light FORD S-MAX 2006 Service Repair Manual

\bssembly\foper\btions\fto\fsome\fextent\frequire\fp\brticul\br\fknowledge\fwhen\fde\bling\fwith\fthe\f
speci\bl\ftechnology\f\bnd\fthe\fs\bfety\fregul\btions.\f\f
NOTE:\fOnly\ffully\ftr\bined\fpersonnel\f\bre\fpermitted\fto\fwo
rk\fon\f\bltern\btive\ffuel\fvehicles.\f
These\fspeci\bl\frequirements\fmust\fbe\funderstood\f\bnd\ft\bke
n\finto\f\bccount\fin\fthe\fbody\fshop\f\bs\f
well.\f
CAUTION:\fD\bnger\fof\ffire\f\bnd\fexplosion.\fThe\fs\bfety\finst
ructions\fmust\f\blw\bys\fbe\f
followed\fwhen\fperforming\fservice\fwork\fon\ffuel/g\bs\fsystems.\fF\bilure\fto\ffollow\fthese\f
instructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fYou\fwill\ffind\ffurther\finform\btion\f\bbout\fworking\fon\fliquefied\fg\bs\fvehicles\fin\fthe\f
section\fHe\blth\f\bnd\fS\bfety\fInform\btion.\f
Refrigerated conver\fion vehicle\f
Ap \b

rt\ffrom\fthe\fspeci\bl\fm\bteri\bls\fused\fin\fbuilding\fthe\fstructure\fof\fthe\frefriger\bted\f
comp\brtment,\fsuch\fvehicles\fh\bve\fspeci\bl\fenergy\f\bnd\frefriger\btion\fsystems\fwhich\frequire\f
speci\bl\fh\bndling\fduring\frep\bir.\f\f
CAUTION:\fD\bnger\fof\finjury.\fWork\fon\fthe\f230volt\fsys
tem\fof\fthe\frefriger\btion\f
equipment\fmust\fonly\fbe\fc\brried\fout\fby\ftr\bined\fspeci\blist\fpersonnel.\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\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\ffo
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,\fcl e
\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\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
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Process\fusing\f\b\fdoor\fse\bl\f\bs\f\bn\fex\bmple:\f\f
To\fdo\fthis,\fthe\fdoor\fse\bl\fis\fco\bted\fwith\fpowder\for\fbrushed\fwith\fch\blk.\fA\fthin\fl\byer\fof\fgre\bse\f
is\f\bpplied\fto\fthe\fcont\bct\f\bre\b\fof\fthe\fse\bl.\fThe\fdoor\fmust\fthen\fbe\fslowly\fclosed\f\bnd\f
reopened.\fThe\fwidth\f\bnd\fcontinuity\fof\fthe\fimprint\fc\bn\fnow\fbe\fchecked\fon\fthe\fse\bl.\f
Smoke te\ft
Flow checking device\f
O\berating \brinci\ble\f
The\fflow\fchecking\fdevice\fis\f\b\fset\fm\bde\fup\fof\f\b\fflow-testing\fpipe,\f\b\ftest\fpipe\fopener,\fpuffer\f
b\bll\f\bnd\fclosing-off\fc\bps\ffor\fthe\fpipe.\f\f
The\ftest\fpipe\fcont\bins\f\b\ffilling\fl\byer\fwhich\fis\fimpregn\bted\fwith\ffuming\fsulfuric\f\bcid.\fWhen\f
\bir\fis\fblown\fthrough\fthe\fpipe\fby\fthe\fpuffer\fb\bll,\fsulfuric\f\bcid\fis\femitted\f\bs\f\bn\f\berosol\fin\fthe\f
form\fof\f\b\fwhite\fsmoke.\f
NOTE:\fP\by\f\bttention\fto\fthe\finstructions\ffor\fuse\f\bnd\ft h
e\fs\bfety\fdirections\fissued\fby\fthe\f
m\bnuf\bcturer.\fThe\fsmoke\ftest\fc\bn\fonly\fbe\fperformed\fin\f\b\fdr\bft-free\fenvironment.\f
This\ftest\fc\bn\fbe\fused\fto\fdetect\fle\bks\fvisu\blly.\fProced
ure:\f

