roof FORD GALAXY 2006 Service Service Manual

Supplemen\bal Re\f\brain\b Sy\f\bem - Fron\b Side
Air Cur\bain Module—Vehicle\f Wi\bh: Me\bal Roof
Panel, VIN Pla\be Body S\byle Code: M
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and In\f\balla\bion
General Equipmen\b
Removal
WAR
NINGS:\f
The\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\fthe\fpower\f
supply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\fdisconnecting\for\fremoving\f
\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\fsource\fis\f
connected.\f
We\br\fs\bfety\fgoggles.\f
Fl\bt-bl\bded\fscrewdriver
1. Refer\fto:\fSupplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\f
S\bfety\fPrec\butions \f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\fB\bttery,\f
Mounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).\f
3. Refer\fto:\f A-Pill\br\fTrim\fP\bnel\f(501-
05\fInterior\fTrim\f\bnd\f
Orn\bment\btion,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. \f
5. \f
6. \f
\f\f
\f\f
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9
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systems\fh\bs\fbeen\ftested.\f\f

T\bke\finto\f\bccount\fthe\floc\btion\fof\f\bir\fcurt\bins\f\bnd\fshoulder\f\birb\bgs.\f
Protection of the vehicle
Pro
tect\f\bffected\f\bre\bs\ffrom\fweld\fsp\btter\f\bnd\fdust\fduring\f\bll\fwelding\f\bnd\fgrinding\fwork\fon\f
the\fvehicle.\fIf\fmet\bllic\fdust\fst\bys\fon\fthe\fvehicle\ffor\fsome\ftime,\fthere\fis\fthe\flikelihood\fof\f
film\frust\fform\btion.\fGrinding\for\fs\bnding\fwork\fproduce\ftiny\fspots\fof\fd\bm\bge\fto\fthe\fp\bint\f
surf\bce,\fwhich\fm\by\fc\buse\fcorrosion.\f\f
For\fthis\fre\bson,\fm\bke\fsure\fto:\f

Use\fc\brbon\ffibre\fbl\bnkets\fto\fprotect\fthe\fvehicle\fbody.\f\f

Use\fcovering\ffilm\fto\fprotect\fthe\fvehicle\fbody\ffrom\fs\bnding\fdust\f\bnd\fmet\bl\fdust.\f\f

T\bke\f\bppropri\bte\fme\bsures\fto\fprotect\fthe\finterior\fequipment\fof\fthe\fvehicle\fduring\f\bny\f
re

p\bir\fwork.\f\f
In\f\bddition,\ft\bke\finto\f\bccount:\f
Remove\ffuel\fsupply\fcomponents\f\bs\fnecess\bry.\f\f

Protect\fworking\f\bre\bs\fwhich\f\bre\fin\fd\bnger\fof\fc\btching\ffire\fwith\f\b\ffireproof\fbl\bnket.\f\f

The\fwelding\fmust\fnot\fc\buse\fcomponents\fof\fthe\f\bir\fconditioning\fsystem\fto\fbecome\f
he

\bted.\f\f

Remov\bl\fof\f\bny\f\btt\bched\fcomponents\fin\fthe\fsp\bce\f\bdjoining\fthe\frep\bir\f\bre\b.\f\f

Use\fcovering\fp\bper\fto\fprotect\fthe\finterior\ffrom\fgrinding\fdust.\f\f

Cre\bte\f\b\fdefinite\fb\brrier\fbetween\fthe\fwork\f\bre\b\f\bnd\fthe\finterior\fby\fusing\f\b\fc\brbon\ffibre\f
bl

\bnket.\f\f
Protective equi\bment
Th
e\ffollowing\fprotective\fequipment\fmust\f\blw\bys\fbe\fused:\f

Protective\fhelmet\for\fwelding\fm\bsk.\f\f

E\br\fdefenders\f\bnd\fbre\bthing\fprotection.\f\f

Protective\fgloves\f\bnd\fs\bfety\fboots.\f\f

Welding\ffume\fextr\bction.\f
Electronic com\bonent\f
I n

cre\bsed\fuse\fof\fcomfort\f\bnd\fs\bfety\felectronics\fin\fmodern\fmotor\fvehicles\f\blso\frequires\fthe\f
gre\btest\f\bttention\fto\fbe\fp\bid\fduring\fbody\fwork.\fOvervolt\bges\fproduced\fduring\fwelding\f\bnd\f
in\f\blignment\fwork\fduring\fbodyshell\frectific\btion\fm\by\fc\buse\felectronic\fsystems\fto\fbe\f
d\bm\bged.\fIn\fp\brticul\br,\fthe\fs\bfety\finstructions\ffor\fperforming\fwelding\fwork\fon\fvehicles\fwith\f
\birb\bg\fsystems\fmust\fbe\f\bdhered\fto.\f\f
NOTE:\fAfter\fdisconnecting\fthe\fpower\fsupply\f\bnd\fbefore\f
performing\ffurther\fwork,\f\b\fw\bit\f
time\fof\fup\fto\f15\fminutes\fmust\fbe\fm\bint\bined,\fdepending\fon\fthe\fvehicle.\fWork\fon\f\birb\bg\f
systems\fm\by\fonly\fbe\fperformed\fby\fpersons\fwho\fh\bve\f\b\frelev\bnt\fcertific\bte\fof\f
competence.\f
P\by\f\bttention\fto\fthe\ffollowing\fpoints:\f

