ECU FORD S-MAX 2006 Service Repair Manual

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$FORD S-MAX 2006 Service Repair Manual 3.WARNING:\fThe\fA-pill\br\freinforcement\fis\f co vered\fwith\f\b\fhot-dip\f\bluminized\fco\bting\fon\f its\fentire\fsurf\bce.\fThis\fco\bting\fneeds\fto\fbe\f fully\fground\foff\fon\fthe\fMIG\fweldi$

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$FORD S-MAX 2006 Service Repair Manual Installation NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f \bn d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fs$

Installation
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\bn
d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f 8.
NOTE:\fWorking\ffrom\fthe\fp\bssenger\f
c
o

mp\brtment,\fhe\bt\fup\fthe\fNVH\felement\f\bnd\f
det\bch\fit.\fThe\fNVH\felement\fis\f\blso\fsecured\f
to\fthe\fw\bter\fdr\bin\fp\bnel\freinforcement\ffrom\f
the\finside\fby\fme\bns\fof\fpl\bstic\fclips.\f
Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1.

Mill\fout\fthe\fspot\fwelds.\f
2. Grind\fout\fthe\fspot\fwelds.\f
3. He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f det\bch\fthe\fNVH\felement\ffrom\fthe\finner\f
qu\brter\fp\bnel.\f
1. NOTE:\fWorking\ffrom\fthe\finside,\finsert\fthe\f
NV

H\felement\f\bt\fthe\fw\bter\fdr\bin\fp\bnel\f
reinforcement\fusing\fPU\fwindow\f\bdhesive\f
\bnd\fsecure\fit\fwith\fthe\ftwo\fpl\bstic\fclips.\f
Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1.
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
element.\f
2. Continuous\fMIG\fweld\fse\bm.\f
2. NOTE:\fOnly\ft\bck-weld\fthe\fw\bter\fdr\bin\fp\bnel\f
r
e

inforcement\fto\fthe\ft\bilg\bte\f\bperture\f\bnd\f
the\fside\fwindow\f\bperture.\fThe\ffin\bl\fwelded\f
joint\fis\fm\bde\fwhen\fthe\fqu\brter\fp\bnel\fis\f inst\blled.\f
Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1.
Resist\bnce\fspot\fweld.\f
2. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
3. NOTE:\f\f
By\fdrilling\fout\fthe\fholes\fit\fis\fpossible\fto\f
we

ld\f\bll\fthree\fl\byers\fof\fmet\bl\ftogether.\f\f
Only\ft\bck-weld\fthe\fw\bter\fdr\bin\fp\bnel\f
re

inforcement\f\bt\fthe\ft\bilg\bte\f\bperture\f\bnd\f
\bt\fthe\finner\fqu\brter\fp\bnel.\fThe\ffin\bl\f
welded\fjoint\fis\fm\bde\fwhen\fthe\fw\bter\fdr\bin\f
p\bnel\f\bnd\fthe\fqu\brter\fp\bnel\f\bre\finst\blled.\f
Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Drill\fout\fby\fone\fp\bnel\fthickness\f\bnd\f
\f\f
\f\f
\f\f
\f\f
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$FORD S-MAX 2006 Service Repair Manual 2.NOTE:\fPosition\fthe\fexh\bust\fbr\bcket\f\bnd\fthe\f D- pill\br\fgusset\fpl\bte\fon\fthe\flongitudin\bl\f member\f\bnd\fsecure.\f Exh\bust\fbr\bcket\f\bnd\fD-pill\br\fgusset\fpl\bte\f Resist\bnce\$

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$FORD S-MAX 2006 Service Repair Manual Paint - \beneral \fnformation - Painting Plastic PartsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Description and Operation \beneral Al though\fthese\fd\bys\fpl\bstics\fc\bn\fbe\fproduced\fin\f\b$

Paint - \beneral \fnformation - Painting
Plastic PartsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
\beneral
Al

though\fthese\fd\bys\fpl\bstics\fc\bn\fbe\fproduced\fin\f\bll\fcolors\f\bnd\fwith\f\b\fm\btt\for\fgloss\fsurf\bce,\f
p\binting\fis\foften\fnecess\bry.\f\f
NOTE:\fM\bnuf\bcturer's\flimit\btions\fconcerning\fthe\ffe\bsib
ility\fof\fp\binting\fcert\bin\fcomponents\f
must\f\blw\bys\fbe\fobserved.\f
Re\bsons\fin\ff\bvor\fof\f\bpplying\fp\bint\fto\fpl\bstic\f\bre:\f
Individu\bl\fcoloring,\fm\btching\fthe\fbody\fp\bint.\f\f
More\fgloss\f\bnd\fcolor\fbrilli\bnce\fthrough\fp\binting.\f\f
Remov\bl\fof\fproduction\fimperfections.\f\f
Protection\ffrom\f\btmospheric\fexposure.\f
Now\bd\bys\fp\binting\fpl\bstic\fpresents\fno\fproblems\fbec\buse\fthe\fm\bteri\bls\f\bre\fknown\f\bnd\f
m \b

