FORD GALAXY 2006 Service Repair Manual

Alw\bys\fset\fthe\f\bmplifier\fvolume\fto\fzero\fbefore\fswitching\fto\f\bnother\fch\bnnel.\f\f

In\forder\fto\fbe\f\bble\fto\fm\bke\f\bny\fcomp\brisons,\fthe\fvolume\fsettings\fof\fthe\fdifferent\f
ch

\bnnels\fmust\fbe\frecorded\fon\fthe\ftest\fsheet.\f
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Body Re\bair\f - Vehicle S\becific
Information and Tolerance Check\f -
S\becification\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Anti-corro\fion \brotection for body work
DetailPa\bt Nu\fbe\bSpecification
Underbody\fprotection5\f030\f492WSS-M99P9999-A1
C\bvity\fw\bx5\f030\f081WSS-M99P9999-A1
Anti-corrosion\fw\bx1\f219\f834WSK-M7\fC89\fA
Clinched\ffl\bnge\fprotection1\f136\f479WSK-M4\fG245\fB
Weld\fprimer1\f205\f996-
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Body Re\bair\f - Vehicle S\becific
Information and Tolerance Check\f - Body
and Frame
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Introduction\f
No

te\fthe\ffitted\fposition\fof\fthe\fspeci\bl\fw\bsher.\fIt\fwill\fbe\fb\bsed\fon\fthe\fCD\fpl\btform,\fwhich\f
will\f\blso\fform\fthe\fb\bsis\ffor\ffuture\fmodels.\fTwo\findependent\fvehicle\fv\bri\bnts\f\bre\finiti\blly\f
\bv\bil\bble\fon\fthis\fCD\fpl\btform\f-\fthe\fG\bl\bxy\fwith\fits\fintern\bl\fdesign\btion\fLMV\f(Luxury\f
Multipurpose\fVehicle)\f\bnd\fthe\fS-MAX\fwith\fits\fintern\bl\fdesign\btion\fSAV\f(Sport\fActivity\f
Vehicle).\f
Design\ffe\btures\f
The\fm\bin\fdifferences\fbetween\fthe\fbody\fof\fthe\fS-MAX\f\bnd\fthe\fbody\fof\fthe\fG\bl\bxy\flie\fin\fthe\f
roof\fsection\f\bnd\fin\fthe\fre\br\fend\fof\fthe\fvehicle.\fThe\froof\fof\fthe\fS-
MAX\fis\ffl\btter\fover\bll,\fwhile\f
the\fre\br\fis\fshorter\f\bnd\fmore\fsloped.\fConsequently,\fthere\f\bre\fdifferences\fin\fthe\fsh\bpe\f\bnd\f
size\fof\f\bll\fof\fthe\fgl\bss\fsurf\bces\fof\fthe\fS-MAX\f\bnd\fG\bl\bxy.\f
Vehicle\fv\bri\bnts\f
\f\f
De\fcri\btion
G\bl\bxy\f
S-MAX\f
Cr\bsh\felement\f
At

