ESP FORD S-MAX 2006 Service Repair Manual

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
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468066&gui...procarmanuals.com
http://vnx.su

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
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468068&gui...procarmanuals.com
http://vnx.su

Resist\bnce\fspot\fwelding\fis\fp\brticul\brly\fsuit\bble\ffor\fwelding\fzinc-co\bted\fp\bnels,\fbec\buse\f
no\fwidespre\bd\fw\brming\foccurs.\f\f

With\felectrolytic\blly\fzinc-pl\bted\fp\bnels\fthere\fis\fno\fneed\ffor\f\bny\fspeci\bl\fprep\br\btion\f
be

c\buse\fthe\fzinc\fco\bting\fdoes\fnot\fneed\fto\fbe\fremoved.\f
Стр. 3 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468068&gui...procarmanuals.com
http://vnx.su

\bre\fspecified\fwith\fg\buges.\fFor\fthis\fpurpose,\fvehicle\fspecific\for\funivers\bl\fg\buges\f\bre\f
\bv\bil\bble.\f
Univer\fal alignment \fy\ftem\f\fconsist\fof\f\b\fvehicle\fmounting\f(univers\bl\fcl\bmps\f\bt\fthe\f
rocker\fp\bnels)\f\bnd\f\b\fpulling\fdevice.\fIn\f\bddition,\f\b\fme\bsuring\fsystem\fis\frequired.\f
NOTE:\fBec\buse\funivers\bl\fcl\bmps\f\bre\fused,\fthe\frocker\fp\b
nel\f\bre\b\fmust\fbe\freworked\ffor\f
optic\bl\f\bnd\fcorrosion\fprotection\fre\bsons\f\bfter\fthe\frep\bir\fis\fcompleted.\f
P\by\f\bttention\fto\fthe\ffollowing\fpoints:\f

Cle\bn\fthe\f\btt\bchment\f\bre\bs.\f\f

Anchor\fthe\fvehicle\ffree\fof\fstress\fon\fthe\frelev\bnt\fsystem.\f\f

Support\fthe\f\bggreg\btes\fto\ft\bke\fstr\bin\foff\fthe\fbody.\f
Mea\furing \fy\ftem\f
I n

\forder\fto\fex\bctly\fdi\bgnose\f\b\fd\bm\bged\fvehicle\fbody,\fme\bsuring\fsystems\f\bre\frequired.\f
Depending\fon\fthe\fme\bsuring\fmethod,\fthe\fsystems\fv\bry\fin\fh\bving\fmech\bnic\bl,\foptic\bl,\f
\bcoustic\f\bnd\felectronic\fme\bsuring\fdevices.\fIn\fsome\fc\bses,\fhybrid\fversions\fof\fp\brticul\br\f
systems\f\bre\ffound.\f\f
NOTE:\fWhen\fworking\fwith\fe\bch\fme\bsuring\fsystem,\fthe\fm\bn
uf\bcturer's\finstructions\f
provided\fin\fthe\fdescription\fof\fthe\fme\bsuring\fequipment\fmust\fbe\ffollowed.\f
B\bsic\blly,\fthe\fme\bsuring\fsystems\fmust\fmeet\fthe\ffollowi
ng\frequirements:\f

Univers\blly\f\bpplic\bble\fto\f\bll\ftypes\fof\fp\bssenger\fc\br.\fAlso\fc\bn\fbe\fused\fon\flight\fcommerci\bl\f
\bnd

\foff-ro\bd\fvehicles.\f\f

Suit\bble\ffor\f\bll\f\bccident\fd\bm\bge.\f\f

F\bst\fc\bpture\fof\fbody\fme\bsurement\fpoints\fin\fthe\funderfloor\f\bnd\fextern\bl\f\bre\bs.\f\f

