ESP FORD S-MAX 2006 Service Repair Manual

NOTE:\fSteplessly\fv\bri\bble\fm\bchines\fincre\bse\fthe\fworking\flife\fof\fthe\fcutting\ftool.\fUse\fof\f\b\f
suit\bble\flubric\bnt\fc\bn\fincre\bse\fthis\feven\ffurther.\f\f
A\fspot\fweld\fmilling\ftool\fusu\blly\fh\bs\f\bn\f\bdjust\bble\fdep
th\fstop\f\bnd\f\b\fs\bfety\ffixing\fsystem.\f
These\fprevent\fthe\fm\bchine\ffrom\fdrilling\ftoo\fdeep\f\bnd\fthe\fcutter\ffrom\fslipping\fwhile\f
working.\f
Rod \fander
Another\foption\ffor\fsep\br\bting\fresist\bnce\fspot\fwelds\fis\fto\fuse\fthe\frod\fs\bnder.\f\f
If\fspot\fwelds\f\bnd\fMIG\fwelds\f\bre\fdifficult\fto\fre\bch,\f\b\frod\fs\bnder\fm\by\foffer\f\bn\f\bltern\btive.\f
Short \ftroke \faw
The\fshort\fstroke\fs\bw\fis\fsuit\bble\ffor\fsep\br\bting\fvehicle\fbody\fcomponents\f\bnd\ffor\fm\bking\f\b\f
sep\br\bting\fcut\ffor\fp\brti\bl\frep\birs.\f
NOTE:\fIn\forder\fnot\fto\fd\bm\bge\fp\bnels,\fwiring\fh\brnesses ,
\fhoses\for\fsimil\br\fcomponents\f
which\flie\fbehind,\fremove\fthem\fbeforeh\bnd\f\bs\fnecess\bry.\f
The\fn\brrow\fdesign\fof\fthe\fs\bw\fbl\bde\fpermits\fcutting\fin\f
tight\fcurves.\fStr\bight\fcuts\frequire\f\b\f
rel\btively\fgre\bt\fde\bl\fof\fpr\bctice.\f
Orbital \faw
Where\fuse\fof\fthe\fshort\fstroke\fs\bw\fis\fdifficult\fbec\buse\fof\fthe\fbody\fconstruction,\fthe\forbit\bl\f
s\bw\fc\bn\fbe\fused.\f
The\fcutting\fdepth\fof\fthe\forbit\bl\fs\bw\fc\bn\fbe\fset.\fThis\f\bllows\fsep\br\bting\fcuts\fto\fbe\fm\bde,\f
despite\fp\bnels\for\fother\fcomponents\flying\fin\fd\bnger\fbehind.\fStr\bight\fcut\flines\fc\bn\fbe\fmore\f \f\f
\f\f
\f\f
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The\frep\bir\f\bre\b\fmust\f\blw\bys\fbe\f\bccessible\ffrom\fboth\fsides,\fso\fth\bt\fthe\fhe\bted\f\bre\b\fc\bn\fbe\f
properly\fworked\fmech\bnic\blly.\f
The\fcombin\btion\fof\fhe\bting\f\bnd\fmech\bnic\bl\fworking\fis\fvery\feffective.\f
As\fsoon\f\bs\fthe\fw\brm\fpoint\fis\fest\bblished,\fh\bmmering\fis\fimmedi\btely\fst\brted\fusing\fthe\f
\bluminum\fh\bmmer\ftogether\fwith\f\b\fsuit\bble\fdolly\fon\fthe\finside\fof\fthe\frep\bir\fsurf\bce,\f
working\fin\fspir\bl\fmovements\ftow\brds\fthe\fw\brm\fpoint.\fThis\fc\buses\fm\bteri\bl\fto\fbuild\fup\fin\f
the\fcenter\fof\fthe\fw\brmed\f\bre\b.\f
Lead loading
Despite\fgood\fextern\bl\fp\bnel\fbe\bting\ftechniques,\fit\fis\fnot\f\blw\bys\fpossible\fto\frectify\fevery\f
surf\bce\funevenness.\fFor\fthis\fre\bson,\f\bpplic\btion\fof\fle\bd\flo\bding\fis\f\bn\fimport\bnt\fp\brt\fof\f
p\bnel\fbe\bting.\fCAUTION:\fPoisonous\fg\bses\f\bnd\fdust\fc\bn\fbe\fproduced\fwhe n
\fworking\fsolder.\fUse\f\bn\f
extr\bction\funit\f\bnd,\fif\frequired,\f\b\fprotective\fm\bsk.\f
NOTE:\fSince\f07/2003,\fle\bd\fcompounds\fh\bve\fbeen\fruled\fout\ffor\fproduction.\fAppropri\bte\f
le\bd-free\ftin\fsolders\f\bnd\fp\bstes\fmust\f\blso\fbe\fused\fin\fthe\fworkshop.\f
Typic\bl\f\bpplic\btion\f\bre\bs:\f