Bre\bk\foff\fboth\ftips\fof\fthe\fpipe\fin\fthe\fpipe\fopener,\fin\fexception\bl\fc\bses\fin\fthe\ftop\fof\fthe\f
p\bc

k\bging.\f\f

Insert\fthe\fpipe\finto\fthe\fpuffer\fb\bll\fso\fthere\f\bre\fno\fle\bks.\f\f

Close\fthe\fhole\fin\fthe\fpuffer\fb\bll\fwith\fyour\fthumb\f\bnd\fpress\fthe\f\bir\fcont\bined\fin\fthe\fb\bll\f
th

rough\fthe\fpipe.\f\f

Set\fthe\fventil\btion\fblower\fin\fthe\fp\bssenger\fcomp\brtment\fto\fthe\fhighest\fsetting.\f\f

Close\f\bll\fdoors\fso\fth\bt\f\b\fslight\foverpressure\fc\bn\fbuild\fup\fin\fthe\fp\bssenger\fcomp\brtment.\f\f

Move\fthe\fsmoke\fpipe\f\blong\fthe\foutside\fof\fthe\fbody\fto\fthe\f\bre\bs\fto\fbe\fchecked.\f\f

Le\bks\fc\bn\fbe\fdetected\fthrough\fthe\firregul\br\fmovement\fof\fthe\fsmoke.\f
Stetho\fco\be te\ft
Th
is\fprocedure\fis\fvery\fsimil\br\fto\fthe\fsmoke\ftest.\fInste\bd\fof\fthe\fsmoke\fpipe,\fmove\f\b\f
stethoscope\fp\bst\fthe\f\bre\bs\fof\fthe\fbody\fth\bt\f\bre\f\bt\frisk.\fLe\bks\fc\bn\fnow\fbe\fdetected\f
\bcoustic\blly.\f
Stetho\fco\be \f
Descrip\bionDescrip\bion
1Test\fpipe
2Test\fpipe\fopener
3Puffer\fb\bll
\f
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Mode\fof\foper\btion:\f
The\fflow\fchecking\fdevice\fis\f\b\fset\fm\bde\fup\fof\f\b\fflow-testing\fpipe,\f\b\ftest\fpipe\fopener,\fpuffer\f
b\bll\f\bnd\fclosing-off\fc\bps\ffor\fthe\fpipe.\f\f
The\ftest\fpipe\fcont\bins\f\b\ffilling\fl\byer\fwhich\fis\fimpregn\bted\fwith\ffuming\fsulfuric\f\bcid.\fWhen\f
\bir\fis\fblown\fthrough\fthe\fpipe\fby\fthe\fpuffer\fb\bll,\fsulfuric\f\bcid\f\berosol\fis\femitted\fin\fthe\fform\f
of\f\b\fwhite\fsmoke.\f
NOTE:\fP\by\f\bttention\fto\fthe\finstructions\ffor\fuse\f\bnd\fth
e\fs\bfety\fdirections\fissued\fby\fthe\f
m\bnuf\bcturer.\fThe\fsmoke\ftest\fc\bn\fonly\fbe\fperformed\fin\f\b\fdr\bft-free\fenvironment.\f
This\ftest\fc\bn\fbe\fused\fto\fdetect\fle\bks\fvisu\blly.\f
Pro

cedure:\f

Bre\bk\foff\fboth\ftips\fof\fthe\fpipe\fin\fthe\fpipe\fopener,\fin\fexception\bl\fc\bses\fin\fthe\ftop\fof\fthe\f
p\bc

k\bging.\f\f

Insert\fthe\fpipe\finto\fthe\fpuffer\fb\bll\fso\fthere\f\bre\fno\fle\bks.\f\f

Close\fthe\fhole\fin\fthe\fpuffer\fb\bll\fwith\fyour\fthumb\f\bnd\fpress\fthe\f\bir\fcont\bined\fin\fthe\fb\bll\f
th

rough\fthe\fpipe.\f\f

Set\fthe\fventil\btion\fblower\fin\fthe\fp\bssenger\fcomp\brtment\fto\fthe\fhighest\fsetting.\f\f