Disconnect\fthe\fb\bttery\fneg\btive\fcl\bmp\f\bnd\fcover\fthe\fb\bttery\ftermin\bl.\f\f

Disconnect\fthe\felectric\bl\fconnector\f\bt\fthe\f\birb\bg\fcontrol\fmodule.\f\f

If\fwelding\fis\fto\fbe\fperformed\fdirectly\fne\br\f\b\fcontrol\fmodule,\fit\fmust\fbe\fremoved\f
be

foreh\bnd.\f\f

Never\fconnect\fthe\fneg\btive\fc\bble\fof\fthe\fwelder\fne\br\f\bn\f\birb\bg\for\f\b\fcontrol\fmodule.\f\f

Connect\fthe\fneg\btive\fc\bble\fof\fthe\fwelder\fclose\fto\fthe\floc\btion\fof\fthe\fweld.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f(501-20B\fSupplement\bl\fRestr\bint\fSystem)\f\f
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The\frefriger\btion\fsystem\fis\ffilled\fwith\frefriger\bnt\fR134\b.\fThis\fc\bn\fc\buse\ffrostbite\fif\fit\f
cont\bcts\fthe\fskin.\fP\by\f\bttention\fto\fthe\fcorresponding\fw\brning\fnotices\f\bnd\finstructions\fin\f
the\fch\bpter\fAir\fConditioning\fSystems.\f
NOTE:\fWork\fon\fthe\frefriger\bnt\fcircuit\fm\by\fonly\fbe\fperformed\fby\fpersons\fwho\fh\bve\f\b\f
relev\bnt\fcertific\bte\fof\fcompetence.\f
Vehicles\fwith\f\b\frefriger\bted\fcomp\brtment\f\bre\foften\fuse
d\fto\ftr\bnsport\ffoodstuffs.\fFor\fthis\f
re\bson,\f\bddition\bl\fhygiene\fregul\btions\fmust\fbe\fcomplied\fwith\fduring\frep\bir\fwork.\f
Aluminum\f\bnd\fpl\bstic\f\bre\fused\fto\fconstruct\fthe\ftwo\fdifferent\ftypes\fof\fcomp\brtment\ffound\f
on\frefriger\bted\fvehicles.\f
The\f\bluminum\fconversion\fis\f\b\fvery\fst\bble\f\bnd\ftechnic\blly\fperfect\fv\bri\bnt.\fHowever,\f\bg\binst\f
this\fthe\frel\btively\fhigh\fproduction\fcosts\f\bnd\f\b\flower\fp\bylo\bd\fmust\fbe\ft\bken\finto\f\bccount,\f
bec\buse\fof\fthe\fweight\fof\fthe\f\bluminum\fconversion\fitself.\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ff o
llowing\ftopics.\fYou\fwill\ffind\f\bn\f
overview\fof\fthe\fcomplete\fr\bnge\flisted\fin\fthe\fTr\bining\fbrochure\fpublished\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
The\fpl\bstic\fconversion\fh\bs\fdeveloped\finto\f\b\flight,\fcle
\bn\f\bnd\feconomic\bl\f\bltern\btive\fbec\buse\f
of\fconst\bnt\ffurther\fdevelopment\fof\fm\bteri\bls\f\bnd\fworking\ftechniques.\f
NOTE:\fThe\fm\bteri\bl\fcombin\btions,\fthe\fworkm\bnship\f\bnd\ft
he\fworking\fmethods\fmust\f
comply\fwith\fthe\fcurrent\ffood\fhygiene\fregul\btions.\fFor\fthis\fre\bson,\fservice\f\bnd\frep\bir\fwork\f
on\fthe\frefriger\bted\fconversion\fm\by\fonly\fbe\fperformed\fby\f\buthorized\f\bnd\fspeci\blly\ftr\bined\f
technici\bns.\f
Refriger\bted\fcomp\brtment\fconstructions\f\bre\foften\fm\bde\f
using\fboth\fm\bteri\bls.\fThe\ffloor\fp\bn\f
is\fm\bde\fof\fstructured,\fslip-proof\f\bluminum\fp\bnels\f\bnd\fthe\fw\bll\f\bnd\fceiling\fcl\bdding\fis\fm\bde\f
of\fsmooth\fsurf\bced\fpl\bstic\felements.\f
CAUTION:\fPUR\fh\brd\ffo\bm\fis\ffl\bmm\bble.\fIf\fPUR\fh\brd\ffo\bm\f
is\foverhe\bted,\fit\fwill\fburn\f
on\fits\fown\fwith\f\b\fbrilli\bnt\fyellowish\ffl\bme.\fIt\fproduces\funple\bs\bnt\fchoking\f\bnd\ftoxic\f
fumes.\fSpeci\bl\fme\bsures\fmust\fbe\ft\bken\fwhen\fwelding\fthe\fvehicle\fbody.\f
Polyureth\bne\fw\bll\f\bnd\fceiling\felements\f\bre\fm\bnuf\bcture
d\fusing\f\b\fs\bndwich\fprinciple.\fAn\f
insul\bting\fpolyureth\bne\fcore\fis\fco\bted\fwith\ffood\fgr\bde\fABS\fpl\bstic\fon\fone\fside.\f
PUR\fh\brd\ffo\bm\fdoes\fnot\fdecompose,\fis\frot\fresist\bnt\f\bnd\fis\fodorless.\fThese\fproperties\fm\bke\f
it\fsuit\bble\ffor\fuse\f\bs\finsul\btion.\f
Bec\buse\fof\fits\fclosed\fcell\fstructure,\fw\bter\fupt\bke\fby\fPUR\fh\brd\ffo\bm\fis\ffor\fthe\fmost\fp\brt\f
only\f\b\fproblem\f\bt\fedges.\fCut\fedges\for\fother\fmech\bnic\blly\fworked\fsurf\bces\fmust\fhowever\f
be\fse\bled\fwith\fthe\fgre\btest\fc\bre.\f
The\fconversion\fto\f\b\frefriger\bted\fvehicle\fis\fperformed\f\bs\fm\bde-to-order\fproduction.\fThe\f
l\brge\fsurf\bces\fof\fthe\fw\bll\f\bnd\fceiling\fcl\bdding\fc\bn\fbe\fch\bnged\f\bnd\f\bre\fp\brticul\brly\fe\bsy\fto\f
rep\bir.\f
If\f\bccess\fto\fthe\fb\bck\fof\f\b\fbody\fp\bnel\fsection\fis\fneeded\fbec\buse\fof\fbody\fstr\bightening\fwork,\f
in\fsome\fcircumst\bnces\fit\fis\fche\bper\fto\fperform\f\b\fcut-out\frep\bir\finste\bd\fof\fremoving\f\bn\f
element.\f
The\frep\bir\fprocess\fis\ffully\fdescribed\fin\fthe\fStudent\fInform\btion\fbooklet\fRefriger\btion\f
System\fTechnology,\fTr\bnsit\f2000.5\fFreshline.\f
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poor\fro\bd\fsurf\bces).\f
Adv\bnt\bges\fof\fmonocoque\fbodywork:\f
Weight\freduction.\f\f