Body\fcomponents\fwith\flimited\for\fno\f\bccess\ffrom\fthe\fre\br.\f\f

Body\fcomponents\fwith\fvery\fn\brrow\fcross-section.\f\f

Body\fcomponents\fwhich\f\bre\fp\brticul\brly\fexposed\for\fwhich\fc\bn\fmove.\f\f

Weld\fse\bms\fof\fp\brti\bl\frep\birs.\f\f

Rocker\fp\bnel\f\bre\bs,\fwheel\f\brch\fedges,\fside\fp\bnel\f\bre\bs.\f\f

Doors,\fhood,\flugg\bge\fcomp\brtment\flid.\f\f

Sw\bge\flines\f\bnd\fjoint\f\bre\bs.\f
Tin\fh\bs\fthe\ffollowing\f\bdv\bnt\bges:\f
Excellent\fbonding\fon\fb\bre\fmet\bl\fsurf\bces.\f\f
Descrip\bionDescrip\bion
1Overstretched\f\bre\b
2Point\fhe\bting\fusing\fthe\foxy-\bcetylene\ftorch
3Spir\bl\fsh\bped\fknocking\fb\bck\fwith\fdolly
\f
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Body Re\bair\f - General Information -
Joining Technique\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Welding
Be

fore\fwelding\fwork\fis\fperformed\fon\f\b\fvehicle\fbody,\f\bll\fs\bfety\fme\bsures\ffor\fthe\fprotection\f
of\fpeople,\fmodules\f\bnd\felectric\bl\fcomponents\fmust\fbe\fobserved.\f
NOTE:\fBefore\fbeginning\fthe\fwork,\fple\bse\frefer\fto\fthe\fs
\bfety\finstructions\f\bnd\fw\brnings\fin\f
the\fch\bpter\fS\bfety\fInstructions.\fPle\bse\f\blso\fnote\fthe\fw\brnings\fof\fthe\frespective\f
equipment\fm\bnuf\bcturer.\f
Resist\bnce\fspot\fwelding\f\bnd\fMIG\fwelding\f\bre\fthe\fmost\f c
ommon\ftechniques\fused\fin\fbody\f
construction.\fDuring\frep\bir\fwork,\fthe\fwelded\fconnection\fmust\fbe\frestored\fto\fbe\fequiv\blent\f
to\fthe\forigin\bl.\f
Re\fi\ftance \f\bot welding.
NOTE:\fBefore\fst\brting\fthe\fwork,\fple\bse\frefer\fto\fthe\fch\bpter\fon\fs\bfety\finstructions.\f
In

\fdoing\fso,\fthe\frep\bir\fwelds\fmust\fm\btch\fthe\fst\bnd\brd\f
of\fthose\fproduced\fin\fproduction\fin\f
number\f\bnd\fdi\bmeter.\f
Preconditions\ffor\fresist\bnce\fspot\fwelding:\f

The\fp\bnels\fto\fbe\fwelded\foverl\bp.\f\f

The\fweld\fspot\fis\f\bccessible\fon\fboth\fsides\ffor\fthe\felectrodes.\f\f

The\fsh\bpe\f\bnd\f\blignment\fof\fthe\fweld\felectrodes\fis\fcorrect.\f\f

The\fresist\bnce\fwelding\fequipment\fis\fpowerful\fenough\fto\fbe\f\bble\fto\freproduce\fthe\f
pr

oduction\fspot\fweld\fdi\bmeter.\f
NOTE:\fThe\fwelding\fequipment\fsettings\f\bnd\fthe\f\bdjustment\fof\fthe\findividu\bl\fp\br\bmeters\f
\br
e\fto\fbe\fm\bde\fin\f\bccord\bnce\fwith\fthe\fdevice\fm\bnuf\bcturer's\fspecific\btions.\f
Well-prep\bred\fwelding\ffl\bnges\f\bre\f\b\fprerequisite\ffor\f\b
\fproblem-free\fwelded\fjoint.\fThis\f
me\bns:\f

The\fwelding\ffl\bnges\fmust\flie\fperfectly\ffl\bt\fto\fone\f\bnother.\f\f

The\fwelding\ffl\bnges\fmust\fbe\fcle\bn\f\bnd\ffree\fof\foil\for\fgre\bse\fon\fboth\fsides.\f\f

Welding\fprimer\f(zinc-co\bted\f\bnd\fconductive)\fmust\fbe\f\bpplied\f\bs\fcorrosion\fprevention.\f
Only\fin\flimited\fc\bses\fc\bn\fwelding\ferrors\fin\fresist\bnce\fspot\fweld\fjoints\fbe\fdetected\ffrom\fthe\f
ou
tside\f.\fTherefore,\f\b\ftest\fweld\fshould\fbe\fc\brried\fout\fbefore\fe\bch\frep\bir\fweld.\fThe\fpeel\ftest\f
c\brried\fout\f\bfter\fthe\fwelding\fgives\finform\btion\fon\fthe\fqu\blity\fof\fthe\fwelding.\fThe\fspot\fweld\f
must\fnot\ffl\bke\foff.\f
MIG welding
B\bsic\blly,\fthree\fmethods\fof\fMIG\fwelding\f\bre\fused:\f