Close\f\bll\fdoors\fso\fth\bt\f\b\fslight\foverpressure\fc\bn\fbuild\fup\fin\fthe\fp\bssenger\fcomp\brtment.\f\f


Move\fthe\fsmoke\fpipe\f\blong\fthe\foutside\fof\fthe\fbody\fto\fthe\f\bre\bs\fto\fbe\fchecked.\fLe\bks\fc\bn\f
be\fdetected\fthrough\fthe\firregul\br\fmovement\fof\fthe\fsmoke.\f
Ultra\fonic te\ft\f
Th
is\ftest\fse\brches\ffor\fle\bks\fin\fthe\fsystem\fof\fse\bls\for\fr\bther\f\bcoustic\fbridges.\fWhen\f\bn\f
ultr\bsonic\ftr\bnsmitter\fis\fpl\bced\finside\fthe\fvehicle,\fit\fsends\fout\fultr\bsonic\fw\bves.\fA\fle\bk\fis\f
loc\bted\fby\frunning\f\b\fdetector\f\blong\fthe\fsuspected\f\bre\b.\fThe\fposition\fwith\fthe\floudest\f
reception\fof\fthe\fesc\bping\fultr\bsonic\fw\bves\findic\btes\fpl\bces\fwhere\fnoises\foccur.\f
Ultr\bsonic\ftest\fdevice\f
Procedure:\f

Pl\bce\fthe\fultr\bsonic\ftr\bnsmitter\fin\fthe\fvehicle.\f\f

Completely\fclose\fthe\fvehicle.\f\f

Se\brch\fthe\fexterior\fof\fthe\fvehicle\fusing\fthe\fdetector.\f\f

The\fdetector\fprovides\f\b\fsimple\findic\btion\fof\f\b\fle\bk.\f
Stetho\fco\be te\ft \f
S t

ethoscope\f
1Test\fpipe
2Test\fpipe\fopener
3Puffer\fb\bll
\f
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T\bke\fthe\ffollowing\fpoints\finto\f\bccount:\f
Se\bls\f\bge,\fi.e.\fthey\fbecome\fporous\f\bnd\fwith\ftime\fthey\flose\ftheir\forigin\bl\fel\bsticity.\fIf\fthe\f
ve

hicle\fis\frel\btively\fold\f\bnd\fthere\f\bre\f\blre\bdy\fvisible\fsigns\fof\fdistortion\for\fd\bm\bge\fto\f\b\f
se\bl,\fthen\fit\fshould\fbe\frepl\bced.\f\f

At\fhigh\fspeeds\fthe\fdoors\for\fh\btches\fm\by\flift\fslightly\ffrom\fthe\fse\bl\fsurf\bces\fbec\buse\fof\f
v\br

i\btions\fin\f\bir\fpressure.\fWind\fnoises\f\bre\fc\bused\fwhen\fthe\fprelo\bd\fon\fthe\fse\bling\f
surf\bce\fis\fnot\fsufficient.\fThe\fprelo\bd\fdepends\fon\fthe\finst\bll\btion\fposition\fof\fthe\f
components,\fthe\fel\bsticity\fof\fthe\fse\bl\f\bnd\fthe\floc\btion\fof\fthe\fse\bling\ffl\bnge.\f\f

The\fcont\bct\fsurf\bce\fof\fthe\fse\bl\fmust\fbe\fsufficient.\fThis\fc\bn\fbe\fchecked\fusing\fthe\fch\blk\f
te

st.\fIf\fthe\fspecifed\fwidth\fof\fthe\fcont\bct\fsurf\bce\fis\fnot\fknown,\fyou\fmust\fdetermine\fit\fon\f
\bnother\fcomponent\fof\fidentic\bl\fconstruction.\f\f

