dimensions FORD S-MAX 2006 Service User Guide

2\f-12\f=\f1078\fmm6\f-9\f=\f860\fmm
3\f-13\f=\f1362\fmm10\f-14\f=\f835\fmm
4\f-7\f=\f1204\fmm
4. Body\fdimensions\f(side\fview),\fG\bl\bxy\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fedge\fof\fthe\fsteel\fp\bnel\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f

Me\bsuring\fpoints\f2,\f3,\f4,\f6,\f7,\f10\f\bnd\f11\f
\bre

\fme\bsured\fin\fthe\fcurve\f\bnd\frepresent\f
the\fgre\btest\fdist\bnce\fto\fthe\fme\bsuring\f
point\fopposite.\f

The\fdet\biled\fviews\fof\fme\bsuring\fpoints\f1,\f
5,

\f8,\f9\f\bnd\f12\f\bre\fshown\flooking\ffrom\fthe\f
vehicle\finterior\foutw\brds.\f
\f
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Mea\furing \boint\f and dimen\fion\f
1\f-10\f=\f1062\fmm4\f-7\f=\f1365\fmm
2\f-11\f=\f1393\fmm5\f-8\f=\f859\fmm
3\f-6\f=\f1230\fmm9\f-12\f=\f837\fmm
5. Re\br\fbody\fdimensions,\fS-MAX\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1193\fmm3\f-6\f=\f1451\fmm
2\f-5\f=\f1021\fmm
\f
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6. Re\br\fbody\fdimensions,\fG\bl\bxy\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1240\fmm3\f-6\f=\f1456\fmm
2\f-5\f=\f1105\fmm
\f
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7. P\bssenger\fcomp\brtment\fbody\fdimensions,\fS-MAX\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1508\fmm5\f-6\f=\f1498\fmm
2\f-3\f=\f1476\fmm
\f
Стр. 7 из 9
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8. P\bssenger\fcomp\brtment\fbody\fdimensions,\fG\bl\bxy\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1508\fmm5\f-6\f=\f1498\fmm
2\f-3\f=\f1476\fmm
\f
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Front En\b Sheet \fetal Repairs - Front Si\be
\fember SectionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
General Equipment
Removal
WARNING:\f\f

Due\fto\fthe\fpositions\fof\finner\freinforcements,\fit\fis\fvery\fimport\bnt\fth\bt\fthe\fdimensions\f
qu

oted\ffor\fthe\fsep\br\bting\fcuts\f\bt\fpositions\f1\f\bnd\f3\fon\fthe\finner\fside\fmember\f\bre\f
\bccur\btely\fmet.\f\f

The\fre\br\fsep\br\bting\fcuts\fmust\fnot\fbe\fm\bde\fon\fthe\fexisting\fl\bser\fweld\fse\bms.\fThe\f
in

dic\bted\fdist\bnces\f\bt\fpositions\f2\f\bnd\f4\fmust\fbe\fs\btisfied\fin\fthe\fevent\fof\f\b\fp\brti\bl\f
repl\bcement.\f
Me\bsurement\f\bnd\f\blignment\f\bngle\fsystem
1.NOTE:\fThe\frequired\fp\brti\bl\frepl\bcement\f
se

ctions\fneed\fto\fbe\fcut\fout\ffrom\fthe\fouter\f
side\fmember\fwith\f\bpron\fp\bnel\for\ffrom\fthe\f
inner\fside\fmember.\f
Replacement parts \f

Inner\fside\fmember\f

Outer\fside\fmember\fwith\f\bpron\fp\bnel\f

Longitudin\bl\fmember\ffl\bnge\fpl\bte\f
1 .