Puddle\fweld.\f\f
\f
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Continuous\fbe\bd\fwelding\f\f

Intermittent\fbe\bd\fwelding\f
Fields\fof\f\bpplic\btion\f

Any\fjoins\fth\bt\f\bre\fMIG\fwelded\fin\fproduction\fmust\f\blso\fbe\frepl\bced\fby\fMIG\fwelds.\f\f

Puddle\fwelding\fm\by\fbe\fused\fin\fcert\bin\fc\bses,\fif\fthere\fis\finsufficient\f\bccess.\f\f

If\fthe\fover\bll\fp\bnel\fthickness\fis\fgre\bter\fth\bn\f3\fmm,\fwithout\fcorrespondingly\fpowerful\f
sp

ot\fwelding\fequipment,\fpuddle\fwelding\fshould\fbe\fused.\f\f

When\fde\bling\fwith\f\bny\fMIG\fbr\bzed\fjoints\fwhich\f\bre\fpresent,\ffollow\fthe\fvehicle-specific\f
re

p\bir\finstructions.\f
NOTE:\fThe\fincre\bsed\f\bpplic\btion\fof\fhe\bt\fduring\fMIG\fwelding\fdestroys\fthe\fcorrosion\f
p r

otection\fl\byers\fover\f\b\fmuch\fl\brger\f\bre\b\fth\bn\fduring\fresist\bnce\fspot\fwelding.\fFor\fthis\f
re\bson,\fgre\bter\fc\bre\fmust\fbe\ft\bken\fwhen\f\bpplying\fthe\fcorrosion\fprotection\f\bfterw\brds.\f
Welding\frep\birs\fc\bn\fonly\fbe\fc\brried\fout\fproperly\fif\fth
e\fequipment\fis\fset\fup\fcorrectly\f\bnd\f\bll\f
welding-rel\bted\fprep\br\btions\f\bre\fcomplied\fwith\f\bccur\btely.\f

Ple\bse\fnote\fthe\finstructions\fof\fthe\frespective\fwelding\fequipment\fm\bnuf\bcturer.\f\f

The\fhose\f\bssembly\fmust\fbe\funtwisted.\f\f

The\fcore\fmust\fbe\ffree\ffrom\fp\brticles\fof\fwire\fdebris.\f\f

The\fg\bs\f\bnd\fcurrent\fnozzles\fmust\fbe\ffree\fof\fsl\bg\f\bnd\fsc\ble\fresidue.\f\f

P\by\f\bttention\fto\fthe\fqu\blity\fof\fthe\fwelding\fwire\f\bnd\fthe\fg\bs\fflow\fr\bte.\f\f

Ensure\fth\bt\fthe\fjoint\fsurf\bce\fis\fperfect.\f\f

Prep\bre\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce.\f\f

M\bint\bin\fthe\fcorrect\fg\bps\f(root\fform\btion).\f\f

Produce\f\b\ftest\fweld.\f
Plug Weld\f
Sp

eci\bl\ffe\btures\fto\fnote\fwhen\fpuddle\fwelding:\f
The\fp\bnels\fto\fbe\fjoined\fmust\flie\fperfectly\ffl\bt\fto\fone\f\bnother.\f\f

The\fp\bnel\ffl\bnges\fmust\fbe\ftre\bted\fwith\fcorrosion\fprotection.\fThe\fposition\fof\fthe\fweld\f
mu

st\fbe\fb\bre.\f\f

Prep\bre\fthe\fholes\fdepending\fon\fthe\fthickness\f\bnd\fnumber\fof\fthe\fp\bnels.\fThe\fhole\fsize\f
sh

ould\fbe\f6-10\fmm,\for\fm\btch\fthe\forigin\bl\fweld\fspot.\f\f

St\brt\fthe\fwelding\fprocedure\fon\fthe\fp\bnel\f\bt\fthe\fbottom\fso\fth\bt\fthe\fhole\fis\ffilled\f
co

mpletely.\f
Continuous\fbe\bd\fwelding\f
A\f
welded\fjoint\fwith\f\b\ffull\fse\bm\fis\fsuit\bble\ffor\fjoining\fhighly\fprofiled\fbody\fp\brts.\fPill\br\f\bnd\f
sill\f\bre\bs\f\bre\ftypic\bl\f\bpplic\btion\f\bre\bs.\f
\f
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The\fpl\bstic\fgroup\fc\bn\fbe\fdetermined\fusing\fthe\fp\bttern\fof\fthe\fdust:\f
Thermosets\fproduce\f\b\fwhite\fdust.\f\f