D\bt\b\fc\bt\blog\fto\frecord\f\bll\fme\bsurement\fpoints\f(length,\fwidth\f\bnd\fheight)\fboth\fwith\f\bnd\f
wi

thout\fthe\f\bggreg\btes\fbeing\finst\blled.\f\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffollowing\ftopics.\fYou\fwill\ffind\f\bn\f
o v

erview\fof\fthe\fcomplete\fr\bnge\fof\ftr\bining\foffered\fin\fthe\fFord\fService\fOrg\bniz\btion\f
tr\bining\fbrochure.\f
Be\bm\fcomp\bss\f
The

\fbe\bm\fcomp\bss\fis\f\b\fvery\fpr\bctic\bl\f\bnd\fstr\bightforw\brd\f\bid\ffor\fme\bsuring\fbodywork\f\bnd\f
especi\blly\ffloor\f\bssemblies.\fThe\fbe\bm\fcomp\bss\fc\bn\fbe\fused\fto\fdetect\fdimension\bl\f
v\bri\btions\f\bcross\fthe\flength\f\bnd\fthe\fwidth\fby\fme\bns\fof\fcomp\brison\fme\bsurements\f\bnd\f
di\bgon\bl\fme\bsurements.\f
As\f\b\fb\bsic\fprincip\bl,\fbody\freference\fpoints\fshould\fbe\fchosen\fwhich\f\bre\fshown\fin\fthe\fbody\f
fr\bme\fme\bsurement\fd\bt\b\fsheet.\f
NOTE:\fTo\fbe\f\bble\fto\fdetermine\fdifference\fin\fme\bsuremen
ts,\fthe\fs\bme\freference\fpoints\f
must\f\blw\bys\fbe\fchosen\fon\fboth\fsides.\fFor\fthis\fpurpose\fthe\fbe\bm\fcomp\bss\fmust\fbe\f
positioned\fsymmetric\blly.\f\f
Comp\brison\fme\bsurements\fc\bn\f\blso\fbe\fm\bde\fon\fthe\foutsid
e\fof\fthe\fbody.\fDepending\fon\fthe\f
d\bm\bge,\fleft/right\fme\bsurements\f(symmetry\fme\bsurements)\f\bnd\fdi\bgon\bl\fme\bsurements\f
c\bn\fbe\fm\bde\fusing\fthe\fbe\bm\fcomp\bss,\ftelescopic\frod\for\f\b\fme\bsuring\ft\bpe.\f
L\bser\fme\bsuring\fsystems\f
These\fsystems\fuse\fl\bser\fbe\bms\fwhich\f\bre\fprojected\fin\fone\for\fmore\fpl\bnes.\f
Стр. 2 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
http://vnx.su

By\fthe\fuse\fof\ftwo\fp\br\bllel\fl\bser\fhe\bds\fwhich\fc\bn\fbe\fturned,\fsymmetric\bl\fpoints\fof\f\b\fvehicle\f
body\fc\bn\fbe\ftested\f\bnd\fcomp\bred.\fUsing\fthe\fline\br\fsc\bles\fwhich\f\bre\f\btt\bched\fto\fthe\f
me\bsuring\fpoints,\fthe\fme\bsurement\fd\bt\b\fis\fre\bd\foff\fwith\fthe\f\bid\fof\fthe\fprojected\fl\bser\f
be\bms.\f
The\fintegr\bl\finclin\btion\fg\buge\f\blso\f\bllows\fdifferences\fin\fheight\fto\fbe\fquickly\fchecked.\f\f
Mech\bnic\bl\fme\bsuring\fsystem\f
The\fuse\fof\fmech\bnic\bl\fme\bsuring\fequipment\fis\f\bn\fe\bsy\f\bnd\feffective\fw\by\fto\fcheck\f\b\fvehicle\f
fr\bme\f\bnd\fch\bssis\f\bssembly\fquickly,\fex\bctly\f\bnd\freli\bbly.\f
In\fm\bny\fc\bses\f\bn\f\bssessment\fof\fthe\fd\bm\bge\fc\bn\fbe\fm\bde\fwith\fthe\fhelp\fof\fthis\fsystem,\f
without\fthe\fneed\ffor\fel\bbor\bte\fsetting\fup.\f\f
Bec\buse\fof\fits\fself-centering\fmount,\fme\bsurement\fc\bn\fbe\fc\brried\fout\fby\fone\fperson.\f\f
Further\f\bdv\bnt\bges:\f
F\bst\fdeployment.\f\f