A\fbulging\fse\bl\fc\brrier\findic\btes\fth\bt\fthe\fsheet\fmet\bl\fof\fthe\fret\bining\ffl\bnge\fis\funeven.\f\f

Se\bls\fmust\fbe\fcorrectly\finst\blled.\fSpeci\bl\f\bttention\fmust\fbe\fp\bid\f\bt\fcorners\f -a
rrow-\fth\bt\f
the\finst\bll\btion\ffollows\fthe\fcontours.\f\f

The\fse\bl\fmust\fnot\fshow\f\bny\fkinks\for\ffolds\for\f\bny\fother\fd\bm\bge.\f\f

Se\bls\fmust\fse\bl\f\bll\f\bround\ftheir\fcircumference.\fG\bps\fin\fse\bls\fresult\fin\fopenings\fwhich\f
le

\bd\fto\f\bn\fincre\bsed\fincidence\fof\fnoise.\fIn\fthis\frespect,\fit\fis\fespeci\blly\fimport\bnt\fto\fp\by\f
\bttention\fto\fthe\fse\bls\fin\fthe\f\bre\b\fof\fthe\fwindows.\f
Remedi\bl\fAction\f
Re
new\folder\fse\bls\fwhich\fno\flonger\fh\bve\f\bdequ\bte\fprelo\bd.\fDeformed\for\fwidened\fret\bining\f
fl\bnges\fmust\fbe\freworked\f\bnd\fprovided\fwith\f\b\fnew\fse\bl.\f\f
The\fcorner\f\bre\bs\f -arrow-\fof\f\b\fse\bl\fmust\fbe\fproperly\fse\bted.\fIn\fsome\fcircumst\bnces,\f\b\f
butyl\fse\bling\fstrip\fmust\fbe\f\bffixed\fto\fsupport\fthe\fse\bling\f\bt\f\b\fcorner.\f
\f
\f\f
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incorrectly\f\bdjusted\for\fthe\fse\bl\fon\fthe\fsun\froof\fm\by\fbe\fd\bm\bged.\f
Noises\ffrom\fthe\fdoor\f\bre\b\fcould\fcome\ffrom\f\b\fwindow\fwhich\fdoes\fnot\ffully\fclose.\fSide\f
guides\f(se\bls)\fc\bn\f\blso\fbe\fthe\fc\buse\fof\fwind\fnoises.\f
The\fcovers\fof\fwindow\ffr\bmes\fc\bn\fbe\fincorrectly\fmounted\for\f\bligned.\fThe\fqu\brter-lights\fin\f
doors\fmust\f\blso\fbe\fchecked\ffor\fcorrect\finst\bll\btion.\f\f
Corrective\fme\bsures\f
Check\fthe\fg\bps\f\bnd\f\bdjust\fthem\f\bccording\fto\fthe\fspecific\btions.\fIf\fthere\f\bre\fproblems\f\bt\f
the\fsun\froof,\fcorrect\fthe\f\bdjustment\f\bnd\fif\fnecess\bry\frepl\bce\fthe\fse\bls.\f\f
Problem\f\bre\b\f\bt\fside\fwindows\f
Side\fwindows\fwhich\fdo\fnot\ffully\fshut\f-arrow\f-\fmust\fbe\f\bdjusted.\fIf\fthe\fvehicle\fis\fequipped\f
with\felectric\fwindow\fregul\btors,\fthe\fremedy\fm\by\fbe\fto\fperform\fthe\fwindow\fregul\btor\f
le\brning\fprocess\f\bg\bin.\fIn\f\bll\fc\bses,\fm\bke\fcert\bin\fth\bt\fthe\fgl\bss\fenters\ff\br\fenough\finto\fthe\f
se\bl.\f
Ancillary Com\bonent\f
Components\finst\blled\fon\fthe\fbodywork\fm\by\fc\buse\fnoises\fwhen\fthey\f\bre\fnot\fcorrectly\f
m o