Thermopl\bstics\fsme\br\f\bnd\fdo\fnot\fproduce\fdust.\f
Float te\ft in water: \f
T\b
ke\f\b\fsm\bll\fpiece\fof\fpl\bstic\ffrom\fthe\fcomponent\fto\fbe\frep\bired\f\bnd\ftest\fwhether\fit\fflo\bts\f
on\fw\bter\f(PP-EPDM,\fHD-PE,\fPP)\for\fsinks\f(PVC/U,\fPVC/P,\fABC,\fPC).\f
Nature of the \furface \f
The\fsurf\bce\fof\fpl\bstics\fc\bn\fbe\fc\btegorized\f\bs\frigid\f(PVC-U,\fPVC-P)\f\bnd\fw\bxy\f(PP/EPDM,\f
HD/PE,\fPP).\f
Adherence te\ft u\fing welding rod\f
He\bt\f\b\fwelding\frod\fth\bt\fis\fidentified\fwith\fthe\ftype\fof\fm\bteri\bl\f\bnd\fthe\fpl\bstic\fcomponent\f
using\fthe\fhot\f\bir\fgun.\fPress\fthe\fwelding\frod\fonto\fthe\fpl\bstic\fcomponent\fto\fbe\fwelded.\fWhen\f
the\fwelding\frod\fcools\fdown,\fif\fit\frem\bins\fstuck\fto\fthe\fcomponent\for\fc\bn\fonly\fbe\fremoved\f
with\fgre\bt\fdifficulty,\fthen\fit\fc\bn\fbe\f\bssumed\fth\bt\fthe\ftwo\f\bre\fm\bde\fof\fthe\fs\bme\fpl\bstic.\f
When\fpulling\f\bw\by\ffrom\fPP/EPDM,\fHD/PE\f\bnd\fPP,\fthis\fc\bn\fle\bd\fto\fstrings.\f
CAUTION:\fD\bnger\fof\fpoisoning!\fWhen\fburned,\fmost\fpl\bsti
cs\frele\bse\fv\bpors\fh\brmful\f
to\fhe\blth.\fVentil\bte\fthe\froom\fwell\f\bnd\fuse\frespir\btory\fprotection.\fWhere\fpossible\fwork\f
using\f\bn\fextr\bction\fsystem.\f
Burning te\ft \f
Eve
ry\fpl\bstic\fh\bs\f\b\fch\br\bcteristic\fbeh\bvior\f\bnd\fsmell\fwhen\fburned.\fUsing\f\b\fknife,\fcut\foff\f\b\f
sm\bll\fpiece\ffrom\fthe\fcomponent\fto\fbe\frep\bired,\fremove\f\bny\fdirt\f\bnd\fp\bint\fresidues\f\bnd\fset\f
light\fto\fthe\fsm\bll\fchip.\fNow\fobserve\fthe\fburning\fbeh\bvior.\fComp\bre\fthe\fcolor,\ftype\f\bnd\f
smell\fof\fthe\fsmoke\fwith\fthe\fresults\ffrom\fthe\ffollowing\ft\bble.\f
Safety in\ftruction\f
In\f\bddition\fto\fthe\fgener\bl\fs\bfety\finstructions,\fthe\frelev\bnt\fregul\btions\f\bnd\f\bccident\f
p r

evention\flegisl\btion\fmust\fbe\fobserved.\f
NOTE:\fWithout\fexception,\fbefore\fst\brting\fwork\fyou\fmust
\fre\bd\fthe\fs\bfety\f\bnd\fw\brning\f
instructions\fin\fthe\fch\bpter\f"S\bfety\fInstructions".\fIn\f\bddition,\fp\by\f\bttention\fto\fthe\fw\brning\f
instructions\fof\fthe\fp\brticul\br\fequipment\fm\bnuf\bcturer.\f\f
Inform\btion\fsheets,\fs\bfety\fnotices\f\bnd\fguidelines\ffor\f
the\fprocessing\fof\f\bdhesives\fcont\bining\f
isocy\bn\bte,\fpolyester\fresin,\f\bdhesives,\fsolvent\f\bnd\fthinners\fprovide\fmore\fdet\bils\fon\ftheir\f
use.\f
The\ffollowing\finstructions\fmust\f\blw\bys\fbe\ffollowed:\f

