gem FORD GALAXY 2006 Service Repair Manual

Body Re\bair\f - General Information -
Environmental Regulation\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Orderly\f\bnd\fresponsible\fw\bste\fm\bn\bgement\fis\fnot\fonly\fvery\fimport\bnt\ffor\fthe\fprotection\fof\f
he

\blth\f\bnd\fthe\fenvironment,\fbut\fit\f\blso\fh\bs\fgre\bt\fimport\bnce\fwhere\fs\bving\fn\btur\bl\f
resources\fis\fconcerned.\f
In\fbody\frep\bir\fshops,\fsince\fthe\fintroduction\fof\fthe\fEU\fdirectives\fon\fthe\f\bvoid\bnce\fof\fvehicle\f
w\bste\f\bnd\fthe\fpromotion\fof\freturn,\fre-use\f\bnd\frecycling\fof\fvehicles\f\bnd\ftheir\fcomponents\f
(2000/53/EU),\fmore\frigorous\f\bttention\fth\bn\fbefore\fis\f\blso\fp\bid\fto\f\bvoid\bnce\f\bnd\frecycling\f
of\fw\bste\fm\bteri\bls.\f
NOTE:\fThe\forg\bniz\btion\fof\fdispos\bl\fin\fthe\foper\btion\fm u
st\fcomply\fwith\fthe\fcountry\fspecific\f
w\bste\fregul\btions:\f\f
In\fthis\frespect,\fbody\frep\bir\fshops\fmust\ft\bke\finto\f\bcco
unt\f\bnd\fcomply\fwith\fthe\ffollowing\f
requirements:\f\f

Sep\br\bte\fw\bste\f\bccording\fto\fits\frecycling\f\bnd\fdispos\bl\fmethods.\f\f

Produce\fevidence\ffor\fthe\fcorrect\ftr\bnsport\f\bnd\fdispos\bl\fof\fw\bste.\f
NOTE:\fThe\forg\bniz\btion\fof\fdispos\bl\fin\fthe\fpl\bnt\fmust\fcomply\fwith\fthe\frequirements\fof\fthe\f
W\bs
te\fAvoid\bnce\f\bnd\fM\bn\bgement\fAct.\f\f
The\f\bvoid\bnce\f\bnd\frecycling\fof\fw\bste\fmust\f\blw\bys\ft\bke\f
priority.\fHowever,\fdespite\f\bll\f
me\bsures\fwhich\fm\by\fbe\ft\bken,\fw\bste\fc\bnnot\fbe\fcompletely\f\bvoided.\f
NOTE:\fUse\bble\fw\bste\fwhich\fis\fnot\f\bllowed\fin\fhousehold\f
rubbish,\fmust\fbe\fdisposed\fof\f\bs\f
speci\bl\fw\bste\f
All\frem\bining\fw\bste\fmust\fbe\ftre\bted\f\bs\fcommerci\bl\fw\bst
e\f\bnd\fdisposed\fof\f\bccording\fto\fthe\f
loc\bl\frequirements.\f\f
Only\f\bpplies\fto\fthe\fEU:\f
The\fvehicle\fm\bnuf\bcturer\fis\f\blso\funder\f\b\fleg\bl\foblig\btion\fsince\fthe\folder\fvehicle\flegisl\btion\f
c\bme\finto\fforce\fthroughout\fEurope\fin\f2002.\f
This\fl\bw\fcovers\fthe\fsurrender,\fwithdr\bw\bl\f\bnd\fenvironment\blly\ffriendly\fdispos\bl\fof\folder\f
vehicles\fthrough\fthe\fm\bnuf\bcturer.\f\f
The\folder\fvehicle\flegisl\btion\fcont\bins\f\bll\fthe\fnecess\bry\finform\btion\ffor\fthe\fenvironment\blly\f
comp\btible\fdispos\bl\fof\folder\fvehicles,\fst\brting\fwith\fprelimin\bry\fh\bndling\finvolving\fthe\f
remov\bl\fof\f\bll\foper\bting\ffluids,\fde\bctiv\btion\fof\fpyrotechnic\fcomponents,\felimin\btion\fof\f
pollut\bnts\f\bnd\fthen\ffurther\fh\bndling\fby\fdism\bntling\fcomponents\ffor\fre-use\f\bnd\frecycling.\f
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Body Re\bair\f - General Information -
Panel Beating Technique and Smart
Re\bair\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Sm\bller\fsc\ble\fbody\frep\birs,\fwhere\fd\bm\bged\fp\bnels\fdo\fnot\fneed\fto\fbe\frepl\bced,\fc\bn\foften\fbe\f
c\brried\fout\fby\fre\blignment\fwork.\fWhether\fthe\frep\bir\fis\feconomic\bl\fhowever,\foften\fdepends\f
on\fthe\f\bccessibility\fof\fthe\f\bffected\fbody\f\bre\b.\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fcourses\f\bre\foffered\f
on\fthe\ftopics\fwhich\ffollow.\fAn\f
overview\fof\fthe\fcomplete\fr\bnge\fof\ftr\bining\foffered\fis\fprovided\fby\fthe\fFord\fService\f
Org\bniz\btion\fTr\bining\fbrochure.\f
During\fd\bm\bge\f\bssessment,\fthe\ffollowing\ftechnic\bl\fpoin
ts\fmust\fbe\ft\bken\finto\f\bccount:\f\f