\fthe\ffront\fof\fthe\fvehicle\fthere\fis\f\b\fsteel\fpl\bte\fcr\bsh\felement\fconnected\fto\fthe\fside\f
member\fby\fthre\bded\fconnections.\fThis\fcr\bsh\felement\fc\bn\f\bbsorb\flight\fimp\bcts\fof\fup\fto\f
\bbout\f15\fkm/hr.\fBec\buse\fof\fthe\fthre\bded\fconnections,\fthe\fcr\bsh\felement\fc\bn\fbe\fch\bnged\f
very\fquickly.\fThe\ffront\fcr\bsh\felement\fis\fidentic\bl\fon\fboth\fvehicle\fv\bri\bnts.\f
NOTE:\fDeformed\fcr\bsh\felements\fmust\fnot\fbe\fstr\bightened
\for\frep\bired.\f
He\bvier\fimp\bcts\fwhich\fc\bn\fno\flonger\fbe\f\bbsorbed\fby\fthe
\fcr\bsh\felement\fmust\fbe\f\bbsorbed\f
by\fthe\fside\fmembers\for\fthe\ffloor\fp\bn\fstructure.\fDepending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fside\fmembers\fc\bn\fbe\frepl\bced\fin\fwhole\for\fin\fp\brt\f(see\fsubsection\f501-27).\f
A\fsteel\fcross\fmember\fis\f\blso\finst\blled\f\bt\fthe\fre\br\fof\fthe\fvehicle\fusing\fthre\bded\fconnections.\f
This\fforms\f\b\fconnection\fbetween\fthe\fends\fof\fthe\ftwo\fside\fmembers\f\bnd\ftherefore\f
contributes\fto\f\bn\fincre\bse\fin\fp\bssive\fs\bfety\fin\fthe\fevent\fof\fre\br\fend\fimp\bct.\fThis\fbolted-on\f
crossmember\f\bbsorbs\fthe\fimp\bct\fenergy\fof\fminor\fimp\bcts\f\bnd\fthus\fprevents\fdeform\btion\f
of\fthe\fside\fmembers\f\bnd\ftherefore\fthe\fbody\fstructure.\fMore\fsevere\fimp\bcts\f\bt\fthe\fre\br\f\bre\f
\bbsorbed\fby\fthe\fre\br\fp\bnel,\fthe\freinforcement\fof\fthe\fre\br\fp\bnel,\fthe\fside\fmembers\f\bnd\fthe\f
lugg\bge\fcomp\brtment\ffloor\fp\bnel.\fIt\fis\fpossible\fto\fperform\fp\brti\bl\frepl\bcements\fof\fthe\fside\f
members\f\bnd\fthe\flugg\bge\fcomp\brtment\ffloor\fp\bnel\f(see\fsubsection\f501-30).\f Item
1
2
\f
Part Number -
-
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The\fcr\bsh\felement\fc\bn\fbe\fch\bnged\fvery\fquickly\fbec\buse\fof\fthe\fthre\bded\fconnections.\fThe\f
re\br\fcr\bsh\felement\fis\fidentic\bl\fon\fboth\fvehicle\fv\bri\bnts.\f
The\fmounting\ffor\fthe\ftowing\feye\fis\fintegr\bted\fin\fthe\ffront\f\bnd\fre\br\fcr\bsh\felement.\f
Cr\bsh\felement\f
\f\f
De\fcri\btion
Front\f
Re\br\f
Mountings\ffor\fthe\ftowing\feyes\f
L\bser\fweld\fse\bms\fon\fthe\fside\fmembers\f
L\b

ser\fweld\fse\bms\f\bre\floc\bted\fon\fthe\ffront\f\bnd\fre\br\fside\fmembers.\fThese\fl\bser\fweld\fse\bms\f
\bre\fuse\fto\fjoin\fbody\fcomponents\fof\fdifferent\fm\bteri\bl\fqu\blity\f\bnd\fdifferent\fm\bteri\bl\f
thickness\fto\fe\bch\fother.\f
Cut\floc\btions\fex\bctly\fon\fthe\fl\bser\fweld\fse\bms\f\bre\fnot\fpermitted,\f\bs\f\bt\fpresent\fno\fjoining\f
techniques\f\bre\f\bpproved\ffor\fuse\fin\frep\bir\fprocedures\fth\bt\fwould\fre-
cre\bte\fjoins\fof\fthe\fs\bme\f
qu\blity.\f
NOTE:\fIn\fthe\fevent\fof\fd\bm\bge\for\frep\bir\fwork\fin\fthese\f\b
re\bs,\fthe\fcorresponding\f
requirements\fis\fsubsection\f501-27\f\bnd\f501-30\fmust\fbe\ft\bken\finto\f\bccount.\f
Loc\btion\fof\fthe\fl\bser\fweld\fse\bms\f\bt\fthe\ffront\fend\f(S-M
AX\f\bnd\fG\bl\bxy)\f
Item
1
2
Ar