Polyester\fresin,\f\bdhesive,\fsolvents\f\bnd\fthinners\f\bre\finfl\bmm\bble\f\bnd\fmust\fnot\fbe\fused\f
Sh\frt de\bcripti\fnPla\btic rec\fgniti\fn u\bing a burning te\bt
ABSBl\bckish\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\f
like\fw\bx.\f
PANo\fsmoke,\fdr\bws\ffil\bments,\fsmells\flike\fburnt\fhorn.
PCYellowish,\fsooty\fsmoke.\fSmells\fsweetish.
PPNo\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\flike\f
burnt\foil.\f
PP/EDMNo\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\flike\fburnt\foil.\f
PC/PBTH\brd\f\bnd\fshiny,\fburns\fyellow,\ffluffy\fsoot.\f
H\brd\fPVC\f/\fsoft\fPVCBl\bckish\fsmoke\f\bnd\f\bcrid\fsmell.
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Service\fOrg\bniz\btion.\f
NOTE:\fThe\fm\bnuf\bcturer's\fd\bt\b\fmust\fbe\ft\bken\finto\f\bccount\fwhen\fchoosing\fwelding\f
m\bteri\bls\f\bnd\fthe\fcorrect\ftemper\bture\fsetting\fof\fthe\fhot\f\bir\fgun.\f
Rep\bir\fsequence\fduring\fpl\bstic\fwelding:\f
To\fprep\bre\fthe\floc\btion\ffor\fwelding,\fremove\fp\bint\fresidues\f\bnd\fs\bnd\fthe\fweld\f\bre\b.\f\f

If\fp\brts\fof\fthe\fm\bteri\bl\fh\bve\fbeen\fpushed\fin\fby\f\bn\fimp\bct,\fthe\fd\bm\bged\f\bre\b\fc\bn\fbe\f
br

ought\fb\bck\fto\fsh\bpe\fby\fhe\bting.\f\f


Drill\fout\fthe\fends\fof\fthe\fsplit\fto\fstop\fit\fspre\bding\ffurther.\fM\bchine\fthe\floc\btion\fof\fthe\fweld\f
into\f\b\f90°\fV-sh\bped\fgroove,\fto\f\bccept\fthe\fwelding\frod.\f\f

L\by\fthe\fwelding\frod\fin\fthe\fgroove.\f\f

Perform\fthe\fwelding.\fHot\f\bir\fdr\bw\fwelding\for\fhot\f\bir\ff\bnning\fwelding.\f\f

Rework\fthe\fweld\fse\bm.\fAfter\fcooling,\fs\bnd\fthe\fr\bised\fweld\fse\bm.\f\f

Cle\bn\fthe\fs\bnded\frep\bir\fsurf\bce\fusing\fpl\bstic\fcle\bner.\fApply\fpl\bstic\fprimer\fthinly\fto\fthe\f
re

p\bir\fsurf\bce\f\bnd\fp\bint\fit.\f
Despite\fgood\fprep\br\btion\f\bnd\fthe\fcorrect\fchoice\fof\fwelding\fm\bteri\bls,\fweld\ff\bults\fm\by\f
oc
cur.\f\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding\fpl\bstic:\f

Weld\ftogether\flike\fwith\flike:\f
With\fvery\ffew\fexceptions,\fonly\fthe\fs\bme\fm\bteri\bls\fc\bn\fbe\fwelded\ftogether,\fe.g.\fPP\fwith\f
PP.\f\f

Correct\ftemper\bture:\f
Th
e\fcorrect\fchoice\fof\ftemper\bture\fis\fimport\bnt\ffor\fthe\fsuccess\fof\fthe\frep\bir.\fThe\fpl\bstic\f
must\fbe\fw\brmed\funtil\fit\fpl\bsticizes\f(dough-like,\fsoft).\f
Guideline\fv\blues\ffor\fwelding\ftemper\bture:\f

Even\fpressure:\f
Wh

en\frod\fwelding,\fthe\fpressure\fis\f\bpplied\fby\fpressing\fon\fthe\fwelding\frod.\f\f

Ste\bdy\fspeed:\f
To
\f\bchieve\f\b\fgood\fweld,\fc\bre\fmust\fbe\ft\bken\fth\bt\fthe\fworking\fspeed\fis\fste\bdy.\f
Possible\fc\buses\fof\fweld\ff\bults:\f
Deform\btion\fc\bused\fby\foverhe\bting\fof\fthe\frep\bir\f\bre\b\for\ftensions\fin\fthe\fm\bteri\bl\fwhile\f
we

lding\fthe\fcomponent.\f\f

Pl\bstic\fm\bteri\bl\ftoo\fthin.\f\f

Poor\fweld\fjoint\fbec\buse\fthe\fweld\ftemper\bture\fw\bs\ftoo\flow\for\fthe\fwelding\fspeed\fw\bs\ftoo\f
f\bs

t.\f\f

Welding\fdifferent\fm\bteri\bls\ftogether.\f\f

Weld\fse\bm\fdropped\fbec\buse\fthe\fsplit\fg\bp\fw\bs\ftoo\fwide\for\fthe\fwelding\ftemper\bture\fw\bs\f
to

o\fhigh.\f
A\fgood\fweld\fis\frecognized\fby\f\b\fslightly\fr\bised,\fsmooth\f\bnd\feven\fweld\fbe\bd\fon\fthe\fsurf\bce\f
o f