tched\fto\fthe\fp\bint.\fIn\forder\fth\bt\fthe\fp\binter\fc\bn\fuse\fthe\fcorrect\fp\binting\fm\bteri\bls,\fthe\f
type\fof\fpl\bstic\fmust\ffirst\fbe\fcorrectly\fdetermined.\f
To\f\bllow\fthis,\fpl\bstics\f\bre\fm\brked\fon\fthe\fre\br\fin\f\bccord\bnce\fwith\fthe\frecommend\btions\fof\f
the\fAssoci\btion\fof\fVehicle\fM\bnuf\bcturers.\f
Once\fthe\ftype\fof\fpl\bstic\fis\fdetermined\fit\fis\f\bn\fe\bsy\fm\btter\fto\f\bssign\fspeci\bl\fp\bint\f
recommend\btions,\fm\btched\fto\fth\bt\fp\brticul\br\fpl\bstic.\fUnm\brked\fpl\bstics\frequire\fknowledge\f
of\fm\bteri\bls\fso\fth\bt\f\b\fcorrect\fchoice\fof\fp\bint\fm\bteri\bls\fc\bn\fbe\fm\bde\f\bnd\fthe\fcomponent\fc\bn\f
be\freli\bbly\fp\binted.\f
Plastic groups
Thermopl\bstics\f
When\fw\brmed\fthese\fundergo\f\b\freversible\ftr\bnsform\btion\finto\f\b\fpl\bstic\fdeform\bble\fst\bte\f
\bnd\fonce\fcooled\fthey\fm\bint\bin\ftheir\fsh\bpe.\fThey\fconsist\fof\fstring-like\f(line\br)\for\fonly\f
slightly\fbr\bnched\fmolecul\br\fch\bins.\f
Thermosets\f
Thermosets\f\bre\fh\brd\f\bnd\fh\bve\fthe\fform\fof\f\b\fclose-meshed\fnetwork\fin\f\bll\fdirections.\fThey\f
do\fnot\fundergo\fpl\bstic\fdeform\btion,\f\bre\fespeci\blly\fresist\bnt\fto\fchemic\bls,\f\bre\fdifficult\fto\f
swell\f\bnd\f\bre\finsoluble.\fAt\fnorm\bl\ftemper\btures\fthey\f\bre\fh\brd\fto\fbrittle.\fAt\ffirst\fthe\f
m\bteri\bl\fdoes\fnot\fundergo\f\bny\fch\bnge\fwhen\fhe\bted,\fbut\fwhen\fit\fre\bches\f\b\fcritic\bl\fpoint,\f
the\fthermoset\fis\ftot\blly\fdestroyed.\f\f
El\bstomers\f
El\bstomers\f\bre\fch\br\bcterized\fby\fhigh\fel\bsticity\fover\f\b\fwide\ftemper\bture\fr\bnge.\fThey\fh\bve\f
properties\flike\frubber\for\f\b\fsponge\f\bnd\f\bfter\fcompression\for\fdistension\fthey\freturn\fto\ftheir\f
origin\bl\fst\bte.\f\f
Types\fof\fpl\bstic\f
The\fpl\bstics\fused\fin\fthe\f\butomotive\f\bre\b:\f
ABS\f-\fAcrylonitrile\fbut\bdiene\fstyrene\f(polymer)\f\f
PA\f-\fPoly\bmide\f\f
PC\f-\fPolyc\brbon\bte\f\f
PE\f-\fPolyethylene\f\f
PP\f-\fPolypropylene\f\f
PP/EPDM\f-\fPolypropylene/ethylene\fpropylene\fdiene\fcopolymer\f\f
PC/PBT\f-\fPolyc\brbon\bte/Polybutylene\fterephth\bl\bte\f\f
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Page 4352 of 4402

$FORD S-MAX 2006 Service Repair Manual NOTE:\fUse\fof\fdiffering\fm\bsking\fm\bteri\bls\fis\foften\fmuch\fmore\ftime-consuming.\fAdv\bnt\bges\f Good\fcover\bge.\fN\brrower\ft\bpes\fmust\foften\fbe\f\bpplied\fin\fsever\bl\fl\byers.\f\f$

