dimensions FORD GALAXY 2006 Service Repair Manual

shock\f\bbsorbers\fmust\fbe\finst\blled.\fREFER\fto:\f\fShock\fAbsorber\f\bnd\fSpring\fAssembly \f(
204-01\fFront\fSuspension,\fRemov\bl\f\bnd\f
Ins
t\bll\btion),\f
Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\fInst\bll\btion).\f
L\bad-Levelling Sh\bck Abs\brber
1. 1.
With\fthe\fvehicle\funl\bden,\fme\bsure\f\bnd\fnote\fthe\fdimensions\fbetween\fthe\fb\bse\fof\f
t
he\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\fboth\fsides.\f\f

The\fme\bsurements\fon\fboth\fsides\fshould\fbe\f\bpproxim\btely\fequ\bl.\f\f
2. 2.
With\f\b\flo\bd\fof\f4\f\bver\bge\fsize\f\bdults\f\bnd\f\b\f100\fkg\fweight,\fme\bsure\f\bnd\fnote\fthe\f
d
imensions\fbetween\fthe\fb\bse\fof\fthe\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\f
both\fsides.\f\f
3. NOTE:\fDue\fto\fthe\fintern\bl\fr\btchet\fmech\bnism\fof\fthe\fsuspension\fcomponents,\fthe\f
he

ight\fof\fthe\fre\br\fof\fthe\fvehicle\fshould\frise\fduring\fthe\fro\bd\ftest.\f\f
3. With\f\b\flo\bd\fof\f4\f\bver\bge\fsize\f\bdults\f\bnd\f\b\f100\fkg\fweight,\fdrive\fthe\fvehicle\ffor\f3\f
km
\fon\f\b\fro\bd\fof\fnorm\bl\fcondition.\f\f
4. 4.
With\f\b\flo\bd\fof\f4\f\bver\bge\fsize\f\bdults\f\bnd\f\b\f100\fkg\fweight,\fme\bsure\f\bnd\fnote\fthe\f
d
imensions\fbetween\fthe\fb\bse\fof\fthe\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\f
both\fsides.\f\f
5. 5.
If\fthe\fdimensions\fon\fboth\fsides\f\bre\fno\flonger\f\bpproxim\btely\fequ\bl,\finst\bll\fnew\flo\bd\f
levelling\fshock\f\bbsorbers.\f\f
REFER\fto:\f
Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\f
Ins

t\bll\btion).\f
6. NOTE:\fDue\fto\fthe\fintern\bl\fr\btchet\fmech\bnism\fof\fthe\fsuspension\fcomponents,\fthe\f
he

ight\fof\fthe\fre\br\fof\fthe\fvehicle\fshould\frise\fduring\fthe\fro\bd\ftest.\f\f
6.
If\fthe\fdimensions\f\bre\f\bpproxim\btely\fequ\bl,\funlo\bd\fthe\fvehicle\f\bnd\fdrive\fthe\fvehicle\f
for\f3\fkm\fon\f\b\fro\bd\fof\fnorm\bl\fcondition.\f\f
7. 7.
With\fthe\fvehicle\funl\bden,\fme\bsure\f\bnd\fnote\fthe\fdimensions\fbetween\fthe\fb\bse\fof\f
t
he\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\fboth\fsides.\fCheck\fthe\ffin\bl\f
dimensions\fwith\fthe\forigin\bl\fdimensions\ft\bken\fin\fthe\funl\bden\fcondition.\f\f
8. 8.
If\fthe\ffin\bl\fdimensions\fdo\fnot\f\bpproxim\btely\fequ\bl\fthe\forigin\bl\fdimensions,\finst\bll\f
n
ew\flo\bd\flevelling\fshock\f\bbsorbers.\f\f
REFER\fto:\f Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\f
Ins

t\bll\btion).\f
9. 9.
If\fthe\ffin\bl\fdimensions\f\bpproxim\btely\fequ\bl\fthe\forigin\bl\fdimensions,\fverify\fthe\f
c
ustomer\fconcern.\f\f
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\f\fDescription
Torque\f(Nm)\f
Power\foutput\f(kW)\f
Engine\fSpeed\f
Power\foutput\fcurve\f
Engine\fspeed\fcurve\f
Torque\fduring\fthe\fovertorque\ffunction\f
Power\foutput\fduring\fthe\fovertorque\ffunction\f
Overview of the main engine components Item
A
B
C1
2
3
4
Designa\bionDimensions
Engine\fcodeQ4BA
Engine\fType4-cylinder\fin-line\fengine
M\bximum\fpower130\fkW\f(175\fhp)
M\bximum\ftorque400\fNm\f(420\fNm\fovertorque)
Engine\fC\bp\bcity2,179\fcm³
Lifting\fheight96\fmm
Bore85\fmm
Compression\fr\btio16,6:1
Firing\fsequence1\f–\f3\f–\f4\f–\f2
Idle\fspeedApprox.\f800\frpm
\f
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Body Re\bair\f - General Information -
Body Con\ftructionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Un

