TEST RESULTS

Having carried out the road test

 See table S015 NOISE WHILST DRIVING

there was a knocking noise from the front.

Continue depending on the circumstances in which the noise occurs.

End of diagnosis

1. The noise disappears when the brake pedal is operated.

2. The noise only occurs whilst accelerating or braking with the wheels steered.

3. The noise is also present in other conditions.

1. Check the clearances for the front brake calipers and lubricate the wheel bolt pins

2. Replace the wheel bearing on the side where the fault occurred

 Op. 4450C32 ONE FRONT WHEEL HUB BEARING, LEFT OR RIGHT - REPLACE

fitting it with the magnetic track facing the strut Seeger ring.

This bearing is used by the ABS active sensors to calculate the wheel speed. It should NEVER come into contact with metal shavings because they could alter the gap and prevent a correct reading from the sensor

3. Move on to Step 1

Raise the vehicle on a two column lift and check that there are no oil leaks from the shock absorber stem, lifting up the dust cover.

Slight dampness on the stem is considered normal because there is evaporation during the operation of the shock absorber.

If there is a persistent oil leak on the shock absorber stem, make sure that it is not coming from other parts of the vehicle that are lubricated.

Move on to Step 2

1. Leaks from other parts that are lubricated.

2. Leaks from the shock absorber stem.

1. Search for the cause of the leak following the appropriate diagnostic procedure

2. Replace the shock absorber

 Op. 4410A12 FRONT SUSPENSION DAMPER (ONE), LH OR RH - FOR MCPHERSON STRUT SYSTEM - INCLUDES DISMANTLING/REASSEMBLY OF ASSEMBLY AT BENCH - R.R

Raise the vehicle on a two column lift and rotate the front wheels by hand.

Make sure that there are no impediments to the movement or noise during rotation.

Move on to Step 3

Constant velocity joint seized.

Replace the constant velocity joint

 Op. 2710A20 WHEEL SIDE CONSTANT VELOCITY JOINT (ONE), L/H OR R/H - R + R WITH DRIVESHAFT REMOVED - INCLUDES BOOT REPLACEMENT

Check that the bolts fixing the differential side joint flange are correctly tightened.

Move on to Step 4

Torque tightenings not correct.

Restore the correct tightening.

Check that there is no interference between the driveshafts and adjacent parts (track control arms, front crossmember).

Move on to Step 5

Interference between the driveshafts and adjacent parts.

Restore the correct tightening of the elements causing interference.

Try and move the driveshaft and check that there is not excessive clearance for the constant velocity joints.

Move on to Step 6

1.Gearbox side constant velocity joint chamber broken.

2.Wheel side constant velocity joint chamber broken.

3.Wheel side joint worn.

1.Replace the constant velocity joint

 Op. 2710A52 DIFFERENTIAL SIDE SLIDING JOINT (ONE) L/H OR R/H - R + R WITH DRIVESHAFT REMOVED - INCLUDES BOOT REPLACEMENT

2.Replace the constant velocity joint

 Op. 2710A20 WHEEL SIDE CONSTANT VELOCITY JOINT (ONE), L/H OR R/H - R + R WITH DRIVESHAFT REMOVED - INCLUDES BOOT REPLACEMENT

3.Replace the constant velocity joint

 Op. 2710A20 WHEEL SIDE CONSTANT VELOCITY JOINT (ONE), L/H OR R/H - R + R WITH DRIVESHAFT REMOVED - INCLUDES BOOT REPLACEMENT

Check the condition of the wheel side boot.

If it is not intact, check that there are no leaks or no grease in the actual boot.

If everything is okay and the noise was more pronounced whilst steering, check the wheel bearings.

Move on to Step 7

1. Boot broken.

2. Grease leaks/no grease.

3. Wheel bearing faulty.

1.Replace the boot

 Op. 2710A20 WHEEL SIDE CONSTANT VELOCITY JOINT (ONE), L/H OR R/H - R + R WITH DRIVESHAFT REMOVED - INCLUDES BOOT REPLACEMENT

2. Renew the correct amount of grease of the appropriate type.

3.Replace the wheel bearing

 Op. 4450C32 ONE FRONT WHEEL HUB BEARING, LEFT OR RIGHT - REPLACE

on the side where the problem occurs, positioning it with the magnetic race towards the steering knuckle ring.

Check that there are no signs of interference between the suspension elements or between the latter and the bodyshell.

In particular, check that there are no signs of wear on the suspension springs and that they do not show signs of abrasion.

If the spring shows signs of abrasion, its mechanical properties could be weakened as a result of oxidation.

Move on to Step 8

1.Inteference due to incorrect fitting.

2.Abrasions or spring does not comply.

1.Eliminate the interference and restore correct fastening. If this is not possible, replace the defective components

2.Replace the spring

 Op. 4410A12 FRONT SUSPENSION DAMPER (ONE), LH OR RH - FOR MCPHERSON STRUT SYSTEM - INCLUDES DISMANTLING/REASSEMBLY OF ASSEMBLY AT BENCH - R.R

taking care to fit it correctly.

Check that there is no clearance between the ball joint pin and the steering knuckle and between the ball joint flange and the track control arms and make sure that the boot is intact

In order to do so the guard under the engine must be removed

 Op. 7055B54 PROTECTION/GUARD UNDER ENGINE -R.R.

then loosen the bolt connecting the track control arm to the front steering knuckle.

Also check the condition of the suspension bushes.

