fexh\bust\fsystem\fneutr\blizing\fprocedure.\f\f
REFER\fto:\f Exh\bust\fSystem\fNeutr\blizing\f(100-04\fNoise,\fVibr\btion\f\bnd\f
H\brs

hness,\fGener\bl\fProcedures).\f
1
Is\fthe\fexh\bust\fsystem\fOK?\f
Yes GO\fto\fC4 .\f\f
No
R

EPAIR\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\fnecess\bry.\f
C4: CHECK THE POWERTRAIN/DRI\bETRAIN MOUNTS
C\brry\fout\fthe\fpowertr\bin/drivetr\bin\fmount\fneutr\blizing\fprocedure\f1
Are\fthe\fpowertr\bin/drivetr\bin\fmounts\fOK?\f
Yes Vehicle\fcondition\fcorrected.\fROAD\fTEST\f\bs\fnecess\bry.\f
No
INSTALL\fnew\fpowertr\bin/drivetr\bin\fmounts\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\f
necess\bry.\f
PINPOINT TEST D : WHEEL END \bIBRATION ANALYSIS
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
D1: INSPECT THE WHEELS AND TIRES
Inspect\fthe\fwheels\f\bnd\ftires.\f\f
REFER\fto:\f Wheels\f\bnd\fTires \f(204-04\fWheels\f\bnd\fTires,\fDi\bgnosis\f\bnd\f
Tes

ting).\f
1
Are\fthe\fwheels\f\bnd\ftires\fOK?\f
Yes GO\fto\fD2.\f\f
No
I

NSTALL\fnew\fwheels\for\ftires\f\bs\fnecess\bry.\f\f
REFER\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\fTires,\fRemov\bl\f\bnd\f
In s

t\bll\btion).\f
ROAD\fTEST\f\bs\fnecess\bry.\f
Стр. 13 из 15
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D2: INSPECT THE WHEEL BEARINGS
Inspect\fthe\fwheel\fbe\brings.\f\f
REFER\fto\fin\fthis\fsection.\f1
Are\fthe\fwheel\fbe\brings\fOK?\f
Yes
GO\fto\fD3.\f\f
No I

NSTALL\fnew\fwheel\fbe\brings\f\bs\fnecess\bry.\fREFER\fto:\f Front\fWheel\fBe\bring \f(204-01\fFront\fSuspension,\fRemov\bl\f\bnd\f
Ins

t\bll\btion),\f
Wheel\fKnuckle \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\fInst\bll\btion).\f
RO

AD\fTEST\f\bs\fnecess\bry.\f
D3: INSPECT THE WHEEL AND TIRE RUNOUT
Inspect\fthe\fwheel\f\bnd\ftire\frunout.\f\f1
Is\fthe\fwheel\f\bnd\ftire\frunout\fOK?\f
Yes B\bl\bnce\fthe\fwheels\f\bnd\ftires.\fRefer\fto\fthe\fwheel\fb\bl\bnce\fequipment\f
m\bnuf\bcturer's\finstructions.\fROAD\fTEST\f\bs\fnecess\bry.\f
No
INSTALL\fnew\fwheels\for\ftires\f\bs\fnecess\bry.\f\f
REFER\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\fTires,\fRemov\bl\f\bnd\f
Ins

t\bll\btion).\f
ROAD\fTEST\f\bs\fnecess\bry.\f
PINPOINT TEST E : NON-AXLE NOISE
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
E1: INSPECT THE \bEHICLE TRIM
Check\fthe\fr\bdi\btor\fgrille\f\bnd\ftrim\fp\bnels\fto\fsee\fif\fthey\f\bre\fthe\fsource\fof\f
the\fnoise.\f\f1
Are\fthe\fvehicle\ftrim\fcomponents\fc\busing\fthe\fnoise?\f
Yes INSTALL\fnew\ftrim\fcomponents\for\fREPAIR\f\bs\fnecess\bry.\fROAD\fTEST\f\bs\f
necess\bry.\f
No GO\fto\fE2 .\f\f
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
Ignition\fswitch\fin\fposition\fIII.\f1
Ignition\fswitch\fin\fposition\fII.\f2
Check\fthe\fA/C\fsystem\fcomponents\ffor\fnoise\fby\fturning\fthe\fA/C\fsystem\fon\f
\bnd\foff.\f
3
Is\fthe\fA/C\fsystem\fc\busing\fthe\fnoise?\f
Yes
INSPECT\fthe\fA/C\fsystem.\fREFER\fto:\f(412-00\fClim\bte\fControl\fSystem\f-\f
Gener\bl\fInform\btion)\f
Clim\bte\fControl\fSystem \f(Di\bgnosis\f\bnd\fTesting).\f
ROA