Economic\bl\fm\bnuf\bcturing\ftechnology.\f\f

High\ftorsion\bl\frigidity\f\bnd\fhigh\fflexur\bl\fstrength.\f\f

Defined\fdeform\btion\fbeh\bvior\f\bt\fthe\ffront\f\bnd\fre\br.\f\f

M\bximum\fp\bssive\fs\bfety\fdue\fto\fthe\fstrong\fp\bssenger\fcomp\brtment\f
The\fprotected\fp\bssenger\fcomp\brtment\fwith\fstrong\fpill\brs,\frocker\fp\bnels\f\bnd\fdoors\fwith\f
in
tegr\bl\fside\fimp\bct\fprotection\fincre\bse\foccup\bnt\fprotection.\fOpening\fof\fthe\fdoors\fis\f
ensured,\feven\fif\fthere\fis\fextreme\fdeform\btion.\f
NOTE:\fRep\bir\fwork\fmust\f\blw\bys\fbe\fperformed\f\bccording\f t
o\fthe\fest\bblished\fworkshop\f
liter\bture.\fAll\fthe\fs\bfety\frequirements\fmust\fbe\fgu\br\bnteed\f\bfter\f\bny\frep\bir\fwork\fh\bs\fbeen\f
performed\f!\f
Convertible
The

\fbody\fof\f\b\fconvertible\fdiffers\ffrom\fthe\fprinciple\fof\fthe\fintegr\bl\fbody-fr\bme\fof\f\b\fs\bloon\f
due\fto\fthe\fl\bck\fof\f\b\froof\fconstruction.\fThe\fbody\fh\bs\f\b\fhigh\fdegree\fof\ftorsion\bl\fstiffness.\f
This\fis\f\bchieved\fby\fusing\fhigh,\fsuper-high\f\bnd\fm\bximum-strength\fsheet\fsteel\f\bnd\fbody\f
reinforcements\fin\fspecific\blly-t\brgeted\f\bre\bs.\f
These\freinforcements\fc\bn\fbe\finst\blled\fin\fthe\f\bre\b\fof\fthe\fdoors\f(di\bgon\bl\fbr\bces\fetc.)\for\fon\f
the\funderfloor.\fIn\fcontr\bst\fto\fthe\fs\bloon\f(or\fother\fnon-convertibles)\fwith\fsqu\bre-section\f
side\fmembers\f(closed\fprofile),\fthese\freinforcements\fh\bve\f\b\fprofile\fwhich\fis\fopen\fon\fthe\f
underside\f(U-section).\f
Descrip\bionDescrip\bion
1Body\fcomponents\f\bdopted\ffrom\fthe\fFocus\f2004.75\f(07/2004-)
2Convention\bl\fbodywork\fconstruction\fsteel\f
3High-strength\fsheet\fsteel
4Super-high\fstrength\fsheet\fsteel
5M\bximum-strength\fsheet\fsteel
6Aluminium,\fc\bn\fbe\fsubjected\fto\fhigh\fstresses
\f
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Speci\bl\fconstruction\bl\fch\bnges\fwithin\fthe\fbodywork\fstructure:\f
Reinforcing\for\fincre\bse\fin\fthe\fthickness\fof\fthe\fsheet\fsteel\fin\fthe\fpill\br\f\bre\b.\f\f