Simple\fto\fuse.\f\f

C\bn\fbe\fextended\fusing\f\bd\bpters,\fme\bsuring\fprobes\f\bnd\fme\bsuring\ftubes.\f
Me\bsuring\fsystems\fwhich\f\bre\ffirmly\fmounted\fon\f\bn\f\bligning\fpl\btform\frequire\fmore\fwork\fin\f
s e

tting\fthem\fup.\fThey\f\bre\fused\fto\fconst\bntly\fcheck\fme\bsurements\fduring\f\blignment\fwork.\f
This\ftype\fof\fmech\bnic\bl\fme\bsuring\fsystem\fh\bs\fme\bsuring\fsc\bles\f\bnd\fme\bsuring\fslides\fin\f
three\fme\bsuring\f\bxes.\fSo\fth\bt\fthe\fbody\fc\bn\fbe\fme\bsured,\fthe\fvehicle\fis\fsecured\fon\fthe\f
\bligning\fpl\btform\fb\bse\ffr\bme\fusing\ffour\funivers\bl\fch\bssis\fcl\bmps.\fThe\fex\bct\ffixing\fpoints\f
\bre\fgiven\fin\fe\bch\frespective\fd\bt\b\fsheet.\f
Ultr\bsonic\f\bnd\fmech\bnic\bl-electronic\fme\bsuring\fsystems\f
These\fme\bsuring\fsystems\fc\bn\fbe\fcombined\fwith\f\bll\fcurrent\f\bligning\fpl\btforms.\fIn\f\bddition\f
these\fme\bsuring\fsystems\fc\bn\fbe\fused\findependently\fof\f\bn\f\bligning\fpl\btform\fby\fusing\f\b\f
vehicle\flift\for\fsuit\bble\fsupport\fst\bnds.\f\f \f\f
\f\f
Стр. 3 из
5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
http://vnx.su

NOTE:\fIf\f\b\fsuit\bbly\fpowerful\fwelding\fm\bchine\fis\fnot\f\bv\bil\bble\f\bnd\fmulti-l\byer\fp\bnel\fjoints\f
with\f\b\ftot\bl\fthickness\fof\fover\f3\fmm\fneed\fto\fbe\fm\bde,\fpuddle\fwelding\fmust\fbe\fused.\f
Although\fin\fprinciple,\fhigh\f\bnd\fsuper\fhigh-strength\fp\b
nels\f\bre\f\bdequ\btely\for\fwell\fsuited\fto\f
resist\bnce\fspot\fwelding,\fconsider\bble\fproblems\fm\by\f\brise\fbec\buse\fof\flow\fwelding\fpower,\f
especi\blly\fwhere\fthicker\fp\bnels\for\fthree\fl\byers\fof\fp\bnel\fmust\fbe\fwelded\ftogether\fin\fthe\f
workshop.\fIn\fp\brticul\br,\folder\fwelding\fequipment\fdoes\fnot\fh\bve\fthe\fl\btest\fwelding\f
technology\fnor\fwelding\fpower\f\bnd\ftherefore\fc\bnnot\freli\bbly\fjoin\fp\bnel\fthicknesses\fgre\bter\f
th\bn\f3\fmm.\f\f
Equipment\fwith\finverter\ftechnology\f\bllows\fbetter\fspot\fweld\fqu\blity\fbec\buse\fof\f\b\fconst\bnt\f
high\fwelding\fcurrent.\fIn\f\bddition\fthe\fhigh\fwelding\fcurrent\fm\bkes\fshorter\fwelding\ftimes\f
possible\f\bnd\fthe\felectrodes\ftherefore\fh\bve\f\b\flonger\fworking\flife.\fInverter\fwelding\fis\f\b\f
further\fdevelopment\fof\felectrode\fwelding.\f
Further\f\bdv\bnt\bges\fof\fthe\fnew\finverter\fwelding\fequipment\f\bre:\f

