Ford Falcon. Manual — part 10

100-04-12

Noise, Vibration and Harshness

100-04-12

DIAGNOSIS AND TESTING (Continued)

engine rpm and, if possible, determine the

If the vibration/noise is duplicated when carrying

vibration frequency.

out this test, the belts and accessories are not

sources.

Attempt to identify what part of the vehicle the

concern is coming from.

If the vibration/noise was not duplicated when

carrying out this test, install each accessory belt,

Attempt to identify the source of the concern.

one at a time, to locate the source.

Proceed as necessary.

Vehicle Cold Soak Procedure

Drive Engine Run-Up (DERU) Load Test

To carry out this procedure, proceed as follows:

To carry out this test, proceed as follows:

Test preparations include matching customer

conditions (if known). If not known, document the

WARNING: Block the front and rear

test conditions: gear selection and engine rpm.

wheels, and apply the parking brake and the

Monitor the vibration/noise duration with a watch

service brake, or injury to personnel can

for up to three minutes.

result.

Park the vehicle where testing will occur. The

CAUTION: Do not carry out the Engine

vehicle must remain at or below the concern

Load Test for more than five seconds or

temperature (if known) for 6-8 hours.

damage to the transmission or transaxle can

Before starting the engine, conduct a visual

result.

inspection under the hood.

Block the front and rear wheels.

Turn the key on, but do not start the engine.

Apply the parking brake and the service brake.

Listen for the fuel pump, anti-lock brake system

Install a tachometer.

(ABS) and air suspension system noises.

Shift the transmission into DRIVE, and increase

Start the engine.

and decrease the engine rpm between an idle to

approximately 2,000 rpm. Note the engine rpm

CAUTION: Never probe moving parts.

and, if possible, determine the vibration

Isolate the vibration/noise by carefully listening.

frequency.

Move around the vehicle while listening to find the

general location of the vibration/noise. Then,

Repeat the test in REVERSE.

search for a more precise location by using a

If the vibration or noise is duplicated when

stethoscope or EngineEAR.

carrying out this test, inspect the engine and

Refer to Idle Noise/Vibration in the Symptom

transmission or transaxle mounts.

Chart to assist with the diagnosis.

If the concern is definitely engine speed-related,

carry out the Engine Accessory Test to narrow

6: Check OASIS/TSBs/Repair History

down the source.

After verifying the customer concern, check for OASIS

Proceed as necessary.

reports, TSBs and the vehicle repair history for related

Engine Accessory Test

concerns. If information relating to a diagnosis/repair

is found, carry out the procedure(s) specified in that

To carry out this test, proceed as follows:

information.
If no information is available from these sources, carry

WARNING: Block the front and rear

out the vehicle preliminary inspection to eliminate any

wheels, and apply the parking brake and the

obvious faults.

service brake, or injury to personnel can

result.

7: Diagnostic Procedure

CAUTION: Limit engine running time to

Qualifying the concern by the particular sensation

one minute or less with belts removed or

present can help narrow down the concern. Always

serious engine damage will result.

use the “symptom” to “system” to “component” to

NOTE: A serpentine drive belt decreases the

“cause” diagnosis technique. This diagnostic method

usefulness of this test. In these cases, use a

divides the problem into related areas to correct the

vibration analyzer, such as the EVA, to pinpoint

customer concern.

accessory vibrations. An electronic listening

Verify the “symptom”.

device, such as an EngineEAR, will also help to

Determine which “system(s)” can cause the

identify noises from specific accessories.

“symptom”.

Remove the accessory drive belts.

If a vibration concern is vehicle speed related,

Increase the engine rpm to where the concern

the tyre and wheel rpm/frequency or

occurs.

driveshaft frequency should be calculated.

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100-04-13

Noise, Vibration and Harshness

100-04-13

DIAGNOSIS AND TESTING (Continued)

If a vibration concern is engine speed related,

deceleration. Goto Tire

the engine, engine accessory or engine firing

Noise/Vibration.

frequencies should be calculated.

Noise varies with wind/vehicle speed

and direction. Goto Air Leak and

After determining the “system”, use the diagnostic

Wind Noise.

tools to identify the worn or damaged

Related to engine speed.