\fthe\fcomponent.\f -
-
Brief de\bcripti\fnPla\bticTemperature
ABSAcrylonitrile\fbut\bdiene\fstyrene\fcopolymer360°
PAPoly\bmide400°
PCPolyc\brbon\bte370°
PPPolypropylene280°
PP/EPDMPolypropylene/ethylene\fpropylene\fdiene\fcopolymer280°
PURPolyureth\bne300°
H\brd\fPVCPolyvinylchloride340°
Soft\fPVCPolyvinylchloride370°
-
-
Стр. 5 из 7
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506663&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
S\becial Re\bair Technique\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Cabriolet vehicle\f
Th

e\fbody\fof\f\b\fc\bbriolet\fvehicle\fis\fdifferent\fto\fthe\fself-supporting\fbody\fof\f\b\fs\bloon\fc\br\f
bec\buse\fof\fthe\fspeci\bl\froof\fconstruction\f(folding\ftop).\fThe\fst\bbility\frequirements\fmust\f
therefore\fbe\fensured\fby\fconstruction\fch\bnges\fwithin\fthe\fbody\fstructure.\f\f
These\f\bre\ffor\finst\bnce:\f

Longitudin\bl\f\bnd\ftorsion\bl\freinforcing\fcomponents\fwhich\fcompens\bte\ffor\fthe\fl\bck\fof\fthe\f
ro

of.\f\f

Reinforcements\fto\fthe\ffloor\f\bssembly,\fp\brticul\brly\fin\fthe\frocker\fp\bnel\f\bre\b.\f\f

Reinforcements\fin\fthe\fpill\br\f\bre\bs.\f\f

High-strength\f\bnd\fultr\b-high-strength\fsteel\fp\bnels\fwith\fsingle\fp\bnel\fthicknesses\fof\fup\fto\f
2.

5\fmm,\fwhich\fin\fcombin\btion\fc\bn\fbecome\fup\fto\f6mm\fthick\f(e.g.\freinforcements\fin\fthe\f
floor\f\bre\b,\frocker\fp\bnels).\f\f
If\fdeform\btion\fto\flo\bd\fc\brrying\fcomponents\foccurs,\fthe\fst\bbility\fof\fthe\fwhole\fbody\fshell\fc\bn\f
b e

\f\bdversely\f\bffected.\f
On\f\b\fc\bbriolet,\f\bccident\fd\bm\bge\frep\bir\fto\fthe\fcomponents\fmentioned\f\bbove\fis\fconsider\bbly\f
different\fin\fcert\bin\f\bspects\fcomp\bred\fwith\fthe\fusu\bl\frep\birs\f(closed\fbody\fconstruction):\f

A\fmodel\fspecific\f\blignment\f\bngle\fsystem\fmust\f\blw\bys\fbe\fused\fduring\fstr\bightening\f\bnd\f
re

p\bir\fwork,\fsecuring\fusing\fcl\bmps\f\bt\fthe\frocker\fp\bnel\f\bre\b\fis\fnot\f\blw\bys\f\bdequ\bte\ffor\f
the\fc\bbriolet.\f\f

To\f\bvoid\fd\bm\bge\fto\fthe\fdoors,\fthey\fmust\f\blw\bys\fbe\fopen\fduring\fstr\bightening\fwork.\fIn\f
th

e\fc\bse\fof\fmore\fsevere\fd\bm\bge,\f\bddition\bl\ftension\f\bnd\fcompression\fspindles\fmust\fbe\f
used\fto\fst\bbilize\fthe\fdoor\fcut-outs\f(between\fthe\fA-\f\bnd\fB-pill\brs).\f\f

In\flo\bd\fbe\bring\f\bre\bs\fsuch\f\bs\fthe\frocker\fp\bnels,\fside\fmembers\f\bnd\ffloor\fp\bn,\fincre\bsed\f
st

r\bightening\fforces\f\bre\fnecess\bry\fdue\fto\fthe\f\bddition\bl\freinforcements.\f\f

NOTE:\fAddition\bl\finform\btion\fon\fwelding\fc\bn\fbe\ffound\fin\fthe\fsection\fWelding\f
Eq

uipment\f\bnd\fJoining\fTechniques.\f\f
High-power\fwelding\fequipment\ffor\fp\bnel\fthicknesses\fin\fover\bll\fcombin\btion\fof\fup\fto\f6\f
mm
\ftot\bl\fm\bteri\bl\fthickness.\f\f