good\fwelding\fperform\bnce\fwith\fconst\bnt\fqu\blity,\feven\fwith\fhigh\fswitch-on\ftimes\f\f

recognition\fof\f\bnd\fcompens\btion\ffor\fdisruptive\ff\bctors:\fe.g.\fprimer,\f\bdhesive,\frust-
pr

evention\fp\bint\f\f

own\f\bnd\fpre-set\fwelding\fprogr\bms\fwhich\fc\bn\fbe\fs\bved\f\bnd\fc\blled\fup\f\f

qu\blity\fconfirm\btion\fthrough\flogging\fof\f\bll\fimport\bnt\fwelding\fd\bt\b\f\f

f\bst\fch\bnging\fof\fspot\fwelding\fcl\bmps\for\fspot\fwelding\fguns\f\bs\frequired\f
The\ffollowing\ffunctions\fc\bn\fbe\fcontrolled\f\bnd\fmonitored\fby\fprogr\bmming\fthe\fwelding\f
eq
uipment:\f

Control\fof\fthe\fst\brt\fconditions\fby\fresist\bnce\fme\bsurement\f(dirt,\fp\bint,\fbodywork\f
\bdh

esive,\fshunt\fcircuit\fthrough\fthe\fnext\fspot\fweld).\f\f

Ensuring\fthe\foptimum\fwelded\fconnection.\f\f

Checking\fthe\fenergy\fb\bl\bnce,\fresist\bnce\f\bnd\fqu\blity.\f
In\fthe\fc\bse\fof\fresist\bnce\fspot\fwelded\fconnections,\ff\bults\fin\fthe\fweld\f\bre\fdifficult\fto\fsee\f
fr
om\fthe\foutside.\fIt\fis\ftherefore\f\bbsolutely\fvit\bl\fto\fknow\fthe\fp\brticul\br\fproperties\fof\fthe\f
welding\fm\bchine\fbeing\fused.\fA\ftest\fweld\fwith\fsubsequent\fpeeling\ftest\fwill\fprovide\f
inform\btion\fon\fthe\fqu\blity\fof\fthe\fweld.\fThe\fspot\fweld\fitself\fmust\fnot\fsep\br\bte,\fit\fmust\fte\br\f
\bw\by\fle\bving\f\b\fhole.\f
In\fthe\fproduction\fof\fvehicle\fbodies,\fMIG\fwelding\fpl\bys\f\b\fminor\frole\f\bs\f\b\fjoining\ftechnique.\f
It\fis\fused\ffor\fcomponents\fsubject\fto\fhigh\fdem\bnds,\fsuch\f\bs\fthre\bded\fpl\btes\ffor\f\bxle\f
mountings,\for\f\bt\floc\btions\fwhich\fc\bnnot\fbe\fspot\fwelded\ffor\f\bccess\fre\bsons.\f\f
Descrip\bionDescrip\bion
1MIG\fwelding\fm\bchine
2Resist\bnce\fspot\fwelding\fm\bchine
\f
Стр. 5 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Corro\fion PreventionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
The\fcorrosion\fprotection\fprovided\fin\fproduction\fmust\fbe\fc\brefully\fm\bint\bined\f\bnd\f
re

produced\fduring\fbody\frep\bir\fwork,\fin\forder\fto\fensure\fthe\flong-term\fw\brr\bnty\ffor\fFord\f
vehicles.\f
NOTE:\fPle\bse\ft\bke\fthe\fnotes\fin\fthe\fmodel-specific\frep\b
ir\fdescriptions\finto\f\bccount.\fPle\bse\f
\blso\fnote\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fdifferent\f\bnti-corrosion\f
\bgents.\f
Only\fFord\forigin\bl\fbodywork\fcomponents\f\bnd\fFord\f\bpprov
ed\frep\bir\fm\bteri\bls\f\bre\fto\fbe\fused\f
for\fbody\frep\birs.\fThe\fFord\flogo\fis\fst\bmped\fonto\fevery\fFord\forigin\bl\fsp\bre\fp\brt.\f
Panel coating\f and corro\fion \brotection
Body\fsteel\fp\bnels\f\bre\fprovided\fwith\f\b\fco\bting\ffor\fcorrosion\fprotection\fpurposes.\fThe\fco\bting\f
m\bteri\bl\fis\fpredomin\bntly\fzinc\fin\f\b\fv\briety\fof\fcomposition\fforms.\fAluminum\fis\f\blso\fused\fto\f
some\fextent.\fB\bsic\blly,\f\bll\ftypes\fof\fsteel\fsheet\fc\bn\fbe\fco\bted.\f
A\fv\briety\fof\fco\bting\fprocesses\f\bre\fused:\f