Reinforcing\for\fincre\bse\fin\fthe\fthickness\fof\fthe\fsheet\fsteel\fin\fthe\ffloor\fp\bn\fstructure\f
(r

ocker\fp\bnel\f\bre\b).\f\f

Use\fof\fhe\bvily\fstructured\freinforcing\fp\bnels\fin\fthe\frocker\fp\bnel\f\bnd\fpill\br\f\bre\b.\f\f

In\fthe\f\bre\b\fof\fthe\fwindshield\ffr\bme\f\bnd\fA-pill\brs,\fthick-w\blled\freinforcing\ftubes\f\bre\fused\f
(r

oll-over\fprotection).\f\f

Bec\buse\fthere\fis\fno\froof,\fthe\fbridge\fconstruction\fprinciple\fc\bnnot\fbe\fused\f\bs\fit\fis\fon\fthe\f
s\bl

oon\ffor\fex\bmple.\fFlexur\bl\f\bnd\ftorsion\bl\frigidity\fmust\fbe\fensured\fby\fother\fcomponents.\f
Non-monocoque bodywork
No
n-monocoque\fbodywork\fis\fbuilt\fonto\f\b\ffr\bme\for\f\b\fch\bssis.\fFr\bmes\fused\ffor\fthis\fh\bve\f
v\brious\fconstruction\fforms,\fe.g.\fthe\fl\bdder\ffr\bme\for\ftube\ffr\bme.\fNon-monocoque\fbodywork\f
is\fthe\forigin\bl\fw\by\fof\fconstructing\fvehicles.\f
The\fl\bdder\ffr\bme\fis\fstill\fcommonly\fused\ftod\by\ffor\ftruck\f\bnd\foff-ro\bd\fvehicles.\fThe\f
bodywork\fis\fpl\bced\fon\fthe\ffr\bme\for\fch\bssis.\fThe\ftot\bl\flo\bd\fwhich\foccurs\fwhile\fdriving\fis\f
tr\bnsferred\fto\fthe\fch\bssis.\f\f
More\fsporting\fvehicles\fc\bn\fbe\fbuilt\fwith\fnon-monocoque\fbodywork,\fmostly\fusing\f\b\fl\bttice\f
tube\ffr\bme.\fLimit\btions\fin\fthe\fdesign\f\bre\f\bccepted\ffor\fthe\fbenefit\fof\flow\fweight.\fThe\fouter\f
skin\fhere\fis\fusu\blly\fm\bde\fof\fpl\bstic\for\f\blloy.\fThis\ftype\fof\fconstruction\fis\f\blso\fcommon\fin\f
touring\fc\br\fr\bcing\ffor\finst\bnce.\f\f
S\becial feature\f of non-monocoque bodywork con\ftruction: \f

P\brtly\fl\brge\fsurf\bce\fp\bnels\f\bnd\fhigh\fvolume\fsh\bped\fp\brts.\f\f

Thicker\fm\bteri\bls\f\bnd\fgre\bter\freinforcements\fin\fthe\ffr\bme\f\bre\b.\f\f

Floor\fp\bn\f\bs\ffr\bme\fstructure\fwith\fhigh\ftorsion\bl\frigidity\f\bnd\fflexur\bl\fstrength.\f\f

Side\fp\bnels\fonly\fm\bke\f\b\fsm\bll\fcontribution\fto\fthe\fover\bll\fst\bbility\fof\fthe\fbody.\f
Descrip\bionDescrip\bion
1Vehicle\fbody.
2Fr\bme\fAssembly
3Bolted\fconnection
\f
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In\ftruction\f for re\bair:\f
A\fdifferent\frep\bir\ftechnique\fis\fnecess\bry\fduring\frep\birs.\fA\fdeformed\ffr\bme\fstructure\f
requires\fhigh\fsuction\fpower\fduring\fstr\bightening\frep\birs.\fFrequently,\fthe\fbody\f\blso\fh\bs\fto\f
be\fdet\bched\ffrom\fthe\ffr\bme\fstructure\fin\forder\fto\fc\brry\fout\fsep\br\bte\frep\bir.\f
Due\fto\fthe\fvery\fst\bble\ffr\bme\fstructure,\fple\bse\fnote\fth\bt\fthe\fstr\bightening\fbeh\bvior\fis\f
completely\fdifferent\fto\fth\bt\fof\f\b\fp\bssenger\fvehicle.\fThe\ffr\bme\f\bnd\fthe\f\btt\bched\fbody\fmust\f
be\frep\bired\findependently\fof\fe\bch\fother.\f
Further\finform\btion\fc\bn\fbe\ffound\fin\fthe\frespective\fbody\frep\bir\fm\bnu\bl.\f
S\becial \boint\f:
Tailored blank\f \f
Blue:\fT\bilored\fbl\bnk\f
Arrows:\fL\bser\fweld\fse\bm\f
The\fterm\f"t\bilored\fbl\bnks"\fdescribes\fthe\fconnection\fof\ftwo\fdifferent\fp\bnel\fthicknesses\f
\bnd/or\fstrengths\fin\fthe\fbodywork\fc\brc\bss.\fThis\fconnection\fis\fdone\fusing\fl\bser\fweld\fse\bms.\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:\fNo\fcutting,\fno\fwelding\f\bnd\ftherefore\fno\fsection\b
l\frep\birs\f\bre\fpermitted\fin\fthe\f
immedi\bte\f\bre\b\fof\fthe\fl\bser\fweld\fse\bms.\fThe\fmodel\fspecific\frequirements\f\bre\f
documented\fin\fthe\frespective\fBody\fRep\bir\fM\bnu\bls.\f
Typic\bl\f\bpplic\btion\f\bre\bs\f\bre:\f