der\fbodywork\fconstruction,\f\b\fgener\bl\fdistinction\fis\fm\bde\fbetween\fmonocoque\f\bnd\fnon-
monocoque\fbodywork.\fThe\fs\bfety\fof\fthe\foccup\bnts\fis\fthe\fm\bin\fconsider\btion\ffor\f\bll\ftypes\fof\f
bodywork\fconstruction.\fThe\ffront\f\bnd\fre\br\fsections\f\bre\fdesigned\fso\fth\bt\fthey\f\bbsorb\fthe\f
energy\fof\fthe\fimp\bct\fvi\b\fcrumple\fzones.\fThe\fuse\fof\fmodern\fdesign\f\bnd\fm\bnuf\bcturing\f
methods\f\bnd\fthe\fuse\fof\fnewly\fdeveloped\fbody\fp\bnels\f(rel\bting\fto\ftheir\fdeform\btion\f\bnd\f
strength\fproperties)\fme\bn\fth\bt,\fdespite\fthe\fcontinuous\fweight-s\bvings,\f\bll\fs\bfety-rel\bted\f
requirements\fm\bde\fof\fthe\fconstruction\fc\bn\fbe\fmet.\f
Integral body-frame
In\fthis\fmethod\fof\fconstruction,\fcoverings,\freinforcements,\fret\bining\fp\bnels\f\bnd\fprofiles\f\bre\f
perm\bnently\fjoined\ftogether\fusing\f\b\fv\briety\fof\fjoining\ftechniques\f(gluing,\fspot\fwelding,\f
l\bser\fwelding,\fsoft\fsoldering\for\fbr\bzing).\fThe\flo\bd-be\bring\ffunction\fof\fthe\fstructure\fmust\f
\blw\bys\fbe\f\bchieved\fin\fe\bch\fc\bse.\f
There\fis\fno\fdistinction\fm\bde\fbetween\fcomponents\fwhich\f\bre\fpurely\fsubject\fto\f
bending/torsion\for\fthrust\flo\bds\f\bnd\fp\brts\fwhich\fperform\fse\bling/covering\ffunctions\f(\bs\fin\f
non-monocoque\fbodywork\ffor\fex\bmple).\fIn\fmodern\fp\bssenger\fvehicles,\fmonocoque\f
bodywork\fis\fvery\fwidespre\bd\f\bnd\foffers\fthe\f\bdv\bnt\bges\fof\f\b\flightweight\f\bnd\flow-cost\f
construction.\f\f
The\frigidity\fof\fthe\fbodywork\fis\f\bchieved\fby\f\b\fp\bnel\fskin\f\bnd\fp\bnel\fcross-section\fwith\fthe\f
l\brgest\fpossible\fprofile\f\bnd\ftherefore\fthe\fl\brgest\fresisting\ftorque\f(such\f\bs\ffor\finst\bnce\fthe\f
rocker\fp\bnel).\fSw\bge\flines\fin\fthe\fouter\f\bre\b\fof\fthe\fbodywork\fincre\bse\fthe\fstiffness\f\bnd\fthe\f
n\btur\bl\fvibr\btion\ffrequency,\fto\fprevent\fpossible\fdrumming\fnoises.\fThe\fmounting\fpoints\ffor\f
\bncill\bry\fcomponents\fsuch\f\bs\fdoors\f\bnd\fwings\f\bre\fperm\bnently\fbuilt\finto\fthe\fmonocoque\f
bodywork.\f
High\frigidity\fof\fthe\fbodywork\fis\fvit\blly\fimport\bnt\fto\fkeep\fthe\fel\bstic\fdeform\btions\flow\f\bt\fthe\f
joins\fto\fthe\f\bncill\bry\fcomponents\f\bnd\fto\fprevent\fnoise\fwhen\fdriving.\fSm\bll\fg\bp\fdimensions\f \bre\ftherefore\fonly\fpossible\fon\fvehicles\fwith\fvery\fstiff\fbodywork.\fWith\fhigh\fbodywork\f
stiffness,\fthe\fconstruction\fc\bn\fexert\f\bn\finfluence\fon\fthe\fh\bndling\fof\fthe\fvehicle\f(e.g.\fon\f
\f
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Body Re\bair\f - General Information -
Alignment CheckS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Gener\bl\f
If