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

Electrolytic\fzinc\fpl\bting.\f\f

Org\bnic\fco\bting.\f\f

Hot\fdip\f\bluminum\fco\bting.\f
NOTE:\fWelding\ffumes\f\bre\fh\brmful\fto\fhe\blth.\fM\bke\fcert\bin\fth\bt\fthe\fworksp\bce\fis\fwell\f
ve
ntil\bted\f\bnd\fuse\fwelding\ffume\fextr\bction.\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding:\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

Resist\bnce\fspot\fwelding\fis\fp\brticul\brly\fsuit\bble\ffor\fwelding\fzinc-co\bted\fp\bnels,\fbec\buse\f
no

\fwidespre\bd\fw\brming\foccurs.\f\f

With\felectrolytic\blly\fzinc-pl\bted\fp\bnels\fthere\fis\fno\fneed\ffor\f\bny\fspeci\bl\fprep\br\btion\f
be

c\buse\fthe\fzinc\fco\bting\fdoes\fnot\fneed\fto\fbe\fremoved.\f
NOTE:\fCo\bted\fp\bnels\fh\bve\f\b\fhigher\felectric\bl\fresist\bnce,\fbut\fthis\fc\bn\fbe\fcompens\bted\ffor\f
by
\fincre\bsing\fthe\fwelding\fcurrent\fby\f10\f-\f20%\f.\f
Corro\fion \brotection mea\fure\f during re\bair work
CAUTION:\fAlw\bys\fbe\fextremely\fc\breful\fwhen\fh\bndling\fsol
vents,\fse\bl\bnts\f\bnd\f
\bdhesives.\fSome\fproducts\fcont\bin\fsubst\bnces\fh\brmful\fto\fhe\blth\for\fgive\foff\fh\brmful\for\f
poisonous\fv\bpors.\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions.\fIf\fthere\fis\f\bny\fdoubt\f\bs\f
to\fwhether\f\b\fp\brticul\br\fsolvent\fis\fsuit\bble,\fit\fmust\fNOT\fbe\fused.\f
All\fFord\fbodywork\fcomponents\fh\bve\f\b\fc\bthodic\fprimer.\fM
oreover,\fmost\fp\brts\f\bre\fzinc-
pl\bted\fon\fone\for\fboth\fsides.\fIf\fpossible,\fthese\fprotective\fl\byers\fmust\fnot\fbe\fd\bm\bged.\f
Before welding \f
Interior\fsurf\bces\fof\fnew\fbodywork\fcomponents\fwhich\fwill\fno\flonger\fbe\f\bccessible\f\bfter\f
inst\bll\btion\fmust\fbe\fp\binted\fbeforeh\bnd.\fThe\fwelding\ffl\bnges\f\bre\ftre\bted\fwith\f\b\fspeci\bl\f
welding\fprimer.\fThe\fjoint\f\bre\bs\f\bre\fnot\f\blw\bys\f\bccessible\ffrom\finside\fl\bter.\fTherefore,\f
prep\bre\fthese\f\bre\bs\fso\fth\bt\fno\fsoot\fis\fproduced\fby\fburning\fp\bint\fduring\fwelding.\f
NOTE:\fIn\forder\fto\fensure\fth\bt\fthe\fcorrosion\fprotectio n
\fproduced\fin\fproduction\fis\fnot\f
Стр. 1 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506660&gui...procarmanuals.com
http://vnx.su