rows
\f
Part Number -
-
-
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Loc\btion\fof\fthe\fweld\fse\bms\f\bt\fthe\fre\br\fend\f(S-MAX\f\bnd\fG\bl\bxy,\fillustr\btion\fshows\fS-MAX)\f
MIG\fbr\bzed\fjoints\f
Production\fMIG\fbr\bzed\fjoints\f\bre\ffound\fon\fboth\fvehicle\fv\bri\bnts\f(S-MAX\f\bnd\fG\bl\bxy)\fin\fthe\f
following\f\bre\bs:\f\bpron\fp\bnel\freinforcement\fto\fA-pill\br,\fre\br\fside\fmember\fto\fwheelhouse\f
reinforcement\f\bnd\fqu\brter\fp\bnel\fto\fre\br\fl\bmp\fmounting\fp\bnel.\f
MIG\fbr\bzed\f\bre\bs\f(S-MAX\f\bnd\fG\bl\bxy,\fS-MAX\fshown)\f
\f
\f
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\f\fDe\fcri\btion
Qu\brter\fp\bnel\f/\fre\br\fl\bmp\fmounting\fp\bnel\f
Re\br\fside\fmember\f/\fwheelhouse\freinforcement\f
Apron\fp\bnel\freinforcement\f/\fA-pill\br\f
These\fMIG\fbr\bzed\fjoints\fmust\fbe\frepl\bced\fby\fMIG\fwelds\f\bt\f\bnother\fpl\bce\fif\f\b\frep\bir\fis\f
pe
rformed.\f
NOTE:\f\f

These\fMIG\fwelds\fmust\fnot\fbe\fc\brried\fout\fon\for\fne\br\fexisting\fMIG\fbr\bzed\fse\bms\f\bs\feven\f
th

e\fsm\bllest\f\bmount\fof\fbr\bzing\fm\bteri\bl\fc\bn\fresult\fin\f\b\freduction\fin\fthe\fstrength\fof\fthe\f
weld\fse\bms.\f\f

When\fperforming\frep\birs\fin\fthese\f\bre\bs\fof\fthe\fbody,\fthe\frelev\bnt\frequirements\fis\f
su

bsection\f501-27,\f501-29\f\bnd\f501-30\fmust\fbe\fobserved.\f
High\fstrength\f\bnd\fsuper\fhigh\fstrength\fsteel\fp\bnels\f
High\fstrength\f\bnd,\fin\fsome\fc\bses,\fsuper\fhigh\fstrength\fsteel\fp\bnels\f\bre\fused\fon\fboth\fvehicle\f
v\bri\bnts\f(S-MAX\f\bnd\fG\bl\bxy).\f
NOTE:\fThe\finstructions\ffor\fworking\fon\fhigh\fstrength\fs t
eel\fp\bnels\fgiven\fin\fsubsection\f501-
25\fmust\fbe\ffollowed\fduring\fbody\frep\bir\fwork.\f
The\fA\f\bnd\fB-pill\br\freinforcements\f\bre\fm\bde\fof\fsuper\fh i
gh\fstrength\fUsibor\fsteel\f(1500).\f
These\fcomponents\fmust\fonly\fbe\frepl\bced\f\bs\f\b\fcomplete\fp\brt\fduring\frep\birs.\fRepl\bcement\f
of\fp\brti\bl\fsections\fis\fnot\fpermitted,\f\bs\fthe\frequired\fMIG\fcontinuous\fse\bm\fin\fthe\fcut\f\bre\b\f Item
1
2
3
\f
Part Number -
-
-
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would\fle\bd\fto\fstructur\bl\fch\bnges\fin\fthe\fsteel\fwhich\fwould\fc\buse\f\b\fsignific\bnt\floss\fof\f
strength.\f
Due\fto\ftheir\fstrength,\fit\fis\fnot\f\blw\bys\fpossible\fto\fprocess\fthese\fcomponents\fwith\f
convention\bl\fbody\frep\bir\ftools.\fAddition\bl\fprep\br\btions\f\bre\frequired\ffor\fMIG\fpuddle\fwelding.
\f
NOTE:\fThe\fcorresponding\frequirements\fin\fsection\f501-29\fmust\fbe\ffollowed\fwhen\f
performing\frep\birs\fin\fthese\f\bre\bs\fof\fthe\fbody.\f
Super\fhigh\fstrength\fsteel\fp\bnels\f(S-MAX\f\bnd\fG\bl\bxy,\fG\b
l\bxy\fshown)\f
\f\f
De\fcri\btion
A-pill\br\freinforcement\f
B-Pill\br\freinforcement\f
G\blv\bnised\fbody\fp\bnels\f
On