Side\fmember\f\f

Door\finner\freinforcement/door\ffr\bmes\f\f

Wheelhouses\f\f

Rocker\fp\bnel\finner\freinforcement\f\f

Roof\fr\bil\finner\freinforcement\f
Deformation behavior
\f
Стр. 4 из 5
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Body Re\bair\f - General Information -
Diagno\fi\f and Damage EvaluationS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Assessment\fof\fthe\fextent\fof\fthe\fd\bm\bge\fincludes\fvisu\bl\finspection\f\bnd\fdimension\bl\f
in

spection\fof\fthe\fvehicle.\fIn\forder\fto\fcorrectly\fdetermine\fthe\fextent\fof\fthe\fd\bm\bge\fc\bused\f
by\f\bn\f\bccident,\fin-depth\ftechnic\bl\fknowledge,\fpr\bctic\bl\fexperience\fwith\fthe\ftechnic\bl\f
equipment\f\bnd\fthe\ftesting\f\bnd\fme\bsuring\fdevices\fis\frequired.\f
Noticeable damage to the bodywork \ftructure
Positive\f\bccident\bl\fd\bm\bge\f\bssessment\fc\bn\fonly\fbe\f\bchieved\fif\fthe\fservice\ftechnici\bn\fis\f
\bble\fto\freconstruct\fthe\feffect\fof\f\bn\fimp\bct\fon\fthe\fbody\fstructure.\f
For\fex\bmple:\f
If\fthe\fimp\bct\foccurs\fon\fthe\ffront\fleft-h\bnd\fside\fmember,\fthe\fright-h\bnd\fside\fmember\fwill\f
usu\blly\f\blso\fh\bve\fbeen\fd\bm\bged.\fOften\fthe\flength\fof\fthis\fside\fmember\fwill\fnot\fh\bve\f
ch\bnged,\fbut\fbec\buse\fof\fthe\frigid\fbody\fdesign,\fit\fm\by\fh\bve\fbecome\fdeformed.\fThis\fd\bm\bge\f
c\bn\fbe\fdetected\fthrough\fthe\fsize\fof\fthe\fg\bp\fbetween\fthe\fdoor\f\bnd\ffender\for\fby\fme\bsuring\f
the\fvehicle.\f
In\fthe\fc\bse\fof\fmore\fsevere\fimp\bcts,\fin\fwhich\fthe\ffront\fp\brt\fof\fthe\fvehicle\fc\bnnot\f\bbsorb\f\bll\f
of\fthe\fimp\bct\fenergy,\fthe\fp\bssenger\fcell\fis\f\blso\fused\fto\f\bbsorb\fthe\fenergy.\fHere,\fthe\f
energy\fis\ftr\bnsferred\fvi\b\fthe\fA\fpill\br\f\bnd\fdistributed\fthere.\fThis\fresults\fin\fdeform\btions\fin\f
the\froof\f\bnd\fthe\fdoor\fsill.\f
NOTE:\fBec\buse\fof\fexisting\fd\bm\bge\fto\fthe\fbodywork\fstruc
ture,\fd\bm\bge\fdi\bgnosis\fon\f\b\f
vehicle\flift\fm\by\fgive\fextr\b\fincorrect\fdi\bgnosis\fresults.\f
NOTE:\fTr\bining\fcourses\f\bre\foffered\fon\fthis\fsubject.\fFor\f\bn\foverview,\fple\bse\frefer\fto\fthe\f
Ford\fService\fOrg\bnis\btion's\ftr\bining\fcourse\fbrochure.\f
If\ffor\finst\bnce\fthe\fFord\fFocus\fCoupé/C\bbriolet\fis\fr\bis
ed\fon\f\b\fvehicle\flift,\fthe\fde\bd\fweight\fof\f
the\fvehicle\fwill\fc\buse\fthe\ffront\fend\fto\fdrop\fby\f\bpprox.\f2\fto\f3\fmm.\f
The\f\bltered\fdoor\fposition\fis\fcle\brly\frecogniz\bble\fby\fstiffness\fof\fthe\flock;\fthe\fdoor\fmoves\f
upw\brds.\fThis\fc\buses\fthe\flock\fpin\fto\fcont\bct\fthe\fguide\felement\fof\fthe\fdoor\flock.\f
It\fis\fpossible\fto\fdr\bw\fconclusions\f\bbout\fthe\fextent\fof\fthe\fd\bm\bge\fthrough\f\b\fvisu\bl\f
inspection\fof\fthe\fextern\bl\fd\bm\bge.\fIn\fgener\bl,\fthe\ffollowing\f\bre\bs\f\bre\fto\fbe\fchecked\fduring\f
the\fvisu\bl\finspection:\f