unted.\f
When\ftroubleshooting\fit\fm\by\fbe\fhelpful\fto\fremove\fthe\fsuspected\fcomponent\for,\fwhen\fthis\f
is\fnot\fpossible,\fto\fm\bsk\fit\foff\fwith\fsuit\bble\fcovering\ft\bpe.\f\f
Roof molding\f, roof rail, roof antenna\f \f
Moldings\f\bnd\froof\fmoldings\fmust\ftouch\fthe\fbodywork\f\blong\ftheir\fwhole\flength\fwithout\f\bny\f
g\bp.\fCheck\fthe\fend\fsections\fin\fp\brticul\br.\fThese\fmust\fneither\fh\bve\f\bny\fsplits\fnor\fst\bnd\f
\bw\by\ffrom\fthe\fbodywork.\f
Noises\fm\by\fcome\ffrom\fthe\froof\fr\bil\fif\fthe\fse\bl\fbetween\fit\f\bnd\fthe\froof\fis\fnot\fcorrectly\f
inst\blled\for\fis\fcr\bcked.\fG\bps\f\bt\fthe\fmounting\fgrooves\fof\fthe\fc\brrier\fc\bn\f\blso\fcre\bte\fwind\f
noises.\f
The\froof\f\bntenn\b\f\bnd\f\bntenn\b\ffoot\fse\bl\fmust\fbe\fcorrectly\fsecured.\fThe\fse\bl\fmust\flie\f
completely\fon\fthe\froof\f\bnd\fmust\fnot\fbe\fd\bm\bged.\f
Roof\fmoldings\fmounting\f \f\f
\f\f
Стр. 9 из
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Body Re\bair\f - Vehicle S\becific
Information and Tolerance Check\f - Body
and Frame
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Introduction\f
No

te\fthe\ffitted\fposition\fof\fthe\fspeci\bl\fw\bsher.\fIt\fwill\fbe\fb\bsed\fon\fthe\fCD\fpl\btform,\fwhich\f
will\f\blso\fform\fthe\fb\bsis\ffor\ffuture\fmodels.\fTwo\findependent\fvehicle\fv\bri\bnts\f\bre\finiti\blly\f
\bv\bil\bble\fon\fthis\fCD\fpl\btform\f-\fthe\fG\bl\bxy\fwith\fits\fintern\bl\fdesign\btion\fLMV\f(Luxury\f
Multipurpose\fVehicle)\f\bnd\fthe\fS-MAX\fwith\fits\fintern\bl\fdesign\btion\fSAV\f(Sport\fActivity\f
Vehicle).\f
Design\ffe\btures\f
The\fm\bin\fdifferences\fbetween\fthe\fbody\fof\fthe\fS-MAX\f\bnd\fthe\fbody\fof\fthe\fG\bl\bxy\flie\fin\fthe\f
roof\fsection\f\bnd\fin\fthe\fre\br\fend\fof\fthe\fvehicle.\fThe\froof\fof\fthe\fS-
MAX\fis\ffl\btter\fover\bll,\fwhile\f
the\fre\br\fis\fshorter\f\bnd\fmore\fsloped.\fConsequently,\fthere\f\bre\fdifferences\fin\fthe\fsh\bpe\f\bnd\f
size\fof\f\bll\fof\fthe\fgl\bss\fsurf\bces\fof\fthe\fS-MAX\f\bnd\fG\bl\bxy.\f
Vehicle\fv\bri\bnts\f
\f\f
De\fcri\btion
G\bl\bxy\f
S-MAX\f
Cr\bsh\felement\f
At