D\fTEST\f\bs\fnecess\bry.\f
No GO\fto\fE3 .\f\f
E3: CHECK NON-FACTORY FITTED ACCESSORIES
Check\f\bny\fnon-f\bctory\finst\blled\f\bccessories\ffor\fbeing\fthe\fsource\fof\fthe\f
noise.\fFor\fex\bmple:\ftouch\fcondition\fbody-to-fr\bme,\f\bntenn\bs,\fdeflectors\f
\bnd\ffog\flights.\f1
Are\fthe\f\bccessories\fthe\fc\buse\fof\fthe\fnoise?\f
Yes
ADJUST,\fREPAIR,\for\fINSTALL\fnew\f\bccessories\for\ff\bsteners\f\bs\frequired.\f
ROAD\fTEST\f\bs\fnecess\bry.\f
No
Стр. 14 из 15
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Inst\bll\btion).\f
N\b REINSTALL\fthe\fstrut\f\bnd\fspring\f\bssemblies\for\fshock\f\bbsorbers.\f GO\fto\fB10
.\f
B10: CARRY OUT A ROAD TEST
C\brry\fout\f\b\fro\bd\ftest.\f\f
REFER\fto:\fRo\bd/Roller\fTesting\f(100-00\fGener\bl\fInform\btion,\fDescription\f
\bnd

\fOper\btion).\f
1
Is\fthe\fconcern\fstill\fevident?\f
Yes REFER\fto:\f Noise,\fVibr\btion\f\bnd\fH\brshness\f(NVH) \f(100-04\fNoise,\fVibr\btion\f
\bnd

\fH\brshness,\fDi\bgnosis\f\bnd\fTesting).\f
N\b Vehicle\fcondition\fcorrected.\f
PINPOINT TEST C : VEHICLE LEAN
TEST
CON\fITIONS\fETAILS/RESULTS/ACTIONS
C1: VEHICLE LEAN
Det\bch\fthe\flo\bd\flevelling\fshock\f\bbsorbers\ffrom\fthe\fwheel\fknuckles.\f\f1
Does\fthe\fvehicle\fle\bn?\f
Yes Inst\bll\fnew\fre\br\fsprings.\fREFER\fto:\f Spring\f(204-02\fRe\br\fSuspension,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
N\b CARRY\fOUT\fthe\fLo\bd-Levelling\fShock\fAbsorber\fComponent\fTest\fin\fthis\f
section.\f
PINPOINT TEST D : SHOCK ABSORBER SOLENOID CIRCUIT - SHORT TO
GROUND
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
D1: CHECK THE SHOCK ABSORBER SOLENOID SIGNAL RETURN CIRCUIT FOR SHORT
TO GROUND
Disconnect\fAd\bptive\fD\bmping\fModule\fC4CD01-B.\f1
Disconnect\fAffected\fShock\fAbsorber\fSolenoid\f
Connector.\f2
Me\bsure\fthe\fresist\bnce\fbetween\fthe\ffollowing\f\bffected\f
shock\f\bbsorber\fsolenoid\fconnector\fpins,\fh\brness\fside\f
\bnd\fground:\f

(Left\ffront)\fC1CD03\fpin\f2,\fcircuit\fRCD03B\f(VT/BN).\f\f

(Right\ffront)\fC1CD04\fpin\f2,\fcircuit\fRCD04B\f(BU/OG).
\f

(Left\fre\br)\fC4CD05\fpin\f2,\fcircuit\fRCD05A\f(YE/BU).\f\f

(Right\fre\br)\fC4CD06\fpin\f2,\fcircuit\fRCD06A\f(BU/BN).\f
3
Is\fthe\fresist\bnce\fgre\bter\fth\bn\f10,000\fohms\f(open\fcircuit)?\f
Yes
INSTALL\fnew\ffront\for\fre\br\fshock\f\bbsorbers\f\bs\frequired.\f
\f
REFER\fto:\f Shock\fAbsorber\f\bnd\fSpring\fAssembly \f(204-
01\f

Front\fSuspension,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
Shock\fAbsorber\f\bnd\fSpring\fAssembly \f(204-01\fFront\f
Sus

pension,\fDis\bssembly\f\bnd\fAssembly)\f/\f\f
Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
N\b REPAIR\fthe\fcircuit.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
\f\f
Стр. 18 из
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