“components”.

Noise varies with engine rpm. Goto

After identifying the “components”, try to find the

Engine Noise/Vibration.

“cause” of the failure.

Vibration occurs at a particular speed

Once the concern is narrowed down to a

(mph) regardless of engine speed

symptom/condition, proceed to NVH Condition and

(rpm).

Symptom Categories.

2.

Acceleration

Wide open throttle (WOT)

NVH Condition and Symptom Categories

Engine induced contact between

Operating Condition—Vehicle is Not Moving

components. Inspect and repair as

necessary.

1. Static

operation

Noise is continuous throughout WOT.

Noise occurs during part/system functioning.

Exhaust system or engine ground out.

Goto Squeak and Rattle.

Goto Engine Noise/Vibration.

2. While cranking

Light/moderate acceleration

Tip-in moan. Engine/exhaust noise.

1. Grinding or whine, differential ring gear or

Goto Engine Noise/Vibration.

starter motor pinion noise. Goto Engine

Knock-type noise. Goto Engine

Noise/Vibration.

Noise/Vibration.

2. Rattle. Exhaust hanger, exhaust heat shield

Driveline shudder. Goto Driveline

or A/C line noise. Goto Squeak and Rattle.

Noise/Vibration.

3. Vibration. Acceptable condition.

Engine vibration. Goto Engine

Noise/Vibration.

3. At

idle

3. Turning noise. Goto Steering Noise/Vibration.

Idle noise. Goto Idle Noise/Vibration.

4.

Braking.

Idle vibration or shake. Goto Idle

Clicking sound is signaling ABS is active.

Noise/Vibration.

Acceptable ABS sound.

4. During gear selection

A continuous grinding/squeal. Goto Brake

1. Vehicle parked on a steep incline. Acceptable

Noise/Vibration.

noise.

Brake vibration/shudder. Goto Brake

2. Vehicle parked on a flat surface. Goto

Noise/Vibration.

Driveline Noise/Vibration.

5.

Clutching.

3. Vehicle with a manual transmission. Goto

A noise occurring during clutch operation.

Transmission (Manual) and Transfer Case

Goto Transmission (Manual) and Transfer

Noise/Vibration.

Case Noise/Vibration.

Vibration. Goto Transmission (Manual)

Operating Condition—Vehicle is Moving

and Transfer Case Noise/Vibration.

1. Depends more on how the vehicle is operated

6.

Shifting

Noise or vibration condition related to the

1.

Speed-related

transmission (automatic). Goto

Related to vehicle speed

Transmission (Automatic) Noise/Vibration.

Pitch increases with vehicle speed.

Noise or vibration related to the

Goto Tire Noise/Vibration.

transmission (manual). Goto

Noise occurs at specific vehicle

Transmission (Manual) and Transfer

speed. A high-pitch noise (whine).

Case Noise/Vibration.

Goto Drivline Noise/Vibration.

Loudness proportional to vehicle

7. Engaged in four-wheel drive. Goto

speed. Low-frequency noise at high

Transmission (Manual) and Transfer Case

speeds, noise and loudness increase

Noise/Vibration.

with speed. Goto Driveline

8.

Cruising

speeds

Noise/Vibration.

Accelerator pedal vibration. Goto Engine

A low-pitched noise (drumming). Goto

Noise/Vibration.

Engine Noise/Vibration.

Driveline vibration. Goto Driveline

Vibration occurs at a particular speed

Noise/Vibration.

(mph) regardless of acceleration or

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100-04-14

Noise, Vibration and Harshness

100-04-14

DIAGNOSIS AND TESTING (Continued)

A shimmy or shake. Goto Tire

Noise/Vibration.

9. Driving at low/medium speeds

A wobble or shudder. Goto Tire

Noise/Vibration.

2. Depends more on where the vehicle is operated

1. Bump/pothole, rough road or smooth road.

Goto Suspension Noise/Vibration.

Noise is random or intermittent occurring

from road irregularities. Goto Squeak and

Rattle.

Noise or vibration changes from one road

surface to another. Normal sound

changes.

Noise or vibration associated with a

hard/firm ride. Goto Suspension

Noise/Vibration.