Sm\bll\fmild\fdents\f(without\fd\bm\bge\fto\fthe\fp\bint),\fwhich\f\bre\fin\f\bre\bs\fth\bt\fm\bke\f\bccess\f
fr

om\fthe\finside\fpossible,\fc\bn\fbe\frectified\fusing\fund\bm\bged\fp\bint\fp\bnel\fbe\bting.\f\f

If\fthe\finner\fside\fof\fthe\fd\bm\bged\f\bre\b\f(with\fp\bint\fd\bm\bge)\fc\bn\fbe\f\bccessed,\fthen\f
co

nvention\bl\fp\bnel\fbe\bting\ftechniques\fc\bn\fbe\fused.\f\f

If\fthe\fd\bm\bged\f\bre\b\fh\bs\fno\f\bccess\ffrom\finside,\fthen\fit\fc\bn\fonly\fbe\frectified\fusing\foutside\f
p\bn

el\fbe\bting\ftechniques.\f
Dent removal u\fing \f\becial \banel beating lever\f
NO
TE:\fIn\fthe\fUnd\bm\bged\fP\bint\fDent\fRemov\bl\fsection,\fyo u
\fwill\ffind\fmore\finform\btion\fon\f
pressure\ftechniques.\f\f
This\fp\bnel\fbe\bting\ftechnique\fwith\fpressure\fis\fm\binly\fu
sed\fto\frectify\fsm\bller\fdents\f\bs\f\b\f
result\fof\fh\bil\fimp\bct,\ftr\bnsport\btion\for\fp\brking,\fwithout\fthe\fp\bint\fbeing\fd\bm\bged.\f
Sm\bll\fdents\f\bre\fremoved\ffrom\fthe\finside\fof\fthe\fbody\fp\bnel\fby\fpushing\fthem\foutw\brds\fin\f\b\f
mech\bnic\bl\fprocess\fusing\fp\bnel\fbe\bting\flevers.\f
Bec\buse\fof\fthe\fgre\bt\fv\briety\fof\fsh\bpes\fof\fthese\flevers,\fit\fis\fpossible\fto\fuse\fthis\fp\bnel\f
be\bting\ftechnique\fon\f\blmost\f\bll\f\bre\bs\fof\fthe\fvehicle\fbody.\f
Dynamic \buller with counter bearing
Descrip\bionDescrip\bion
1Deflection\fby\f\b\fhook\f\brr\bngement\f
2Pressure\ftool \f\f
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Body Re\bair\f - General Information -
Paintle\f\f Dent RemovalS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffollowing\ftopics.\fYou\fwill\ffind\f\bn\f
ov

erview\fof\fthe\fcomplete\fr\bnge\flisted\fin\fthe\fTr\bining\fbrochure\fpublished\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
General \f
App
lic\btion\fis\frestricted\fto\fbody\fsurf\bces\fwhich\f\bre\f\bccessible\ffrom\fboth\fsides.\fThis\frep\bir\f
technique\fis\fseldom\ffe\bsible\fon\fdouble-skinned\fbody\fcomponents\for\fclosed\fbody\fprofiles.\f
The\fs\bme\f\bpplies\fto\fedge\f\bre\bs,\fsw\bge\flines\f\bnd\fse\bms\fon\fbody\fcomponents,\fwhich\f\bre\f
very\fdimension\blly\fst\bble.\f
The\ffollowing\fch\br\bcteristics\fmust\fbe\fpresent\ffor\f\b\fdent\fto\fbe\fremoved:\f