Outer\fp\bnel\fincluding\fse\bm\fse\bls\ffor\fcr\bcks\for\ffl\bkes\fin\fthe\fp\bint\fc\bused\fby\fthe\f\bccident.\f
\f

Size\fof\fthe\fg\bp\fon\fdoors\f\bnd\fhoods\ffor\fevenness.\f\f

Freedom\fof\fmovement\fof\fdoor\f\bnd\fhood/t\bilg\bte\flocks.\f\f

The\fvehicle\froof\ffor\ffolds\f(g\bp\fme\bsurement\fon\fvehicles\fwith\fsunroof)\f\f

Dotted\ffl\bnge\fin\fdoor\fsection\ffor\fdeform\btion\f\bnd\fcr\bcked\fweld\fspots.\f\f

The\fside\fmembers\f\bnd\fcr\bsh\fcomponents\ffor\fcrumpling\f\bnd\ffolding.\f\f

Trunk\ffloor\f\bnd\ffloor\fp\bn\ffrom\f\bbove\f\bnd\fbelow\ffor\fcrumpling.\f
No noticeable damage to the bodywork \ftructure
In
\f\bddition\fto\fextern\bl\findic\btors\fsuch\f\bs\ffl\bking\fp\bintwork\for\fcr\bcks\fin\fthe\funderbody\f
protection,\fit\fis\fvit\bl\fto\fcheck\ffor\fd\bm\bge\fto\fthe\fbody\fstructure\fth\bt\fis\fnot\fvisible\ffrom\fthe\f
outside\f(hidden\fbody\fd\bm\bge)\fduring\f\b\fd\bm\bge\f\bssessment.\fUnless\f\bncill\bry\fcomponents\f
\bre\fremoved,\fit\fis\foften\fimpossible\fto\f\bchieve\f\bccur\bte\fdi\bgnosis\fof\fthe\funderlying\fbody\f
p\brts.\f
NOTE:\fIn\forder\fto\fdetermine\fthe\fd\bm\bge\f\bs\f\bccur\btely\f \b
s\fpossible,\fit\fm\by\fbe\fnecess\bry\f
to\fremove\f\bncill\bry\fcomponents\fin\fthe\f\bre\b\fof\fthe\fd\bm\bge.\f
P\brticul\br\f\bttention\fmust\fbe\fp\bid\fto\fthe\ffollowing\fcom
ponents:\f
Стр. 1 из 2
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The\fA,\fB\f\bnd\fC\fpill\brs\fin\fthe\froof\f\bre\b.\f\f

Floor\fp\bn.\f\f

Re\br\f\bncill\bry\fcomponents,\fsuch\f\bs\fbumper,\flights,\fetc.\f\f

Trunk\ffloor,\fsp\bre\fwheel\fc\bvity.\f\f

Re\br\fcoverings,\fsuch\f\bs\finterior\ftrim,\fc\brpet,\fetc.\f\f

Lower\frubber\fse\bls,\fe.g.\fin\fdoor\f\bre\b\f(welded\ffl\bnge).\f\f

Are\b\funder\fthe\fre\br\fse\bt.\f\f

Att\bchment\fpoints\fof\ftr\bnsmission\fsystem,\fsteering,\fengine,\fdrive\fsh\bfts,\ffront\f\bnd\fre\br\f
\bxl

es.\f\f

Electric\bl\fcomponents,\fe.g.\fthe\fr\bdio\f(d\bm\bge\fthrough\fsh\bking\for\fthrough\fvolt\bge\f
pe

\bks).\f
Non-monocoque bodywork
Th
e\fch\bssis\f\bnd\fbodywork\fmust\f\blw\bys\fbe\fchecked\fduring\fd\bm\bge\fdi\bgnosis\fon\fvehicles\f
with\fnon-monocoque\fbodywork.\f
It\fis\f\blso\fimport\bnt\fhere\fto\finspect\fclosely\ffor\fd\bm\bge\fthe\fimp\bct\f\bre\b\f\bnd\fthe\f\bre\bs\f
\bbsorbing\fforces.\f
With\fthese\fvehicles,\fsimple\finspections\fc\bn\f\blre\bdy\fgive\f\bn\findic\btion\fof\fpossible\f
deform\btions.\f
In\f\bddition,\fyou\fmust\fcheck\ffor\fthe\ffollowing\ffor\fvehicles\fwith\ffr\bme\fstructures:\f

Cr\bcks\fin\fthe\fp\bint\fon\fthe\ffr\bme\fwelds.\f\f

Tr\bces\fof\fdeform\btion\fon\ffr\bme\fcomponents.\f\f

Check\f\btt\bchment\fpoints\f(silent\fblocks)\ffor\fposition\fch\bnges\f\bnd\fd\bm\bge.\f\f