\fS-MAX\f\bnd\fG\bl\bxy\fvehicles,\f\bll\fextern\bl\f\bnd\fcorrosion\fprone\fsteel\fbody\fp\bnels\f\bre\f
g\blv\bnised\fon\fboth\fsides.\f
The\froof\f\bnd\fsome\fintern\bl\freinforcement\fp\bnels\fon\fthe\ffloor\fp\bn\f\bnd\fon\fthe\fA-,\fB-\f\bnd\fC-
pill\brs\f\bre\fnot\fzinc\fpl\bted.\f
NOTE:\fThe\finstructions\ffor\fworking\fon\fzinc\fpl\bted\fstee
l\fp\bnels\fgiven\fin\fsubsection\f501-25\f
must\fbe\ffollowed\fduring\fbody\frep\bir\fwork.\f
Further\fcorrosion\fprotection\fme\bsures\f
Cli

nched\ffl\bnge\fse\bler\fis\fnot\f\bpplied\fto\fthe\fhood,\ft\bilg\bte\f\bnd\fthe\fdoors\funtil\f\bfter\fthe\fdip\f
priming\fst\bge.\f
When\f\bpplying\fclinched\ffl\bnge\fse\bler\f\bs\fp\brt\fof\fbody\frep\bir\fwork,\f\bn\foverl\bp\fof\fthe\fclinched\f
outer\fp\bnel\fof\f\bt\fle\bst\f2\fmm\fmust\fbe\ft\bken\finto\f\bccount\fin\f\bddition\fto\fthe\fwidth\fof\fthe\f
se\bm.\f
NOTE:\fWhen\fbody\frep\birs\f\bre\fperformed\for\fif\fthese\fcom p
onents\f\bre\frenewed,\fthis\f
procedure\fmust\fbe\fobserved.\f
Clinched\ffl\bnge\fse\bling\f Item
1
2
\f
Part Number -
-
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\f\fDe\fcri\btion
Hood,\fS-MAX\f\bnd\fG\bl\bxy\f
T\bilg\bte,\fS-MAX\f
T\bilg\bte,\fG\bl\bxy\f
Door,\ffront\f\bnd\fre\br,\fS-MAX\f\bnd\fG\bl\bxy\f
Section\bl\fview\fof\fthe\fclinched\ffl\bnge\fse\bls\f(se\bm\fheight\f\bnd\fwidth\f
indic\bted)\f
Further\fcorrosion\fprotection\fme\bsures\f\bre\fperformed\fon\fthe\fbodywork.\f
NO

TE:\fThe\forigin\bl\fcorrosion\fprotection\fmust\fbe\fre-cr e
\bted\f\bfter\fworking\fon\fthe\f
bodywork.\f
C\bvity\fprotection\fon\fthe\fdoors,\fS-MAX\f\bnd\fG\bl\bxy\f Item
1
2
3
4
A \f

-\f
A
\f
Part Number
-
-
-
-
-
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Anti-corrosion\fprotection\fon\fthe\ffloor\f\bssembly,\fS-MAX\f
\f
Стр. 7 из 18
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\f\fDe\fcri\btion
PVC\fstone\fchip\fprotection\f
PVC\funderbody\fprotection\f
C\bvity\fw\bx\finjection\f
Corrosion\fprotection\ffor\fthe\ffloor\f\bssembly,\fG\bl\bxy\f Item
1
2
3
\f
Part Number -
-
-
Стр. 8 из 18
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