33S09T0 steering and suspension 2006

Diagnose Electronic Steering On Vehicle ...Day One-7 Student’s Answer Sheet ...Day One-7 Worksheet C At Workstation 3Component Diagnosis On Bench ...Day One-9 Student’s Answer Sheet ...D

steering and

suspension

electronic steering and suspension

student guide and self-study

COURSE CODE: 33S09T0 ORDER NUMBER: FCS-14356-REF

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.

• Use safety stands whenever a procedure requires you to

be under the vehicle.

• Be sure that the ignition switch is always in the OFF

position, unless otherwise required by the procedure.

• 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

RE-VERSE (engine OFF) or NEUTRAL (engine ON) unless

instructed otherwise for a specific service operation.

• 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 prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• 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.

• 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.

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 do 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.

Technical Service Support Operations Ford Customer Service Division

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:

first visit.

5. Service status provided within one minute of inquiry.

6. Vehicle ready at agreed upon time.

7. Thorough explanation of work done, coverages and changes.

1. Appointment available within one

day of the customer’s requested

service day.

2. Write-up begins within four minutes of

arrival.

3. Service needs courteously identified,

accurately recorded on Repair

Order, and verified with customer.

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 4

“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

— 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”

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

ii February, 2001 Electronic Steering & Suspension Classroom

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

Base Steering & Suspension –

SS 1

Base Steering & Suspension –

FMT 2

STEERING & SUSPENSION CURRICULUM PATH

Prerequisites – Electrical Part 1 – Electrical Part 2 – Electrical Part 3 – Electronics Part 1 – Electronics Part 2 – Electronics Part 3 – Networks + Multiplexing Part 1 – Networks + Multiplexing Part 2 – Noise, Vibration & Harshness

Base Steering & Suspension –

Classroom

Electronic Steering & Suspension –

FMT Multiplexed Steering & Suspension Systems – Fordstar

Electronic Steering & Suspension – Classroom

Electronic Steering & Suspension –

SS

Steering &

Suspension System Alignment – Fordstar

Planned Training Pathway

Ford Motor Company has identified the skills and knowledge necessary to meet the curriculum goals in theSteering and Suspension Specialty The Planned Training Pathway is a series of courses designed to provide youwith 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 arecurrently in course eight of the steering and suspension curriculum: Electronic Steering and Suspension

Classroom

Intro-2 February, 2001 Electronic Steering & Suspension Classroom

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 Themorning of the second day, you will receive four more opportunities to practice Before the end of the course, youwill have had eight opportunities to practice your diagnostic and service skills The results of your work will berecorded 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 andcomplete another worksheet You will have 5 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 andrepair

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

PREREQUISITE REVIEW QUESTIONS

1 Briefly explain the purpose of the air suspension system

2 Briefly explain the purpose of the ride control system

3 Briefly explain the purpose of the electronic steering system

4 Name the major input and output devices associated with an air suspension system

5 Name some major inputs and outputs associated with the two different types of ride control systems

Driver input ride control system

Road input ride control system

Day One-2 February, 2001 Electronic Steering & Suspension Classroom

PREREQUISITE REVIEW QUESTIONS (Continued)

6 Name some inputs and outputs associated with the electronic steering systems.

8 Explain some of the safety issues involved with air suspension systems

9 What are some of the customer concerns that might be associated with the electronically controlled

suspension and steering systems?

PREREQUISITE REVIEW QUESTIONS (Continued)

10 What happens to the amount of assist during electronic steering system malfunctions?

11 When you begin diagnosis of an electronic controlled system, where within the workshop manual is the firstplace you should go?

12 How does a pinpoint test help to diagnose a system?

Day One-4 February, 2001 Electronic Steering & Suspension Classroom

NOTES

WORKSHEET A (AT WORKSTATION 1) AIR SUSPENSION (ON VEHICLE) STUDENT’S ANSWER SHEET

NAME:

height Then describe the procedure for adjusting or calibrating ride height Then practice thecorrect vent and fill procedure for the air spring system Answer the following questions asyou work

1 What is the procedure for measuring front and rear ride height on this vehicle? (give detail)

Measure the front and rear ride height of this vehicle.

2 List the specification for this measurement, your actual reading, and whether the actual reading is in or out

of specifications

3 Using the data you have gathered, does this vehicle require an adjustment or calibration pertaining to rideheight? Also, is an adjustment or calibration possible on this vehicle? If so, which operation would beperformed an adjustment or a calibration?

4 What is the procedure for adjusting or calibrating this suspension system?

5 What is the procedure for venting/filling on this suspension?

Using the appropriate procedure, raise the vehicle one inch and then turn off the suspension service switch.

Leave the vehicle at the incorrect height for the next group.

