Advanced Steeringand Suspension Textbook SystemsDamage Analysis Version:16.1 ©2014Inter-IndustryConferenceOnAutoCollisionRepair DAM15-STMAN1-E Thispageisintentionallyleftblank. Textbook AdvancedSteeringandSuspensionSystemsDamageAnalysis Contents Introduction..............................................................................................................................7 ObligationsToTheCustomerAndLiability.......................................................................... 7 Module1-ElectronicallyControlledSystems........................................................................13 ElectronicallyControlledSystems....................................................................................... 13 ComputerControlledSystemBasics................................................................................... 15 ProblemSolvingSystemFailures........................................................................................ 18 ModuleWrap-Up............................................................................................................... 22 Module2-ElectronicallyControlledSteering........................................................................25 ElectronicallyControlledSteering.......................................................................................25 HydraulicVariableAssistSteering...................................................................................... 30 Electro-HydraulicPowerSteering........................................................................................34 ElectricAssistPowerSteering............................................................................................. 36 ElectricSteering.................................................................................................................. 40 ModuleWrap-Up............................................................................................................... 42 Module3-ElectronicallyControlledSuspension...................................................................45 TypesOfElectronicSuspensions........................................................................................ 45 AirShockAbsorberHeightControlSystems....................................................................... 48 Activity:SuspensionProblem..............................................................................................50 LoadLeveling/Self-LevelingSuspensionSystems...............................................................51 HydraulicHeightControlSystems......................................................................................54 ComputerControlledDampers...........................................................................................58 ComputerControlledStabilizerBars...................................................................................63 TirePressureMonitors........................................................................................................ 66 ModuleWrap-Up............................................................................................................... 70 TableofContents 3 Thispageisintentionallyleftblank. Introduction Thispageisintentionallyleftblank. Textbook Introduction ObligationsToTheCustomerAndLiability • fit. • finish. Throughoutthedamageanalysisand repairprocesstherepairerandinsurer must: • communicatewitheachother. • maintainconstantcommunication withthecustomer. • beinagreementwitheachother andthecustomeronhowrepairs willbeperformed. Thecollisionrepairindustryhasan • informthecustomerofany obligationtocorrectlyrepairthe changesintherepairplanfrom customer’svehicle.Collisionrepairsmust theoriginalrepairagreement,and beperformedusing: explainthechangesandwhythey havetobemade. • recommendedortested proceduresfromvehiclemakers, I-CAR,andotherresearchand testingorganizations. • qualityreplacementpartsand materials. • repairprocessesandpartsas writtenandagreeduponinthe repairorder.Ifitemsontherepair agreementarenotconsistent withtherepairorder,itcanbe consideredfraud. Performingpropercollisionrepairs Toreduceliability: requiresusingpartsandproceduresthat keepremainingwarrantiesintact. • makesurethatallrepairsare performedthoroughly,correctly Collisionrepairsmustrestore: andaslistedinthedamagereport. • followproperprocedures. • safety. • havedocumentationofrequired • structuralintegrity. repairswithdetailedrecord • durability. keepingavailableforcustomers. • performance. AdvancedSteeringandSuspensionSystemsDamageAnalysis 7 Textbook Introduction Techniciansareconsideredthe finish,durability,andperformat expertsandareexpectedtobe leastaswellastheoriginal. knowledgeableonhowtoperform • keepingthoroughrecords. aqualityrepair. Liabilityinsurancethatcoverstherepair