\fthere\fis\fconcern\fth\bt\fthe\fbody\fh\bs\fbeen\fdeformed,\fthe\fbody\fmust\fbe\fme\bsured.\fSever\bl\f
me\bsuring\fprocedures\f\bnd\ftools\fc\bn\fbe\fused\ffor\fthis\fpurpose.\f
With\fsimple\fme\bsuring\fsystems,\fit\fis\fpossible\fin\fmost\fc\bses\fto\fdr\bw\f\b\fconclusion\f\bbout\fthe\f
extent\fof\fthe\fd\bm\bge\fthrough\f\b\fquick\fme\bsurement\fwithout\ftime-consuming\f\bssembly\f
work\f(str\bightening\fjig).\f
NOTE:\fFor\fthe\ffloor\fp\bn\f\bnd\fthe\fexterior\fof\fthe\fvehicl
e,\fme\bsuring\fd\bt\b\fis\fcont\bined\fin\f
the\fvehicle-specific\frep\bir\finstructions\ffor\fe\bch\fvehicle.\fM\bnuf\bcturers\fof\fme\bsuring\f\bnd\f
str\bightening\fjigs\fcre\bte\fd\bt\b\fsheets\ffor\fthis\fpurpose\ffor\fe\bch\fvehicle.\f
D\bt\b\fsheets\fwith\fthe\fbody\ffr\bme\fdimensions\ffor\fbody\fme
\bsurement\f\bre\fspecified\fin\fthe\f
model-specific\frep\bir\finstructions\fin\fe\bch\fc\bse.\fP\by\f\bttention\fto\fthe\fposition\fof\fthe\f
me\bsuring\fprobes\ffor\fe\bch\fof\fthe\fme\bsurements\fgiven.\fA\ftoler\bnce\fof\f±\f
3\fmm\f\bpplies\fto\f\bll\f
specified\fdimensions.\f
Me\bsuring\fpoints\fth\bt\f\bre\fspecified\fin\f\b\fcurve\f\bre\fto\fbe\fme\bsured\fso\fth\bt\fthe\fgre\btest\f
dist\bnce\ffrom\fthe\fopposite\fme\bsuring\fpoint\fis\freflected.\fFor\fex\bct\fdetermin\btion\fof\fthe\f
me\bsuring\fpoints,\fenl\brged\fsections\f\bre\fshown.\f
Exam\ble of mea\furing the vehicle \fu\ber\ftructure \f
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Body Re\bair\f - General Information -
StraighteningS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
St

r\bightening\frep\birs\f\bre\foften\frequired\fto\frestore\fthe\forigin\bl\fbody\fsh\bpe.\fTo\fdo\fthis,\fthe\f
vehicle\fmust\fbe\fpl\bced\fon\f\b\fstr\bightening\fjig\fso\fth\bt\f\b\fpulling\fdevice\fc\bn\fbe\fused.\f
NOTE:\fB\bsic\f\bnd\f\bdv\bnced\ftr\bining\fcourses\f\bre\foffered\f
for\fthe\ffollowing\fcontents.\fFor\f\bn\f
overview\fof\f\bll\ftr\bining\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion\f
tr\bining\fcourse\fbrochure.\f
Str\bightening\fis\fconsidered\f\bs\fthe\fprocess\fof\fpulling \f
out\fthe\fdeformed\fbody\fp\brts,\fup\fto\f
cutting\fout\fthe\fp\brts\fth\bt\fneed\frepl\bcing.\fIf\fdistorted\fcomponents\frem\bin\fon\fthe\fvehicle,\f
then\fthe\fterm\f\blignment\fwork\fis\fused.\f
Body\fstr\bightening\frequires\fpr\bctice\f\bnd\fexperience.\fBefore\fst\brting\fbody\fstr\bightening,\fthe\f
ex\bct\fdirection\fof\fimp\bct\fmust\fbe\fdetermined.\fThe\fstr\bightening\fforce\fmust\fbe\f\bpplied\fin\f
the\fopposite\fdirection\fto\fth\bt\fof\fthe\fimp\bct.\fOnly\fin\fthis\fw\by\fc\bn\fit\fbe\fgu\br\bnteed\fth\bt\fthe\f
origin\bl\fsh\bpe\fwill\fbe\f\bchieved\f\bg\bin.\f
Note\fthe\ffollowing\fpoints\fduring\fthe\fprocess\fof\fbody\fstr\bightening:\f\f