Symptom Charts

Symptom Chart — Air Leak and Wind Noise

Condition

Source

Action

PINCH the seal carrier to improve

Air leak around door perimeter

Loose fit seal.

retention on the seal flange.

Seal installed incorrectly.

REINSTALL the seal.

REALIGN the door. CHECK door gaps

Door misaligned.

and fit in the door opening and
ADJUST as necessary.

Scuff plate installed incorrectly.

REINSTALL the scuff plate.

Seal or seal push pins damaged.

INSTALL a new seal.

Air leak around glass run

Door glass misaligned.

ADJUST the door glass.

ADJUST the glass run. INSERT foam

Glass run installed incorrectly.

in the glass run carrier.

INSTALL foam rope behind the glass

Leak path behind glass run.

run.

PINCH the glass run channel to

Glass run channel spread wide.

reduce the size of the opening.

Blow-out clip bent or contacting door

ADJUST the blow-out clip or INSTALL

a new glass run/blow-out clip molding

glass.

assembly.

Glass run damaged.

INSTALL a new glass run.

Belt line seal installed incorrectly on

ADJUST the seal. (Do not bend the

Air leak at inner belt line

flange.

flange.)

Belt line seal integrated with door trim

REINSTALL the door trim.

installed incorrectly (no glass contact).

No contact with side glass.

ADJUST the door glass.

No contact with glass runs at both

ADJUST the belt line seal or ADD

ends of belt line seal.

foam at the seal ends.

Belt line seal damaged.

INSTALL a new seal.

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100-04-15

Noise, Vibration and Harshness

100-04-15

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

Belt line seal installed incorrectly on

Air leak at outer belt line

ADJUST the seal.

flange (no glass contact).

Belt line seal does not contact the

ADJUST the door glass.

glass.

No contact with glass runs at both

ADJUST the belt line seal/ADD foam

ends of belt line seal.

at the seal ends.

Belt line seal damaged.

INSTALL a new seal.

Draft at inner door handle/speaker

Hole in watershield.

SEAL the hole with a suitable tape.

opening

REALIGN the watershield. INSTALL a

Watershield misaligned.

new watershield if the pressure
sensitive adhesive fails.

Exterior door handle seal

REALIGN or INSTALL a new seal as

misaligned/damaged.

necessary.

Wind noise from exterior rear view

REALIGN with the edges shingled

Exterior mirror housing misaligned.

mirror

correctly and no gaps.

REINSTALL with the gasket unfolded

Mirror sail gasket folded/misaligned.

and aligned correctly.

Mirror housing trim cap installed

REINSTALL with the edges shingled to

incorrectly.

the air flow.

Fully ENGAGE the mirror into its

Air leak through mirror housing hinge.

operating position/USE foam to block
the air path through the hinge.

REINSTALL the sail trim/ADJUST the

Inner sail trim installed incorrectly.

door trim.

Inner sail gasket/barrier installed

REINSTALL the trim cover with the

incorrectly.

gasket/barrier aligned correctly.

Air path through wiring bundle/fastener

BLOCK the air path(s) with foam/tape.

access holes.

Exposed fastener access hole on

INSTALL a new cap if it is missing.

mirror housing/sail.

Air leak around perimeter of fixed

Gaps in the sealant bead.

APPLY approved sealant.

glass

Air traveling up windshield molding

INSTALL foam rope the full length of

along A-pillar.

the A-pillar.

Windshield/backlite misaligned or not

REINSTALL

the

windshield/backlite.

installed correctly.

Rear hood seal at base of windshield

REALIGN or INSTALL a new seal as

misaligned/damaged.

necessary.

REALIGN or INSTALL a new seal as

Air leak at cowl

Cowl gasket misaligned/damaged.

necessary.

PINCH the seal carrier to improve

Air leak around liftgate perimeter

Loose fit seal.

retention on the seal flange or INSERT
foam in the carrier.

Seal misaligned.

REINSTALL the seal.

REALIGN the liftgate. CHECK the

Liftgate misaligned.

liftgate fit in the body opening and
ADJUST as necessary.

Scuff plate misaligned.

REINSTALL the scuff plate.

Seal or seal push pins damaged.

INSTALL a new seal.

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