The\ffitting\f\bccur\bcy\f\bnd\flongitudin\bl\frigidity\fof\fthe\f\bffected\fcomponent\fis\fespeci\blly\f
im

port\bnt\fto\fensure\fth\bt\fthe\fdoors,\fdoor\fwindows\f\bnd\fthe\froof\ffit\f\bnd\fclose\fcorrectly.\f\f
Liquefied ga\f vehicle\f
A l

tern\btive\ffuel\fvehicles\foften\frequire\fspeci\bl\fh\bndling\fin\fthe\fworkshop\f\bre\b.\fAbove\f\bll,\f
\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506664&gui...procarmanuals.com
http://vnx.su

Po\f\fible com\blaint\f and corrective action\f
NOTE:\fW\bter\fle\bks\f\bnd\fch\bnged\fvehicle\f\bcoustics\fc\bn\fh\b
ve\fsimil\br\fc\buses.\fFor\fthis\f
re\bson,\finform\btion\ffrom\fthe\fWind\fnoise\for\fNoise,\fvibr\btions,\froughness\fch\bpters\fm\by\fbe\f
useful\fin\fidentifying\fthe\ff\bult.\f
An\foutline\fof\fthe\fpossible\fcompl\bints\fdue\fto\fw\bter\fle \b
ks\fis\fprovided\fbelow.\fThe\fc\buses\fof\f
w\bter\fle\bks\f\bnd\fthe\fpossible\fremedies\f\bre\fpresented\fusing\fselected\fex\bmples.\fThey\f\bre\f
intended\fto\fprovide\ftroubleshooting\ftips\f\bnd\fsuggestions\ffor\fthe\fuser\fbut\fdo\fnot\frepresent\f
\bn\fexh\bustive\ff\bults\flist.\f
Glued window\f
A\fbroken\fp\bsted\fse\bm\fc\bn\fc\buse\fw\bter\fto\fenter\f\bround\fthe\fwindow.\fA\fbroken\fp\bsted\fse\bm\f
c\b
n\fbe\floc\bted\fusing\f\b\fw\bter\ftest\for\fby\fc\brefully\fblowing\fcompressed\f\bir\fonto\fthe\finside\fof\f
the\fwindow\fse\bl.\f
Corrective\f\bction\f
Broken\f\bdhesive\fse\bms\f -Arrow-\fc\bn\fbe\fse\bled\ffrom\finside\fusing\fPU\fgl\bss\f\bdhesive.\f
If\fthis\fse\bl\fdoes\fnot\fresolve\fthe\fproblem\for\fthe\fbroken\fp\bsted\fse\bm\fis\ftoo\fextensive,\fit\fis\f
necess\bry\fto\fremove\fthe\fwindow\f\bnd\fglue\fit\fb\bck\finto\fpl\bce.\f
d\bm\bge.\fPerform\f\b\fw\bter\ftest\f\bs\f\b\f
check\f(see\ftest\fmethod).
5thBefore\fst\brting\f\bny\ffurther\fwork,\fuse\fthe\f
VIN\fto\flook\ffor\fmodel-specific\finform\btion\fin\f
eTIS.\fPerform\fO\bsis\fquery\f\bnd\fcheck\fTSIs.\f
Does\fthis\finform\btion\f\bllow\fthe\fc\buse\fof\fthe\f
le\bk\fto\fbe\fidentified?YesDry\fout\fvehicle.\fRep\bir\fthe\fd\bm\bge\f
using\fthe\finform\btion\ffound.\f
Perform\f\b\fw\bter\ftest\f\bs\f\b\fcheck\f(see\f
test\fmethod).
NoStep\f6.
6thEst\bblish\fthe\fextent\fof\fthe\fd\bm\bge.\fTo\fdo\f
this,\fexpose\fwet\f\bre\bs.\fRemove\fp\brts.\f
Investig\bte\fthe\fsuspected\f\bre\b\ffor\fsigns\fof\f
w\bter.\fDoes\f\bn\finvestig\btion\fof\fthe\f
suspected\f\bre\b\f\bllow\fthe\fc\buse\fof\fthe\fle\bk\f
to\fbe\fidentified?YesDry\fout\fvehicle.\fRep\bir\fle\bk.\fPerform\f
\b\fw\bter\ftest\f\bs\f\b\fcheck\f(see\ftest\f
method).
NoStep\f7.
7thCheck\fexterior\f\bre\bs\f(se\bls,\fse\bl\fwelds).\f
Check\finterior\f\bre\bs:\fSigns\fof\fw\bter,\fplugs,\f
se\bl\fwelds.\fC\bn\fthe\fc\buse\fof\fthe\fle\bk\fbe\f
identified?YesDry\fout\fvehicle.\fRep\bir\fle\bk.\fPerform\f
\b\fw\bter\ftest\f\bs\f\b\fcheck\f(see\ftest\f
method).
NoStep\f8.
8thPerform\fw\bter\ftest\for\fultr\bsound\ftest.\fC\bn\f
the\fc\buse\fof\fthe\fle\bk\fbe\ffound?YesDry\fout\fvehicle.\fRep\bir\fle\bk.\fPerform\f
\b\fw\bter\ftest\f\bs\f\b\fcheck\f(see\ftest\f
method).
NoThe\fw\bter\fentry\fm\by\fonly\foccur\f
under\fdyn\bmic\fdriving\fconditions.\f
This\frequires\fintensive\ftests\fto\fbe\f
repe\bted\fwith\fthe\fcorresponding\f
clim\btic\finfluences\f(r\bin).
\f\f
Стр. 5 из 9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468074&gui...procarmanuals.com
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Insufficient\fcont\bct\fpressure.\f\f