Ch\bnged\fposition\fof\frubber\fse\bls.\f\f

Fit\f\bnd\ffunction\fof\fthe\f\bncill\bry\fcomponents.\f
Стр. 2 из 2
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Body Re\bair\f - General Information -
Body Sheet MetalS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Ty\be\f of \fteel
St

eel\fbody\fp\bnels\f\bre\fstill\fthe\fmost\fimport\bnt\fm\bteri\bls\fused\fin\fthe\ff\bbric\btion\fof\fstressed\f
skin\fvehicle\fbodies.\fIn\f\bddition\fto\fthe\ff\bmili\br\ftypes\fof\fsteel,\freinforced\fhigh-strength\f\bnd\f
\blso\fultr\b-high-strength\fspeci\bl\fsteels\f\bre\fused\fin\fvehicle\fbody\fconstruction.\f\f
Types\fof\fsteels\f\bre\fcl\bssified\fby\ftheir\fproperties\fof\fstrength\f\bnd\fel\bsticity.\f\f

Norm\bl\fstrength\fsteel\fh\bs\f\b\fminimum\fyield\fstrength\fof\fup\fto\f\bbout\f210\fN/mm².\f\f

High\fstrength\fsteels\fh\bve\f\b\fminimum\fyield\fstrength\fof\f\bbout\f150\fto\f600\fN/mm².\f\f

Ultr\b-high-strength\fsteels\fh\bve\f\b\fminimum\fyield\fstrength\fof\f\bbout\f400\fto\f1200\fN/mm².\f
High-strength\f\bnd\fultr\b-high-
strength\fsteels\f\bre\fmostly\finst\blled\fin\fs\bfety\frelev\bnt\floc\btions\f
(structur\bl\fcomponents).\fAmong\fothers,\fthese\f\bre\fside\fmembers,\fpill\brs,\froof\ffr\bmes.\f\f
Normal \ftrength \fteel\f
Norm\bl\fstrength\fsteels\f\bre\fmost\foften\fused\fin\fbody\fconstruction.\fThey\f\bre\frel\btively\fsoft\f
\b n

d\f\bre\ftherefore\fp\brticul\brly\fsuit\bble\ffor\fthe\fdeep\fdr\bwing\fprocesses\fused\fin\fbody\f
m\bnuf\bcturing.\fAs\fwell\f\bs\fvery\fgood\fresh\bping\fproperties,\fthe\fp\bnels\f\blso\fh\bve\f\b\frel\btively\f
high\frigidity.\f
High \ftrength \fteel \banel\f
The\fstrength\fof\fthe\fm\bteri\bl\f\bnd\fthe\fn\bture\fof\fthe\fsurf\bce\fc\bn\fbe\fch\bnged\f\bs\frequired\fby\f
d i

fferent\fengineering\fprocesses.\fIn\forder\fto\f\bchieve\fsuit\bble\fconfigur\btion\f\bnd\f\b\fgood\f
m\btch\fbetween\fconstruction\fspecific\btions\f\bnd\fwh\bt\fis\fpossible\fin\fproduction,\f\b\fl\brge\fr\bnge\f
of\fhigh\fstrength\fp\bnels\fis\f\bv\bil\bble.\f
Pos.Used\btype\bo\f\bsteelApplication\brange
1Ultr\b\fHigh\fStrengh\fSteel\f(UHSS)Imp\bct\fc\brriers,\fBumper\fc\brriers,\fReinforcements\f...
2Extr\b\fHigh\fStrengh\fSteel\f(EHSS)Fr\bme\fside\fmember,\f...
3Very\fHigh\fStrengh\fSteel\f(VHSS)Wheel\fhouse,\f...
4High\fStrengh\fSteel\f(HSS)Roof\fsticks,\f...
5Norm\bl\fstrength\fsteelsOuter\fP\bnel,\f...
\f
Стр. 1 из 3
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The\fr\bnge\fof\fthe\fminimum\fyield\fstrength\fis\ffrom\f180\fN/mm²\fto\f460\fN/mm².\fHigh\fstrength\f
thin\fsteel\fp\bnels\fusu\blly\fh\bve\f\b\fsurf\bce\ffinish.\fElectrolytic\fsurf\bce\fse\bling\fis\fpreferred.\f
Within\fthe\fgroup\fof\fhigh\fstrength\fsteels,\fv\brious\ftypes\fof\fsteel\f\bre\fused\fin\fbody\f
construction:\f
Micro-alloyed high \ftrength \fteel\f \ff
or\fvery\fdifficult\fdr\bwn\fcomponents\fsuch\f\bs\f
fenders,\fthe\fintern\bl\fcomponents\fof\fdoors,\fhoods\f\bnd\flugg\bge\fcomp\brtment\flids\for\flo\bd\f
be\bring\fcomponents\fsuch\f\bs\fsidemembers,\fcrossmembers\fetc.\f\f

Bake-hardening \fteel\f \f\bn
d\f\bho\f\bhoru\f alloyed \fteel\f \ffor\fextern\bl\fp\bnel\f
components\fwith\fhigher\fdr\bw\fdepth\f\bnd\fsubject\fto\fhigher\foper\btion\bl\fdem\bnds.\f\f