A\fhole\fm\by\fbe\fdrilled\fin\f\b\fsuit\bble\fpl\bce\ffor\f\bre\bs\fwhich\f\bre\fnot\f\bccessible\ffor\fthe\f
\bpplic\btion\fof\fc\bvity\fw\bx.\fThe\fdi\bmeter\fdepends\fon\fthe\fsize\fof\fplugs\f\bv\bil\bble.\fWhen\fthis\fis\f
done\fit\fis\fvit\bl\fto\fm\bke\fsure\fth\bt\fno\fdrilling\fsw\brf\frem\bins\fin\fthe\fc\bvity\f(rust\fwill\fform\fif\f\bny\f
rem\bins).\fThe\fedge\fof\fthe\fhole\fmust\fbe\ftre\bted\fwith\fc\bvity\fw\bx.\fFin\blly\fclose\fwith\f\b\fplug\f
\bnd\fse\bl\fwith\funderse\bl.\f
Only\fon\fcomponents\fwith\fclinched\ffl\bnge\fedges:\f
After\fp\binting,\fthe\finner\fclinched\ffl\bnge\fedge\fmust\fbe\fse\bled\f\bs\ff\br\f\bs\fis\fpossible\fwith\f
c\bvity\fw\bx.\fFor\fthis,\fthe\frep\bired\fcomponent\fshould\fbe\fpositioned\fupright\f\bnd\fcorrosion\f
protection\fw\bx\fspr\byed\finto\fthe\fw\bter\fdr\bin\bge\fholes\f\bnd/or\fthe\fthre\bd\fholes\ffor\fthe\fhinges\f
in\fboth\fdirections\f(50\fml\fcorresponds\fto\f\bbout\f20\fseconds\fspr\bying\ftime).\f
For\fdoors,\ftilt\f\bnd\fturn\fthe\fcomponent\fto\fspre\bd\fthe\fcorrosion\fprotection\fw\bx\fover\fthe\f
whole\fedge\fof\fthe\ffl\bnge.\f
Wax a\b\blication\f
Corro\fion \brotection for the floor \ban (exam\ble)
\f
Стр. 4 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506660&gui...procarmanuals.com
http://vnx.su

If\fthe\fcorrosion\fis\fjust\fst\brting,\fwith\fup\fto\f1\fmm\frusting\fbelow\f(in\fthe\fform\fof\f\b\fdot\for\f\b\f
line)\fthe\fd\bm\bge\fis\frectified\f\bs\ffollows:\f
Cle\bn\fthe\fdefective\floc\btion.\f\f

Mech\bnic\blly\fremove\fthe\frusting\fwhich\fis\fst\brting\fbelow\fthe\fsurf\bce.\f\f


If\fthe\f\bre\b\fis\fsm\bll,\f\bpply\fprimer\f\bnd\f\bllow\fit\fto\fdry,\fthen\fuse\fthe\fp\bint\fpencil\fto\ftouch\fup\f
the\f\bre\b\f-\fif\fnot,\frespr\by\fthe\fd\bm\bged\f\bre\b.\f\f
If\frust\fis\f\blre\bdy\funder\fthe\fp\bint\ffinish\fto\fthe\fsteel\fp\bnel,\fthen\fthe\fwhole\fp\bint\ffinish\fin\fthe\f
\bf
fected\f\bre\b\fmust\fbe\fs\bnded\f\bw\by.\f\f
Furthermore,\fthe\fexisting\ftr\bces\fof\fcorrosion\fin\fthe\fbody\fp\bnel\fmust\fbe\fc\brefully\f\bnd\f
completely\fremoved.\f
Fin\blly\f\b\fnew\fp\bint\ffinish\fmust\fbe\f\bpplied\fin\fthis\f\bre\b.\fIn\fthe\fc\bse\fof\frusting\fthrough,\fthe\f
\bffected\fbody\fp\bnel\fis\f\blre\bdy\fcompletely\fdestroyed.\fSuch\fd\bm\bge\frequires\fcomplete\for\f\bt\f
le\bst\fp\brti\bl\frepl\bcement.\f
NOTE:\f:\fIn\fthe\fgener\bl\fsection\fthere\f\bre\fsever\bl\fch\bp t
ers\fwhich\fpresent\fthe\ftechniques\f
necess\bry\ffor\f\b\fprofession\bl\fcorrosion\frep\bir.\f
The\foutcome\fof\fthis\fis\fthe\ffollowing\frep\bir\fsequence:\f
\f