Specification Actual Measurement In/Out of Specification

Day One-6 February, 2001 Electronic Steering & Suspension Classroom

NOTES

WORKSHEET B (AT WORKSTATION 2) DIAGNOSE ELECTRONIC STEERING (ON VEHICLE)

STUDENT’S ANSWER SHEET

NAME:

steps and using the correct equipment Answer the following questions as you work

1 Examine the EVTM for this steering system and list all of the inputs and outputs below

2 List all PIDs associated with the steering system

3 List the active commands available for this steering system

4 List the diagnostic steps that you followed and the results obtained from each step

5 What component or circuit faults, if any, have you found? If a component or circuit fault is found, givedetail about the specific fault

Day One-8 February, 2001 Electronic Steering & Suspension Classroom

6 List out the symptom, system, component and cause involved with your diagnosis

Symptom: System: Component: Cause: _

WORKSHEET B (AT WORKSTATION 2) DIAGNOSE ELECTRONIC STEERING (ON VEHICLE) STUDENT’S ANSWER SHEET (Continued)

WORKSHEET C (AT WORKSTATION 3) COMPONENT DIAGNOSIS (ON BENCH) STUDENT’S ANSWER SHEET

NAME:

Day One-10 February, 2001 Electronic Steering & Suspension Classroom

NOTES

WORKSHEET D (AT WORKSTATION 4) NAVIGATE EVTMS (TABLETOP) STUDENT’S ANSWER SHEET

NAME:

that directly correspond to the worksheet are found after each of the worksheet pages

Use the 1997 Town Car EVTM pages that follow to answer these questions:

1 What component is controlled through circuit 420(DB/Y)?

2 Give the symptom or customer concern that may be stated if circuit 420 (DB/Y) were shorted to ground.

3 Might a DTC be present with this symptom, and if so, what would it be?

4 Give the symptom or customer concern that may be stated if circuit 418 (DG/Y) at connector C458 wereopen

5 Might a DTC be present with this symptom, and if so, what would it be?

6 How might you measure the height sensor signals at the control module?

Day One-12 February, 2001 Electronic Steering & Suspension Classroom

7 What readings would indicate a correctly working height sensor?

Continue to the next section of this worksheet.

WORKSHEET D (AT WORKSTATION 4) NAVIGATE EVTMS (TABLETOP) STUDENT’S ANSWER SHEET (Continued)

1997 Town Car

ECL005-A

Day One-14 February, 2001 Electronic Steering & Suspension Classroom

ECL006-A

1997 Town Car

1997 Town Car

ECL007-A

Day One-16 February, 2001 Electronic Steering & Suspension Classroom

1997 Town Car

ECL008-A

Use the 1997 Continental EVTM pages that follow to answer these questions.

1 What voltage would you expect to measure at Pin 27 of the VDM, with a hard fault C1890 present?

2 List the circuits, components, and problems that might set a VDM code C1890 (Assume that C1890 is theonly height sensor code set.)

3 You receive a single code, C1795, while performing an On-Demand Self-Test on the VDM How can youeliminate a loose ground at G401 as a possible cause, just by looking at the EVTM diagram?

4 While backprobing for voltage on the BK/PK wire at the left rear height sensor connector, you obtain areading of approximately 5 volts What does this indicate?

5 How would you check to see if the VDM was receiving a signal from the right rear using a DVOM? Whatvoltage would you expect to see if the sensor was working correctly?

6 How might you verify that the electronic control of the right rear shock actuator can be accomplished by theVDM?

Continue to the next section of this worksheet.

WORKSHEET D (AT WORKSTATION 4) NAVIGATE EVTMS (TABLETOP) STUDENT’S ANSWER SHEET (Continued)

Day One-18 February, 2001 Electronic Steering & Suspension Classroom

NOTES

Day One-20 February, 2001 Electronic Steering & Suspension Classroom

When energized, directs voltage and

Dynamic Module to control air suspension sys- tem and Ride Control.

VEHICLE DYNAMIC MOD- ULE

C1014F C1014M C1015F C1015M C413F C413M C406F C406M

C458F C458M C471F C471M

Day One-22 February, 2001 Electronic Steering & Suspension Classroom

Day One-24 February, 2001 Electronic Steering & Suspension Classroom

NOT USED Ground

840 (W/BK) 843 (W) 841 (W/R) 842 (W/O) 1 418 (DG/Y) 418 (DG/Y) 418 (DG/Y)

429 (P/LG) 421 (PK) 428 (O/BK) – –

Day One-26 February, 2001 Electronic Steering & Suspension Classroom

NOTES

Use the 1996 Mark VIII EVTM pages that follow to answer these questions.

1 Given a fault code for the steering sensor during a self-test, how might you verify correctly steering sensoroperation without disconnecting it and removing it from the vehicle to bench test it?

2 What electrical test could you use to verify that the vehicle speed signal is getting to the suspension/steeringmodule?

3 What might be the symptom if Circuits 150 and 359 were shorted together, and what code might be

generated?

END WORKSHEET D

WORKSHEET D (AT WORKSTATION 4) NAVIGATE EVTMS (TABLE TOP) STUDENT’S ANSWER SHEET (Continued)

Day One-28 February, 2001 Electronic Steering & Suspension Classroom

NOTES

1996 Mark VIII

Day One-30 February, 2001 Electronic Steering & Suspension Classroom

ECL017-A

1996 Mark VIII

WORKSHEET E (AT WORKSTATION 1) DIAGNOSE AIR SUSPENSION PNEUMATICS (ON VEHICLE)

STUDENT’S ANSWER SHEET

NAME:

questions that follow

1 List the diagnostic steps that you followed and the results obtained for each during your diagnosis

2 Were any DTCs associated with the symptom? If so, what were they?

3 List the symptom, system, component, and cause involved with your diagnosis

Symptom: System: Component: Cause: _

Day Two-2 February, 2001 Electronic Steering & Suspension Classroom

NOTES