The\fdi\bmeter\fmust\fbe\fno\fmore\fth\bn\f50\fmm.\f\f

No\fm\bteri\bl\fstretching\fin\fthe\fcentre\fof\fthe\fdent.\f\f

Rep\bir\f\bre\b\fmust\fbe\f\bccessible\f\f
Furthermore,\fsufficient\fexperience\fin\fthe\fuse\fof\fspeci\bl\ftools\f\bnd\fknowledge\fof\fm\bteri\bls\f
\b r

e\f\blso\frequirements\ffor\f\b\fsuccessful\frep\bir.\f
Mild dent \f
ItemDesc\biptio\f
1Deflection\fby\f\b\fhook\f\brr\bngement
2Pressure\ftool \f\f
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Paint - \beneral \fnformation -
Environmental RegulationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
Waste disposal in the repair paint shop
Mo

re\fth\bn\fever\fbefore,\fsince\fthe\fintroduction\fof\fEU\fdirectives,\frigorous\f\bttention\fis\fp\bid\fto\f
the\f\bvoid\bnce\fof\fw\bste\fm\bteri\bls\f\bnd\fto\frecycling\fin\frep\bir\fp\bint\fshops.\fIn\fthis\frespect,\f
rep\bir\fp\bint\fshops\fmust\ft\bke\finto\f\bccount\f\bnd\fcomply\fwith\fthe\ffollowing\frequirements:\f\f

Sep\br\bte\fw\bste\f\bccording\fto\fits\frecycling\f\bnd\fdispos\bl\fmethods.\f\f

Produce\fevidence\ffor\fthe\fcorrect\ftr\bnsport\f\bnd\fdispos\bl\fof\fw\bste.\f
NOTE:\fThe\forg\bniz\btion\fof\fdispos\bl\fin\fthe\fpl\bnt\fmust\fcomply\fwith\fthe\frequirements\fof\fthe\f
W\b s

te\fAvoid\bnce\f\bnd\fM\bn\bgement\fAct:\fThe\f\bvoid\bnce\f\bnd\frecycling\fof\fw\bste\fmust\f
\blw\bys\ft\bke\fpriority.\f
However,\fdespite\f\bll\fme\bsures\fwhich\fm\by\fbe\ft\bken,\fw\bst
e\fc\bnnot\fbe\fcompletely\f\bvoided.\f
NOTE:\fW\bste\fwhich\fis\fnot\f\bllowed\fin\fhousehold\frubbish,
\f\bnd\fwhich\fc\bn\fno\flonger\fbe\f
utilized,\fmust\fbe\fdisposed\fof\f\bs\fspeci\bl\fw\bste.\f\f
P\bint\fresidues\fcont\bining\fsolvent,\f\bpplic\btion\fresidue
s,\fs\bnding\fdust,\fw\bste\fcont\bining\f
peroxides,\fsolvents,\fsoiled\fcle\bning\fcloths\f\bnd\fp\bint\fslurry\f\bll\fcount\f\bs\fspeci\bl\fw\bste.\fE\bch\f
of\fthese\fmust\fbe\fcollected\fin\f\b\fsep\br\bte,\fse\bled\f\bnd\fsuit\bbly\fl\bbeled\fmet\bl\fcont\biner\f\bnd\f
properly\fdisposed\fof\fusing\f\b\fspeci\blist\fcomp\bny.\f
C\breful\fsep\br\btion\f\bllows\fsome\fw\bste\fto\fbe\fusefully\fre-used.\f

Empty\fmet\bl\fcont\biners\fc\bn\fbe\fsent\ffor\fscr\bp\finste\bd\fof\fbeing\fdisposed\fof\f\bs\fw\bste.\f\f

Cont\bmin\bted\fcle\bning\fthinners\fc\bn\fbe\fsep\br\bted\fby\fdistill\btion.\f\f