Move on to Step 9

1. Track control arm clearance.

2. Ball joint boot not intact.

3. Track control arm front bush not intact.

4. Track control arm rear bush not intact.

1.Replace the track rod end

 Op. 4410B40 LOWER TRACK CONTROL ARM (WITH BALLJOINT) FOR LEFT OR RIGHT FRONT SUSPENSION (ONE) - R+R - CHECK WHEEL GEOMETRY SEPARATELY

2.Replace the track rod end

 Op. 4410B40 LOWER TRACK CONTROL ARM (WITH BALLJOINT) FOR LEFT OR RIGHT FRONT SUSPENSION (ONE) - R+R - CHECK WHEEL GEOMETRY SEPARATELY

3. Replace the lower track control arm

 Op. 4410B40 LOWER TRACK CONTROL ARM (WITH BALLJOINT) FOR LEFT OR RIGHT FRONT SUSPENSION (ONE) - R+R - CHECK WHEEL GEOMETRY SEPARATELY

4. Replace the lower track control arm

 Op. 4410B40 LOWER TRACK CONTROL ARM (WITH BALLJOINT) FOR LEFT OR RIGHT FRONT SUSPENSION (ONE) - R+R - CHECK WHEEL GEOMETRY SEPARATELY

Check the condition of the differential side boot.

If it is not intact, check that there are no leaks or no grease in the actual boot.

Move on to Step 10

1.Boot broken.

2.Grease leak/no grease.

1.Replace the boot

 Op. 2710A52 DIFFERENTIAL SIDE SLIDING JOINT (ONE) L/H OR R/H - R + R WITH DRIVESHAFT REMOVED - INCLUDES BOOT REPLACEMENT

2.Renew the correct amount of grease of the appropriate type.

Remove the left wheel

 Op. 4450B02 LEFT FRONT WHEEL - R.R.

and/or the right one.

 Op. 4450B04 RIGHT FRONT WHEEL - R.R.

Check that the constant velocity joint fastening nut is tightened and that the staking is in place.

Move on to Step 11

Nut loosened.

Replace the nut, restore the torque tightening and stake

 Op. 2710A20 WHEEL SIDE CONSTANT VELOCITY JOINT (ONE), L/H OR R/H - R + R WITH DRIVESHAFT REMOVED - INCLUDES BOOT REPLACEMENT

Locate the area of the possible noise source: top or bottom.

Starting from the area where the knocking was identified, check

 See Test 4410OA CORRECT TIGHTENINGS FOR FRONT SUSPENSION CHECK

the tightening torques of the standard fixing bolts:

- shock absorber stem fastening to mounting on turret;

- shock absorber stem fastening to end of travel plate on turret;

- fastening of track rod end to steering knuckle; - front fastening of crossmember to body side member;

- rear inner fastening securing crossmember to body side member;

- rear outer fastening securing crossmember to body side member;

- anti-roll bar to crossmember fastenings;

- fastenings on power assisted steering box crossmember;

- band to crossmember fastenings;

- connecting rod between anti-roll bar and shock absorber fastenings;

- front brake caliper fastenings.

Visually inspect that the yield point type bolts have not loosened, the list is given below:

- steering knuckle to shock absorber bracket fastening;

- fastening of the front bush to the track control arm;

- fastening of the rear bush to the track control arm;

- fastening securing engine suspension connecting rod to crossmember.

Also check that the four special anti-slip washers are present where the crossmember is attached to the bodyshell at the rear (inside and outside).

Move on to Step 12

1. Tightenings for standard bolts not correct.

2. Yield point type bolts loosened.

3. Special anti-slip washers not present / worn.

1. Restore the correct tightening.

2. Replace the yield point type bolts and restore the correct tightening.

3. Place new special anti-slip washers on the (inner and outer) rear mountings between the crossmember and the bodyshell.

Check

 See Test 4410CA FRONT ANTI-ROLL BAR CHECKS

after having disconnected the upper track rod end for the shock absorber connecting rod, check that the anti-roll bar does not come down quickly.

Also check that there is not excessive clearance for the pins connected to the bar and to the shock absorber bracket.

Move on to Step 13

1. The anti-roll bar comes down quickly.

2. Excessive clearance for the connecting rod connecting pins.

1. Replace the anti-roll bar

 Op. 4410C10 FRONT SUSPENSION ANTI-ROLL BAR - R+R - CHECK WHEEL GEOMETRY SEPARATELY

2. Replace the connecting rod

 Op. 4410C12 FRONT SUSPENSION ANTI ROLL BAR JOINT (END) (ONE), LH OR RH - R.R

Remove the shock absorber carrying out the

 Op. 4410A12 FRONT SUSPENSION DAMPER (ONE), LH OR RH - FOR MCPHERSON STRUT SYSTEM - INCLUDES DISMANTLING/REASSEMBLY OF ASSEMBLY AT BENCH - R.R

and check that there is no clearance between the shock absorber mounting bearing and the rubber mounting encasing it.

Move on to Step 14

There is clearance for the bearing.

Replace the mounting

 Op. 4410A12 FRONT SUSPENSION DAMPER (ONE), LH OR RH - FOR MCPHERSON STRUT SYSTEM - INCLUDES DISMANTLING/REASSEMBLY OF ASSEMBLY AT BENCH - R.R

Check that the fault is no longer present.

End of diagnosis.

The fault persists.

The fault is due to another system (engine, clutch, differential).

Search for the cause in one of these systems, following the appropriate diagnostic procedures.