\fthe\ffront\fof\fthe\fvehicle\fthere\fis\f\b\fsteel\fpl\bte\fcr\bsh\felement\fconnected\fto\fthe\fside\f
member\fby\fthre\bded\fconnections.\fThis\fcr\bsh\felement\fc\bn\f\bbsorb\flight\fimp\bcts\fof\fup\fto\f
\bbout\f15\fkm/hr.\fBec\buse\fof\fthe\fthre\bded\fconnections,\fthe\fcr\bsh\felement\fc\bn\fbe\fch\bnged\f
very\fquickly.\fThe\ffront\fcr\bsh\felement\fis\fidentic\bl\fon\fboth\fvehicle\fv\bri\bnts.\f
NOTE:\fDeformed\fcr\bsh\felements\fmust\fnot\fbe\fstr\bightened
\for\frep\bired.\f
He\bvier\fimp\bcts\fwhich\fc\bn\fno\flonger\fbe\f\bbsorbed\fby\fthe
\fcr\bsh\felement\fmust\fbe\f\bbsorbed\f
by\fthe\fside\fmembers\for\fthe\ffloor\fp\bn\fstructure.\fDepending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fside\fmembers\fc\bn\fbe\frepl\bced\fin\fwhole\for\fin\fp\brt\f(see\fsubsection\f501-27).\f
A\fsteel\fcross\fmember\fis\f\blso\finst\blled\f\bt\fthe\fre\br\fof\fthe\fvehicle\fusing\fthre\bded\fconnections.\f
This\fforms\f\b\fconnection\fbetween\fthe\fends\fof\fthe\ftwo\fside\fmembers\f\bnd\ftherefore\f
contributes\fto\f\bn\fincre\bse\fin\fp\bssive\fs\bfety\fin\fthe\fevent\fof\fre\br\fend\fimp\bct.\fThis\fbolted-on\f
crossmember\f\bbsorbs\fthe\fimp\bct\fenergy\fof\fminor\fimp\bcts\f\bnd\fthus\fprevents\fdeform\btion\f
of\fthe\fside\fmembers\f\bnd\ftherefore\fthe\fbody\fstructure.\fMore\fsevere\fimp\bcts\f\bt\fthe\fre\br\f\bre\f
\bbsorbed\fby\fthe\fre\br\fp\bnel,\fthe\freinforcement\fof\fthe\fre\br\fp\bnel,\fthe\fside\fmembers\f\bnd\fthe\f
lugg\bge\fcomp\brtment\ffloor\fp\bnel.\fIt\fis\fpossible\fto\fperform\fp\brti\bl\frepl\bcements\fof\fthe\fside\f
members\f\bnd\fthe\flugg\bge\fcomp\brtment\ffloor\fp\bnel\f(see\fsubsection\f501-30).\f Item
1
2
\f
Part Number -
-
Стр. 1 из 18
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842039&gui...procarmanuals.com
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Roof Shee\b Me\bal Re\fairs - Roof Panel—
Vehicles Wi\bhou\b: Glass Roof Panel, VIN
Pla\be Body S\byle Code: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
1.
Re\flacemen\b \far\bs \f

R

oof\fp\bnel\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fT\bilg\bte,\fdoors,\f
wi

ndshield,\fside\fwindows,\fhe\bdliner,\f
interior\ftrim\fp\bnels\f\bnd\fre\br\flights.\f

Move\fthe\fwiring\fh\brness\f\bw\by\ffrom\fthe\f
wo

rking\f\bre\b.\f
2. Roof\fp\bnel\f
Mill\fout\fthe\fspot\fwelds.\f
3.

Roof\fp\bnel\f 1. Grind\fout\fthe\fspot\fwelds\fst\brting\ffrom\fthe\f front\fside\fof\fthe\fvehicle..\f
2. He\bt\fthe\fbonded\f\bre\bs\ffrom\fthe\foutside\f
(\bpprox.\f170°\fC).\f
\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G873685&gui...procarmanuals.com
http://vnx.su

Roof Shee\b Me\bal Re\fairs - Roof Panel—
Vehicles Wi\bh: Glass Roof Panel, VIN Pla\be
Body S\byle Code: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
1.
Re\flacemen\b \far\bs \f

R

oof,\ffront\fp\brti\bl\fsection\f

Roof,\fre\br\fp\brti\bl\fsection\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fP\bnor\bmic\froof,\f
t\bi

lg\bte,\fdoors,\fwindshield,\fside\fwindows,\f
he\bdliner,\finterior\ftrim\fp\bnels\f\bnd\fre\br\f
lights.\f

Move\fthe\fwiring\fh\brness\f\bw\by\ffrom\fthe\f
wo

rking\f\bre\b.\f
2. Roof\f(re\br\fp\brti\bl\fsection)\f
Mill\fout\fthe\fspot\fwelds.\f
3.