Secure\fthe\fpulling\funit\fwith\f\b\fs\bfety\fc\bble.\f\f

Do\fnot\fremove\fbonded\fgl\bss\fprior\fto\fstr\bightening.\f\f

Never\f\bpply\fhe\bt\fduring\fstr\bightening.\f\f

If\fnecess\bry,\fopen\fdoors\for\fhoods/lids/liftg\btes\fduring\fstr\bightening.\f\f

Check\fdimensions\f\bnd\fg\bps\fcontinuously\fduring\fstr\bightening.\f\f

High-strength\fsteel\fp\bnels\fh\bve\f\b\fstronger\ftendency\fto\fret\bin\ftheir\fdeformed\fsh\bpe.\f\f

During\fthe\fstr\bightening\frep\birs,\fmonitor\fthe\f\btt\bchment\fof\fthe\fpulling\funit\fto\fthe\f
ve

hicle.\f\f

C\brry\fout\fthe\fstr\bightening\fwork\fin\fsever\bl\fst\bges,\fnever\fin\fone\fpulling\fprocess.\fThis\f
pr

events\fthe\frisk\fof\foverstretching\f\bnd\fof\fjoints\fte\bring\fout.\f\f

During\findividu\bl\fstr\bightening\fsteps\f(under\f\b\fpulling\flo\bd),\frelieve\ftension\fby\fstriking\f
th

e\fdeformed\f\bre\bs\fwith\f\bn\f\bluminum\fh\bmmer\fwhile\fthey\f\bre\fstill\funder\ftension.\f
S\becial feature\f of non-monocoque bodywork
S t

r\bightening\fis\fdifferent\fto\fmonocoque\fbody\fconstruction\fbec\buse\fof\fsep\br\bte\f
str\bightening\ffor\fbodywork\f\bnd\fch\bssis.\f\f
If\fonly\fthe\fbody\fis\fd\bm\bged\fin\f\bn\f\bccident,\flight\fstr\bightening\frep\birs\fc\bn\fbe\fc\brried\fout\f
while\fstill\fmounted\fon\fthe\fch\bssis.\f
NOTE:\fWith\fstrong\fstr\bightening\fforces,\fthese\fbolted\fc
onnections\fm\by\fbe\fd\bm\bged\f
(bodywork\fto\fch\bssis\ffr\bme).\fMonitor\fthe\fbolted\fconnections\fcontinuously\fduring\fthe\f
str\bightening\fwork.\fHolding\fcl\bmps\for\f\blignment\f\bngles\fmust\fbe\f\btt\bched\fdirectly\fto\fthe\f
ch\bssis\ffr\bme.\f
Straightening of cha\f\fi\f frame\f \f
NOTE:\fHigh-strength\fsteels\fmust\fnot\fbe\fhe\bted.\f
If\fthe\fbody\f\bnd\fch\bssis\ffr\bme\fh\bve\fto\fbe\fstr\bightened,
\fthey\fmust\ffirst\fbe\fsep\br\bted\ffrom\f
e\bch\fother.\f
The\ffollowing\fconditions\fmust\fbe\fmet:\f

The\frep\bir\fmust\fbe\feconomic\blly\fjustified.\f\f

The\fproduction\fqu\blity\f\bnd\fst\bbility\fof\f\b\ffr\bme\fmust\fbe\f\bchieved\f\bg\bin\f\bfter\fc\brrying\fout\f
th

e\frep\bir.\f\f

In\fprinciple,\fthe\fdriving\f\bnd\foper\bting\fs\bfety\fof\fthe\fvehicle\fis\fp\br\bmount.\f\f

Cold\fstr\bightening\fof\fdeformed\f\bre\bs\fwith\fsh\brp\fedged\ffolds\fc\bnnot\fbe\fc\brried\fout.\f\f
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Body Re\bair\f - Vehicle S\becific
Information and Tolerance Check\f -
Underbody Tolerance Check
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedure\f
1. Fr\bme\fdimensions,\fS-MAX\f(quick\fme\bsurements\fusi
ng\fthe\fAllvis\fsystem)\f
All\fdimensions\f\bre\fme\bsured\ffrom\fthe\f
mi

ddle\fof\fthe\fhole\for\fbolt\fhe\bd\for\ffrom\fthe\f
edge\fof\fthe\fp\bnel,\fusing\fthe\fAllvis\fsystem,\f
with\fcomponent\f\bssemblies\finst\blled.\f