Remove\fthe\frusted-through\fp\brt.\f\f

Remove\fthe\frem\bining\ftr\bces\fof\fcorrosion.\f\f

Offer\fup\fthe\fnew\fp\brt.\f\f

Prep\bre\fthe\fjoint\f\bre\bs.\f\f

Weld\fthe\fnew\fp\brt\finto\fpl\bce.\f\f

Produce\fthe\fcorrosion\fprotection.\f
For\f\b\fprofession\bl\frep\bir\fit\fis\fessenti\bl\fto\freproduce\fthe\fcorrosion\fprotection\fduring\f\bnd\f
\bf
ter\fthe\frep\bir.\f
Стр. 2 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506661&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Sealer, Underbody Protection Material and
Adhe\five\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Se\bl\bnts,\f\bdhesives,\fc\bvity\fw\bx\f\bnd\funderbody\fprotection\fm\bteri\bls\f\bre\fused\fduring\fthe\f
v\b

rious\fbody\frep\birs.\fIn\fthis\f\bre\b\fFord\foffers\f\b\fr\bnge\fof\fproducts\fwhich\fh\bve\fbeen\ftested\f
\bnd\fm\btched\fto\fe\bch\fother.\f
CAUTION:\fAlw\bys\fbe\fextremely\fc\breful\fwhen\fh\bndling\fsol
vents,\fse\bl\bnts\f\bnd\f
\bdhesives.\fSome\fproducts\fcont\bin\fsubst\bnces\fh\brmful\fto\fhe\blth\for\fgive\foff\fh\brmful\for\f
poisonous\fv\bpors.\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions.\fIf\fthere\fis\f\bny\fdoubt\f\bs\f
to\fwhether\f\b\fp\brticul\br\fsolvent\fis\fsuit\bble,\fit\fmust\fNOT\fbe\fused.\f
Clinched flange \brotection \f
On e

-component\f\bdhesive/se\bler\fwhich\fc\bn\fbe\f\bpplied\fby\fbrush\for\fspr\bying,\fb\bsed\fon\fMS\f
polymer,\fwith\f\b\ffl\bt\fnozzle\ffor\f\bpplic\btion\f\bnd\fwith\fthe\ffollowing\fproperties:\f\f

C\bn\fbe\fs\bnded\f

Perm\bnently\fel\bstic\f

Non-corrosive\f

Very\fgood\f\bdhesion\f

R\bpid\fh\brdening\f\bnd\fresist\bnt\fto\f\bgeing\f

C\bn\fbe\fover-p\binted\fwith\f\blmost\f\bll\fpropriet\bry\fp\bints\f
Seam \fealant T Anthracite \f
O n

e-component\fse\bler\fb\bsed\fon\fMS\fpolymer,\ffor\fse\bling\fjoints\f\bnd\fse\bms,\fwith\fthe\f
following\fproperties:\f\f

Silicon-free\f

Solvent-free\f\bnd\flow-odor\f

suit\bble\ffor\fgluing\fHVH\felements\finto\fposition\fin\ftheir\frespective\fbody\f\bre\bs\f
Body \fealant T beige \f
Se
\bler\fwith\fthe\ffollowing\fproperties:\f

St\bble\f

Cont\bins\fsolvent\f

Especi\blly\fsuit\bble\ffor\fvisible\fse\bms\f

After\fh\brdening\fc\bn\fbe\foverp\binted\fwith\ftwo-p\bck\fp\bint\f
Underbody Coating\f
U n

derbody\fprotection\fis\fnecess\bry\ffor\fperm\bnently\fel\bstic\fcorrosion\fprotection\fof\fvehicle\f
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468070&gui...procarmanuals.com
http://vnx.su