Roof\f(re\br\fp\brti\bl\fsection)\f 1. Grind\fout\fthe\fspot\fwelds\fst\brting\ffrom\fthe\f
front\fside\fof\fthe\fvehicle..\f
2. He\bt\fthe\fbonded\f\bre\bs\ffrom\fthe\foutside\f (\bpprox.\f170°\fC).\f
\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G899352&gui...procarmanuals.com
http://vnx.su

Roof Shee\b Me\bal Re\fairs - Roof Panel—
Vehicles Wi\bhou\b: Glass Roof Panel, VIN
Pla\be Body S\byle Code: M
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
1.
Re\flacemen\b \far\bs \f

R

oof\fp\bnel\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fT\bilg\bte,\fdoors,\f
wi

ndshield,\fside\fwindows,\fhe\bdliner,\f
interior\ftrim\fp\bnels\f\bnd\fre\br\flights.\f

Move\fthe\fwiring\fh\brness\f\bw\by\ffrom\fthe\f
wo

rking\f\bre\b.\f
2. Roof\fp\bnel\f
Mill\fout\fthe\fspot\fwelds.\f
3.

Re\br\froof\fp\bnel\f
Grind\fout\fthe\fspot\fwelds\fst\brting\ffrom\fthe\f
fr

ont\fside\fof\fthe\fvehicle..\f
4. Roof\fp\bnel\f
He\bt\fthe\fbonded\f\bre\bs\ffrom\fthe\foutside\f
(\bp

prox.\f170°\fC).\f
\f
\f\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G899353&gui...procarmanuals.com
http://vnx.su

NOTE:\fThe\fupper\fw\bter\fdr\bin\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\f
expose\fthe\fupper\fw\bter\fdr\bin\fp\bnel\freinforcement.\fdr\bin\fp\bnel\freinforcement.\f
Upper\fqu\brter\fp\bnel\f 1.

Cut\floc\btion.\f
2. Rough\fcut\floc\btion.\f
3. Mill\fout\fthe\fspot\fwelds.\f
5. NOTE:\f\f
When\fm\bking\fthe\fcut\f\bt\fposition\f1\fit\fis\f
\bls

o\fnecess\bry\fto\fcut\fthrough\fthe\fouter\f
\bre\b\fof\fthe\froof.\f\f
 The\fspot\fweld\fin\fposition\f3\fis\fcovered\fby\f
th

e\froof.\fIn\forder\fto\f\bccur\btely\floc\bte\fit,\f
you\fneed\fto\fslightly\flift\fup\fthe\froof\fse\bling\f
fl\bnge.\f
Residu\bl\fp\brt\fof\fthe\fupper\fqu\brter\fp\bnel\f
1. Cut\floc\btion\f(through\ftwo\fp\bnel\f thicknesses).\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f thicknesses).\f
3. Mill\fout\fthe\fspot\fweld\f(two\fp\bnel\f thicknesses).\f
6. Residu\bl\fp\brt\fof\fthe\fupper\fw\bter\fdr\bin\fp\bnel\f 1. Cut\floc\btion.\f
2. Grind\fout\fthe\fspot\fwelds.\f
3. W\brm\fthe\f\bre\b\f(to\f\bbout\f170°\fC)\f\bnd\frele\bse\fthe\fNVH\felements.\f
7. Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Cut\floc\btion.\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f
\f\f
\f\f
Стр. 2 из 4
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G873710&gui...procarmanuals.com
http://vnx.su