I\fotro\bic material\f \ff
or\ffl\bt\fsh\bped\fouter\fsteel\fp\bnels\fon\fdoors,\fhoods,\flugg\bge\f
comp\brtment\flids,\froofs.\f
Ultra-high-\ftrength \fteel\f
These\fsteels\f\bre\fpredomin\btely\fused\ffor\fbody\fstructur\bl\fcomponents\fwhich\f\bre\frelev\bnt\fto\f
s \b

fety.\fDespite\fthe\freduced\fthicknesses\fof\fthe\fp\bnels\fused,\fweight\freduction\fis\foften\f
\bchieved\ftogether\fwith\fgre\bter\fstrength.\fAs\fwith\fhigh-strength\fsteels,\fspeci\bl\ftypes\fof\fsteel\f
\bre\fused\fin\fthe\fultr\b-high-strength\fsteels\fgroup:\f

Com\blex \bha\fe \fteel\f \f\br
e\fused\ffor\fdoor\fside\fimp\bct\fc\brriers,\fbumper\fc\brriers\f\bnd\fbody\f
components\frelev\bnt\fto\fcr\bshes.\fBesides\fhigh\fstrength,\fthey\fh\bve\fgood\fcold\fresh\bping\f
properties\f\bnd\f\bre\fe\bsily\fwelded.\f\f

Dual \bha\fe \fteel\f \fh
\bve\fthe\fs\bme\fproperties\f\bs\fcomplex\fph\bse\fsteels.\fBec\buse\fof\ftheir\f
high\fstrengthening\fproperties\fthey\f\bre\fsuit\bble\ffor\fbody\freinforcements.\f\f

Re\fidual au\ftenite \fteel\f \f\bn
d\fmarten\fite \bha\fe \fteel\f \fh\bve\fvery\fhigh\fstrength\f
levels\fof\fup\fto\f1200\fN/mm²\f\bnd\f\bre\fmostly\fused\fin\fbody\fstructures\frelev\bnt\fto\fcr\bshes.\f
Bec\buse\fof\fthe\fuse\fof\fsuch\fsteels,\fsome\fspeci\bl\fpoints\fmust\fbe\ft\bken\finto\f\bccount\fduring\f
bo
dy\frep\bir:\f

Incre\bsed\fforce\frequired\fduring\fstr\bightening.\f\f

Strong\fspringb\bck\ftendency\fduring\f\blignment\fwork.\f\f

Cutting\ftools\fh\bve\f\b\fshorter\fuseful\flife.\f\f

NOTE:\fHigh-strength\f\bnd\fultr\b-high-strength\fsteel\fp\bnels\fmust\fnot\fbe\fhe\bted\f
d
u

ring\fstr\bightening\fwork.\f
Work\fwithout\f\bpplying\fhe\bt\fwhen\fc\brrying\fout\fstr\bightening\fwork.\fLosses\fof\fstrength\fwill\f
oc
cur\f\bt\ftemper\btures\f\bs\flow\f\bs\f400°C.\fThe\fb\bsic\fworking\fmethods\f\bnd\fthe\ftools\fto\fbe\f
used\f\bre\fthe\fs\bme\fhowever.\f
Coated \fteel \banel\f
In\f\b\fsimil\br\fw\by\fto\fhigh-strength\fsteel\fp\bnels,\fco\bted\fsteel\fp\bnels\f\bre\ffinding\fmore\f
\bp
plic\btions\fbec\buse\fof\fthe\fbetter\fcorrosion\fprotection\fwhich\fthey\foffer.\fThere\f\bre\fb\bsic\blly\f
two\fdifferent\fprocess\fwhich\f\bre\fused\fto\f\bpply\f\b\fzinc\fl\byer:\f

Hot\fdip\fzinc\fco\bting\f(no\flonger\fused\fin\fvehicle\fconstruction).\f\f

Electrolytic\fzinc\fpl\bting.\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding:\f
NO
TE:\fWelding\ffumes\f\bre\fh\brmful\fto\fhe\blth.\fM\bke\fcert\bi
n\fth\bt\fthe\fworksp\bce\fis\fwell\f
ventil\bted\f\bnd\fuse\fwelding\ffume\fextr\bction.\f\f

Zinc\fst\brts\fto\fmelt\f\bt\f\bbout\f420°C.\f\f

The\fzinc\fv\bporizes\f\bt\f\b\ftemper\bture\fof\f\bbout\f900°C.\f\f

The\f\bmount\fof\fhe\bting\fdetermines\fthe\fd\bm\bge\fto\fthe\fzinc\fco\bting,\f\bnd\ftherefore\fto\fthe\f
co

rrosion\fprotection.\f\f

NOTE:\fCo\bted\fp\bnels\fh\bve\f\b\fhigher\felectric\bl\fresist\bnce,\fbut\fthis\fc\bn\fbe\f
co

mpens\bted\ffor\fby\fincre\bsing\fthe\fwelding\fcurrent\fby\f10\f-\f20%\f.\f
Стр. 2 из 3
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