Gener\bl\finform\btion\f
Necess\bry\fremov\bl\fwork:\fBumper,\fhood,\f
fe

nder,\fhood\fclosing\fp\bnel,\fhe\bdl\bmps\f\bnd\f
crossmember\fwith\fcr\bsh\felements.\f
2. Overview\fof\fcutting\foptions\f 1. Inside\fof\fthe\fmember\f\bt\fthe\ffront\f(right-h\bnd\fside)\f
2. Inside\fof\fthe\fmember\f\bt\fthe\fre\br\f(right-
h\bnd\fside)\f
3. Inside\fof\fthe\fmember\f\bt\fthe\ffront\f(left- h\bnd\fside)\f
4. Inside\fof\fthe\fmember\f\bt\fthe\fre\br\f(left-
h\bnd\fside)\f
3. Inner\fside\fmember\f 1. Sep\br\bting\fcut.\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f
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Installation
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwi
th\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\bnd\fgre\bter,\fthe\fm\bnuf\bcturer's\fwelding\fequipment\finstructions\f\bnd\fsub-section\f501-25\f
must\fbe\ffollowed.\f
Refer\fto:\f Tools\f\bnd\fEquipment\ffor\fBody\fRep\birs \f(501-25\fBody\fRep\birs\f-\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f 6. \f\f

Front Si\be \fember - Resi\bual Part \f

Mill\fout\fthe\fspot\fwelds\f-\fRemove\fresidu\bl\f
p\br

t.\f\f
1. \f\f
Preparation of the Inner Front Si\be
\fe

mber \f

NOTE:\fThe\fspecified\fdimensions\fmust\f
be

\fmet\fwhen\fm\bking\fthe\fsep\br\bting\f
cuts.\f\f
M\brk\fcutline\f\bnd\fcut\fthe\ffront\fside\f
me
mber.\f\f
2. \f\f
Preparation of the Outer Front Si\be
\fe

mber \f

NOTE:\fThe\fspecified\fdimensions\fmust\f
be

\fmet\fwhen\fm\bking\fthe\fsep\br\bting\f
cuts.\f\f
M\brk\fcutline\f\bnd\fcut\fthe\ffront\fside\f
me
mber.\f\f
3. \f\f
Tack-wel\b Inner Front Si\be \fember \f

NOTE:\fFit\fin\fthe\fInner\fFront\fSide\f
\f\f
\f
\f
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Side Pa\bel Sheet \fetal Repairs - A-Pillar
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\fDue\fto\fthe\floc\btions\fof\finner\freinforcements\f\bnd\fNVH\felements,\fit\fis\fvery\f
i m

port\bnt\fth\bt\fthe\fdimensions\fquoted\ffor\fthe\fsep\br\bting\fcuts\fon\fthe\fouter\fA-pill\br\f\bnd\fon\f
the\frocker\fp\bnel\f\bre\f\bccur\btely\fmet.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt parts \f

A-pill\br\fouter\fp\bnel\f

A-pill\br\finner\fp\bnel\f

A-pill\br\freinforcement\f

Rocker\fp\bnel\freinforcement\f

NVH\felements\f
1 .

Gener\bl\fNotes\f

The\f\bpron\fp\bnel\freinforcement\fneeds\fto\fbe\f
removed\fbefore\fthe\frep\birs\fc\bn\fbe\fst\brted.\f

Required\fremov\bl\foper\btions:\fA-pill\br\ftrim\f
p\bn
el,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. A-Pill\br\fouter\f NOTE:\fT\bke\fc\bre\fnot\fto\fd\bm\bge\fthe\f
in

ner\fA-pill\br\freinforcement\fwhen\f
m\bking\fthe\fsep\br\bting\fcut\fon\fthe\ffront\f
of\fthe\fA-pill\br.\f

Cut\fpoints.\f
3.

A-Pill\br\fouter\f
Mill\fout\fthe\fspot\fwelds.\f
\f
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Side Pa\bel Sheet \fetal Repairs - B-Pillar
a\bd Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
WARNING:\f\f

A\fsuit\bbly\fpowerful\fresist\bnce\fspot\fwelding\fdevice\fwith\finverter\ftechnology\fshould\fbe\f
us

ed\ffor\fthis\frep\bir.\fObserve\fthe\fwelding\fequipment\finstructions\fin\fsub-section\f501-25.\f\f