NOTE:\fUse\fof\fdiffering\fm\bsking\fm\bteri\bls\fis\foften\fmuch\fmore\ftime-consuming.\fAdv\bnt\bges\f
Good\fcover\bge.\fN\brrower\ft\bpes\fmust\foften\fbe\f\bpplied\fin\fsever\bl\fl\byers.\f\f
More\fresist\bnt\fto\fte\bring.\f\f
Wide\ft\bpes\fc\bn\fbe\f\bpplied\fdeep\finto\fjoints\f\bnd\ftherefore\fprotect\ffrom\fp\bint\fmist\f\bnd\f
co

nt\bmin\btion.\f\f
Remov\bl\fis\foften\fe\bsier.\f
Masking film
Tr\bnsp\brent\fpl\bstic\ffilm\fh\bs\fbecome\f\bccepted\f\bs\f\b\fpr\bctic\bl\fmethod\fto\fm\bsk\fl\brge\f\bre\bs\fof\f
\b\f
whole\fvehicle.\fIt\fc\bn\fquickly\f\bnd\fe\bsily\fbe\f\bpplied\fto\fthe\fvehicle\ffrom\fthe\froll.\f
NOTE:\fOnly\fm\bsk\fthe\fvehicle\fwhen\fit\fis\fdry.\fMoisture\f u
nder\fthe\ffilm\fc\bn\fle\bd\fto\fm\btt\f
p\bint\fin\fthe\fdrying\fprocess.\f
Using\fm\bsking\ffilm\f
Cle\bn\fthe\fvehicle\fbefore\fm\bsking\fit.\f\f
Pull\fthe\ffilm\fover\fthe\fvehicle.\fBec\buse\fof\fthe\fst\btic\fch\brge,\fthe\ffilm\flies\fon\fthe\fvehicle\f
li

ke\f\b\fsecond\fskin.\f\f
Cut\fout\fthe\frep\bir\f\bre\b\fusing\fthe\ffilm\fknife\f\bnd\fthen\fm\bsk\fit.\f\f
Other\fw\bys\fof\fm\bsking\f\b\fvehicle\f\bre:\f M\bsking\fusing\fm\bsking\fp\bper.\f\f
P\binting\fcloth\f(mostly\fused\fduring\ffilling\fwork).\f\f
Profiled seals
If\fit\fis\fnot\fpossible\fto\fremove\f\b\fprofiled\fse\bl,\fthen\fit\fmust\fbe\fm\bsked\fin\fsuch\f\b\fw\by\fth\bt\fno\f
ed
ges\fc\bn\fform\fdue\fto\fp\bint\f\bccumul\btion.\f
To\fdo\fthis,\fthe\fse\bl\fis\flifted\fslightly\f\bnd\fm\bsked.\fThe\ffollowing\ftechniques\f\bre\fpossible:\f
\f\f
Description
M\bsking\ft\bpe\fwith\fpl\bstic\fstrips\f
Se\bling\flip\f
S\bndp\bper\fwith\fm\bsking\ft\bpe\f
L\bying\f\b\fstring\for\fcord\funder\fthe\fse\bl.\fSuit\bble\ffor\fsoft\f\bnd\fel\bstic\fse\bl\flips.\f\f
Speci\bl\fm\bsking\ft\bpe\fwith\fpl\bstic\fstrips\ffor\fh\brd\fse\bl\flips.\f\f
Inste\bd\fof\fusing\fpl\bstic\fstrips,\ffine\fs\bndp\bper\fcut\finto\fstrips\fc\bn\fbe\finserted\f\bnd\fsecured\f
us

ing\fnorm\bl\fm\bsking\ft\bpe.\f\f
If\fthe\fse\bl\fc\bn\fbe\fe\bsily\fdispl\bced,\fnorm\bl\fm\bsking\ft\bpe\fc\bn\f\blso\fbe\fused.\f
\f
t

em
1
2
3 \f\f
Part Number
-
-
-
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Page 4353 of 4402

$FORD S-MAX 2006 Service Repair Manual Edges/openings Smooth\fp\bint\ftr\bnsitions\fc\bn\fbe\fproduced\fby\fpositioning\f\bdhesive\ft\bpes.\f\f NO TE:\fPull\fthe\f\bdhesive\ft\bpes\f\bw\by\fimmedi\btely\f\bfter\ft he\fp\bint\fh\bs\fbeen\$

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