facilitymaynotalwayscoveralldamages. Forexample: • thepolicymaynotcover faultyrepairs,leavingliability responsibilitycompletelyonthe facility. • ashopownermayfindthatrepair facilityliabilitycoveragemaynot coverthefullamountawardedin alawsuit.Theshopownerwould Keepingthoroughrecordsincludesmore havetopaythedifference. thanrecordingthedate,mileage,andpre- existingdamage.Recordkeepingalso includes: • makingsureallnotesarelegible. • verifyingtherepairsthatwere madeornotmade. • havingthecustomersigna waiverforrepairsthattheydo notwantperformed.Repairers mustdeterminetheirliabilityon notrepairingsafetysystemssuch Itisdifficulttoreducetheriskofliability asrestraintandanti-lockbrake exposure.Thepartthattherepairercan systems. controlisthechanceofbeingfoundat • keepingcomputerprintoutsor fault.Chancescanbeminimizedby: worksheetsonfileshowingwheel alignmentreadingsorvehicle • usingrecommendedortested dimensionsbeforeandafter proceduresfromthevehicle repairs. makers,ICAR,orotherresearch • keepingscantoolprintoutsand andtestingorganizations. recordsofcomputercodesfor • usingqualityreplacementparts airbag,anti-lockbrake,emission, andmaterialsthatrestorefit, andpowertraincontrolmodule (PCM)systems. AdvancedSteeringandSuspensionSystemsDamageAnalysis 8 Textbook Introduction • attachingtheOEMorothertested procedureprintouttothevehicle repairorder. • keepingreceiptsforallsublet workperformed. Referto"Video:TopicsOffLimits"inthe presentation.Thisvideoidentifiestopics thatshouldnotbebroughtupinclass. AdvancedSteeringandSuspensionSystemsDamageAnalysis 9 Thispageisintentionallyleftblank. Module1- Electronically ControlledSystems Thispageisintentionallyleftblank. Textbook Module1-ElectronicallyControlledSystems ElectronicallyControlledSystems Mercedes-BenzE-Class ThisMercedes-BenzE-ClassCoupeisequipped withbothelectronicallycontrolledsteeringand suspension. Referto"Video:LearningObjectives"in thepresentation. Electronicallycontrolledsteeringand suspensionsystemsare: Thelearningobjectivesforthismodule include: • computercontrolledmechanical systems.Theyareadjustable • explainingelectroniccircuit systemsthathavetheadjustments operation. controlledonacontinual • identifyingelectronicsystemparts. basisbytheelectroniccontrol • diagnosingproblemswith module(ECM)ofthesystem. electroniccircuits. Themechanicalpartsofthe • explainingbasicproblemsolving systemaresimilartothosefound stepsforelectronicallycontrolled inconventionalsteeringand systems. suspensionsystemsinregards totheirattachment,withthe exceptionofelectrical,air,and fluidlineconnections. • designedtoallowdifferent characteristicsforsteeringand suspensionfeelwithvarying drivingconditionssuchas vehiclespeedandroadsurface characteristics. AdvancedSteeringandSuspensionSystemsDamageAnalysis 13 Textbook Module1-ElectronicallyControlledSystems Moreinformationonthetypesof mechanicaldamagethatmayoccurto partsofelectronicallycontrolledsteering andsuspensionsystemscanbefoundin SuspensionSystems(STE02)andRackand PinionandParallelogramSteeringSystems (STE03). Physicaldamagecanaffectmanypartsofadvanced steeringandsuspensionsystems. Electronicorcomputercontrolledsteering andsuspensionsystemsonvehiclesthat havebeeninacollisionaresubjectto: • thesametypesofmechanical damageasconventionalsteering Inspectingforcollisiondamageincludeschecking andsuspensionsystems. connectorsforcracksorbreakage. Mechanicalparts,suchasshock absorbers,struts,steeringracks, Electricalandelectronicproblems andothersteeringandsuspension associatedwithcollisiondamageinclude parts,canbebentordamaged. damaged: Whenanalyzingdamageon collisiondamagedvehicles, • wiringandconnectors.This usetheadvantageofknowing includescutwiresanddamaged wherethedamagetothevehicle wiringinsulation,whichmay islocated.Acompletedamage causeelectricalshorts.Connectors inspectionmayrequiresome maybecrackedorsmashed, disassemblytohelplocateany creatinghighresistanceoropens. hiddendamagetoelectronically Wiresthathavebeenstretchedor controlledsteeringandsuspension pinchedbetweenotherpartsmay parts. havewirestrandsbrokeninside • physicaldamagetoelectricaland theinsulationwithnoapparent electronicpartsofthesystem. breakintheouterinsulation. Manyelectronicproblemson • orburnedfuses.Burnedfusesmay collisiondamagedvehiclescanbe beasymptomofanotherproblem, tracedtophysicallydamagedparts suchasdamagedwiringorshorted oftheelectricalcircuit. electricalparts. • relaysandsolenoids. • inputsensorsandloads. • orshortedcontrolmodules. AdvancedSteeringandSuspensionSystemsDamageAnalysis 14 Textbook Module1-ElectronicallyControlledSystems Electronicpartscanbenonfunctionalwith controlvalvesareexamplesof nosignsofphysicaldamage. loadsinelectronicsteeringand suspensionsystems. KPIImprovementTip Carefulinspectionincludesensuring Theinputandoutputcircuitsofthe thewatertightsealisintactandremains