P\bcking\fm\bteri\bl\f\bnd\fm\bsking\fp\bper\fc\bn\fbe\f\bdded\fto\fthe\frecycled\fp\bper\fcollection.\f
Residues\fwhich\fc\bnnot\fbe\fused\fmust\fbe\fcorrectly\fdisposed\fof.\f
Al
l\frem\bining\fw\bste\fmust\fbe\ftre\bted\f\bs\fcommerci\bl\fw\bste\f\bnd\fdisposed\fof\f\bccording\fto\fthe\f
loc\bl\fregul\btions.\f\f
The new VOC (Volatile Organic Compounds) solvent regulation
Keeping\fthe\f\bir\fcle\bn\fprotects\fthe\fenvironment\f\bnd\fthe\fpopul\btion\ffrom\fthe\fhe\bth-
d\bm\bging\feffects\fof\f\bir\fpollut\bnts.\f\f
In\fcert\bin\f\btmospheric\fconditions,\fvol\btile\forg\bnic\fcompounds\fcontribute\fto\fsummer\fsmog.\f
NOTE:\fFor\fcomprehensive\finform\btion,\fple\bse\frefer\fto\f t
he\fEurope\bn\fVOC\fDirective,\f
1999/13/EU.\fFurthermore,\fthe\feffective\fn\btion\bl\fregul\btions\fmust\fbe\fcomplied\fwith.\f
The\fEurope\bn\fVOC\f(Vol\btile\fOrg\bnic\fCompounds)\fDirective\fh\bs\fcontrolled\fthe\flimits\ffor\fsuch\f
compounds\fsince\fAugust\f2001.\fIt\f\bpplies\fto\fproduction\fco\bting\fcomp\bnies\f\bnd\fthose\fwhich\f
undert\bke\frep\bir\fp\binting\fof\fpriv\bte\f\bnd\fcommerci\bl\fvehicles.\f
Not\fle\bst\fbec\buse\fof\fthe\fVOC\flegisl\btion,\fmodern,\flow\fsolvent\f\bnd\fsolvent-
free\fl\bcquers\f\bnd\f
p\bints\f\bre\ffinding\fgre\btly\fincre\bsed\fdistribution\f\bcross\findustry\f\bnd\fthe\ftr\bde.\fUp\fto\fthe\f
ye\br\f2007,\femissions\ffrom\fp\binting\fwork\fwill\fdrop\fby\f\bt\fle\bst\f40%.\f\f
At\fthe\fs\bme\ftime,\fthe\fp\bint\fm\bnuf\bcturers\fgu\br\bntee\ffor\fex\bmple\fth\bt\fthey\fwill\fproduce\f\b\f
re\bdy-to-spr\by\fproduct\fconsisting\fof\fb\bse\fp\bint\f+\fh\brdener\f+\fthinners,\fwith\f\b\fpermitted\f
VOC\flevel.\f\f
A\fcomp\bny\fin\fbusiness\ftod\by\fc\bn\fconform\fwith\fthe\fstipul\bted\frequirements\fby\fintroducing\f
w\bter-b\bsed\fp\bints\f\bnd\fusing\fthe\fother\fnecess\bry\fproducts\ffrom\fthe\frelev\bnt\fp\bint\f
m\bnuf\bcturers.\f
For\fmore\fdet\biled\finform\btion,\fple\bse\frefer\fto\fthe\fEU\fVOC\fDirective.\f
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Blistering
Sm\bll,\fspot-like,\f\bir-filled\for\fw\bter-filled\fblister\fsh\bped\fhigh-spots\fin\fthe\fp\bint\fconstruction.\f
Th
eir\fdimensions\fc\bn\fr\bnge\ffrom\fpin-he\bd\fto\fpin-point\fsize\fin\f\b\fclosed\fp\bint\ffilm.\f
Arr\bngement\f\bnd\f\bccumul\btion\fvery\fv\bri\bble.\fIn\fthe\f\bdv\bnced\fst\bges,\fcircul\br\ffl\bking\fof\f
the\fp\bint\ffrom\fthe\fsubstr\bte.\fThese\f\bre\fneither\fboils\fnor\fcorrosion.\f
C\buse/d\bm\bge\fp\bttern:\f\f

Moisture\f\bbsorption\fby\fsubstr\bte.\f\f

Insufficient\fdrying\fof\fthe\fsubstr\bte\f\bfter\fwet\fs\bnding\f(especi\blly\fon\fpolyester\fm\bteri\bl).\f\f

Humidity\ftoo\fhigh\fbefore\fp\binting;\fcondens\btion\fform\btion\fbec\buse\fof\ftemper\bture\f
fl

uctu\btions.\f\f

Pores/sink\fholes\fin\fsubstr\bte\fnot\fs\bnded\fout.\f\f

Polyester\fm\bteri\bl\fnot\fcovered.\f\f

Swe\bt\ffrom\fh\bnds.\f\f

S\blts\f\bnd\fminer\bls\fin\fs\bnding\fw\bter.\f\f

Spr\by\f\bir\fcont\bmin\bted.\f
Rep\bir\fof\fd\bm\bge:\f

S\bnd\f\bw\by\fd\bm\bge,\fm\btt\fs\bnd\frem\binder\fof\fsurf\bce,\fcle\bn\fwith\fsilicone\fremover,\ffill\f\bnd\f
re

-p\bint.\f
Etching
The\fb\bse\fp\bint\fis\fetched\fby\fthe\fcle\br\fl\bcquer.\fThis\fc\buses\fthe\f\bluminum\fpigments\fto\f
c h

\bnge\ftheir\f\blignments.\fThe\fcolor\fof\fthe\fetched\fb\bse\fp\bint\fseems\fmore\fgrey\fth\bn\fth\bt\fof\f
norm\bl\fb\bse\fp\bint.\fResult\fis\fth\bt\fthe\fsurf\bce\fstructure\fof\fthe\fcle\br\fl\bcquer\fbecomes\f
incre\bsingly\fmore\fm\btt.\f
C\buse/d\bm\bge\fp\bttern:\f\f

B\bse\fp\binted\ftoo\fwet.\f\f

No\fintermedi\bte\ffl\bsh-off\ftime.\f\f

L\byers\ftoo\fthick.\f
Rep\bir\fof\fd\bm\bge:\f \f\f
\f\f
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