The\fwelded\fjoints\f\bt\fthe\ffront\f\bnd\fre\br\fdoor\f\bpertures\fmust\fonly\fbe\fm\bde\fby\fresist\bnce\f
sp

ot\fwelding.\fMIG\fpuddle\fwelding\fis\fnot\f\b\fpermissible\f\bltern\btive.\f
WARNING:\f\f

The\fB-pill\br\freinforcement\fis\fm\bde\fof\fhigh-strength\fsteel\fpl\bte\f(Usibor\f1500).\f\f

A\fp\brti\bl\frepl\bcement\fin\fthe\f\bre\b\fof\fthe\fB-pill\br\freinforcement\fis\fnot\fpermissible.\fThe\f
re

quired\fcontinuous\fMIG\fweld\fse\bm\fin\fthe\f\bre\b\fof\fthe\fcut\fc\buses\fstructur\bl\fch\bnges\f
which\fresult\fin\fsignific\bnt\floss\fof\fstrength\fin\fthe\fB-pill\br\freinforcement.\f\f

Due\fto\fits\fstrength,\fthe\fB-pill\br\freinforcement\fc\bnnot\f\blw\bys\fbe\fworked\fon\fwith\f
co

nvention\bl\fbody\ftools.\f\f

Addition\bl\fprep\br\btions\f\bre\frequired\ffor\fMIG\fpuddle\fwelding.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt Parts \f

B-pill\br\fouter\fp\bnel\f

B-pill\br\finner\fp\bnel\f

B-Pill\br\freinforcement\f

NVH\felement\f
1. Gener\bl\fnotes\f

Necess\bry\fremov\bl\fwork:\fDoors,\fB-pill\br\f
tr

im\fp\bnel,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. NOTE:\fDue\fto\fthe\finner\freinforcements\f\bnd\f
NV
H\felements,\fthe\fspecified\fdimensions\ffor\f
the\fcuts\fto\fbe\fm\bde\fin\fthe\frocker\fp\bnel\f\bre\b\f
must\fbe\fcomplied\fwith.\f
Outer\fB-pill\br\f NOTE:\fOnly\fcut\fthrough\fthe\fouter\f
p\b

nels\fof\fthe\fB-pill\br\f-\fdo\fnot\fd\bm\bge\f
the\finner\freinforcement\fof\fthe\frocker\f
p\bnel.\f
1. Rocker\fp\bnel\fcut\floc\btions\f
2.
B-Pill\br\fcut\floc\btion.\f
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Rear En\b Sheet \fetal Repairs - Quarter
Panel LH—VIN Plate Bo\by Style Co\be: SS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
1.
Replacement Parts \f

Q

u\brter\fp\bnel\f
1.

Gener\bl\fnotes\f
Necess\bry\fremov\bl\fwork:\fRe\br\fdoor,\f
we

\btherstrip,\fside\fwindow,\fre\br\fse\bt,\f
wheelhouse\ftrim\fp\bnel,\fre\br\fl\bmp,\fre\br\f
bumper,\fqu\brter\fp\bnel\ftrim.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f

Depending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fforced\f\bir\fextr\bction\fgusset\fshould\f\blso\f
be\frepl\bced.\f
2. NOTE:\fIf\fit\fis\f\blso\fnecess\bry\fto\finst\bll\f\b\fnew\f
in

ner\fqu\brter\fp\bnel\fwith\fwheelhouse\fduring\f
the\frep\birs,\fthen\fthe\fsep\br\bting\fcuts\fneed\fto\f
be\fm\bde\f\bs\fshown\fin\fthe\fdi\bgr\bm\f(E79835).\f
Sep\br\bting\fcuts\fon\fthe\fqu\brter\fp\bnel\f 1.
Upper\fC-pill\br\fsep\br\bting\fcut.\f
2. Re\br\frocker\fp\bnel\fsep\br\bting\fcut.\f
3. NOTE:\fThe\fspecified\fdimensions\fmust\fbe\f
m
e

t\fwhen\fm\bking\fthe\fsep\br\bting\fcuts.\f
Qu\brter\fp\bnel\f 1.
Cut\fpoints.\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f
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