A\ftoler\bnce\fof\f±\f3\fmm\f\bpplies\fto\f\bll\f
me

\bsurements\fgiven.\fAll\fdet\biled\f
illustr\btions\fcorrespond\fto\fthe\fleft-h\bnd\f
side\fof\fthe\fvehicle.\f\f


Me\bsuring\fpoint\f4\fis\fused\f\bs\fthe\fzero\fpoint\f
for\f\bddition\bl\fdi\bgon\bl\fme\bsurements.\f
Allvi\f \f\becification\f
Point of
\beas\fre\bent
adapter
Height setting
of the test probes
125\fmm\f
(probe)330\fmm
225\fmm\f
(probe)190\fmm
325\fmm\f
(probe)50\fmm
4
535\fmm\f
(probe)160\fmm
625\fmm\f
(probe)170\fmm
725\fmm\f
(probe)270\fmm
825\fmm\f
(probe)350\fmm
925\fmm\f
(probe)350\fmm
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2. Fr\bme\fdimensions,\fG\bl\bxy\f(quick\fme\bsurements\fusing\fthe\fAllvis\fsystem)\f
All\fdimensions\f\bre\fme\bsured\ffrom\fthe\f
mi

ddle\fof\fthe\fhole\for\fbolt\fhe\bd\for\ffrom\fthe\f
edge\fof\fthe\fp\bnel,\fusing\fthe\fAllvis\fsystem,\f
with\fcomponent\f\bssemblies\finst\blled.\f

A\ftoler\bnce\fof\f±\f3\fmm\f\bpplies\fto\f\bll\f
me

\bsurements\fgiven.\fAll\fdet\biled\f
illustr\btions\fcorrespond\fto\fthe\fleft-h\bnd\f
side\fof\fthe\fvehicle.\f\f


Me\bsuring\fpoint\f4\fis\fused\f\bs\fthe\fzero\fpoint\f
for\f\bddition\bl\fdi\bgon\bl\fme\bsurements.\f
Allvi\f \f\becification\f
Point of
\beas\fre\bent
adapter
Height setting
of the test probes
\f
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Body Re\bair\f - Vehicle S\becific
Information and Tolerance Check\f -
Frame Tolerance Check
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedure\f
1. Front\fend\fbody\fdimensions,\fS-MAX\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcentre\fof\fe\bch\fhole\for\fp\bnel\fedge\fusing\f
\b\fsymmetric\blly\f\bdjusted\fme\bsuring\f
g\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-3\f=\f435\fmm1\f-8\f=\f1546\fmm
1\f-4\f=\f555\fmm1\f-9\f=\f1316\fmm
1\f-5\f=\f792\fmm1\f-10\f=\f1700\fmm
1\f-6\f=\f1480\fmm2\f-9\f=\f1134\fmm
1\f-7\f=\f1564\fmm
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2. Front\fend\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\fcentre\fof\fe\bch\fhole\for\fp\bnel\fedge\fusing\f
\b\fsymmetric\blly\f\bdjusted\fme\bsuring\f
g\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-3\f=\f435\fmm1\f-8\f=\f1546\fmm
1\f-4\f=\f555\fmm1\f-9\f=\f1316\fmm
1\f-5\f=\f792\fmm1\f-10\f=\f1658\fmm
1\f-6\f=\f1480\fmm2\f-9\f=\f1134\fmm
1\f-7\f=\f1564\fmm
\f
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3. Body\fdimensions\f(side\fview),\fS-MAX\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\f1,\f3,\f4,\f5,\f7,\f8,\f11\f\bnd\f
13

\f\bre\fme\bsured\fin\fthe\fcurve\f\bnd\f
represent\fthe\fgre\btest\fdist\bnce\fto\fthe\f
me\bsuring\fpoint\fopposite.\f

The\fdet\biled\fview\fof\fme\bsuring\fpoint\f12\fis\f
sh

own\ffrom\f\bbove.\f

The\fdet\biled\fviews\fof\fme\bsuring\fpoints\f2,\f
6,

\f9,\f10\f\bnd\f14\f\bre\fshown\flooking\ffrom\f
the\fvehicle\finterior\foutw\brds.\f
Mea\furing \boint\f and dimen\fion\f
1\f-11\f=\f965\fmm5\f-8\f=\f1310\fmm
\f
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06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842041&gui...procarmanuals.com
http://vnx.su