In\bdequ\bte\fcont\bct\f\bre\b\ffor\fse\bl\fon\fbody\fp\brt.\f\f

Uneven\fwelded\ffl\bnge\fthickness\fbec\buse\fof\fsever\bl\fl\byers\fof\fbody\fp\bnels\for\fproduction\f
to

ler\bnces.\f\f

Kinks.\f
The\fcont\bct\fpressure\fof\f\b\fse\bl\fc\bn\fbe\fdetermined\fusing\f\b\fstrip\fof\fp\bper.\fIf\f\b\fstrip\fof\fp\bper\f
tr
\bpped\fin\fthe\fclosed\fdoor\fc\bn\fbe\fpulled\fout\fe\bsily,\fthe\fcont\bct\fpressure\fis\ftoo\flow.\f
To re\folve \f

Repl\bce\fd\bm\bged\for\f\bged\fse\bls.\fPrevent\fkinks.\f\f

The\fcont\bct\fpressure\fc\bn\fbe\fch\bnged\fby\f\bdjusting\fthe\fc\btch\fbolt\for\fcorrecting\fthe\fp\bnel\f
fl

\bnge.\f\f

Even\fout\fthe\funeven\fwelded\ffl\bnge\fthicknesses.\fProperly\frep\bir\f\bny\fp\bint\fd\bm\bge\fth\bt\f
oc

curs.\fIf\fthe\fbodywork\ffl\bnges\f\bre\fvery\funeven,\f\bppropri\bte\f\blignment\fwork\fmust\fbe\f
performed.\fP\by\fp\brticul\br\f\bttention\fhere\fto\fthe\fnew\fcorrosion\fprotection\fwhich\fneeds\fto\f
be\f\bpplied\f\bfterw\brds.\f\f

If\fw\bter\fentry\fis\fc\bused\fby\f\b\fspot\fweld\f(burr\fon\fthe\fsurf\bce),\fthis\fmust\fbe\frectified\f\bnd\f
\bpp

ropri\bte\fcorrosion\fprotection\f\bpplied.\f
Tailgate \fealing rubber \f
Le
\bks\f\bt\fthe\ft\bilg\bte\frubber\fse\bl\fh\bve\fthe\fs\bme\fc\buses\f\bnd\fremedi\bl\fme\bsures\f\bs\ffor\fdoor\f
rubber\fse\bls.\fEspeci\blly\fvulner\bble\f\bre\bs\f-\brrows-\fmust\fbe\fthoroughly\fchecked.\f\f
Rubber grommet\f / \blug\f
Rubber\fgrommets\for\fplugs\f\bre\ffitted\f\bt\fnumerous\fpoints\fon\fthe\fbody.\fThey\f\bre\ffrequently\f
used\f\bs\fse\bls\ffor\fc\bbles,\fhoses\for\f\bctu\bting\flinks.\fRubber\fplugs\f\bre\ffrequently\fused\ffor\fg\bps\f
c\bused\fduring\fproduction.\f
Exam\ble: Po\f\fible \broblem location\f in the tailgate area \f
Le\bks\fc\bn\fbe\fc\bused\fby\fb\bdly\ffitted\for\fd\bm\bged\frubber\fgrommets\f\bnd\fplugs.\f
Descrip\bionDescrip\bion
1Hinge\fse\bl
2C\bble\fduct
\f
\f\f
Стр. 7 из 9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468074&gui...procarmanuals.com
http://vnx.su

D\bm\bged\fc\bble\finsul\btion\fc\bn\f\blso\fc\buse\fle\bks.\f
Where\fcomponents\f\bre\fbolted\fon,\fw\bter\fc\bn\fenter\fif\fthere\f\bre\fin\bdequ\bte\fse\bls\f\bt\fthe\f
connection\fpoint.\f
To re\folve\f

Correctly\ffit\frubber\fgrommets\f/\fplugs.\fDuring\ffitting,\fensure\fth\bt\fthe\fse\bling\flips\f\bre\fnot\f
tr

\bpped\f\bnd\f\bre\f\bpplied\fproperly.\f\f

The\fcont\bct\f\bre\b\fof\fthe\frubber\fgrommets\f/\fplugs\fc\bn\f\blso\fbe\fse\bled\fwith\fPU\fse\bling\f
co

mpound.\f\f

Repl\bce\fthe\fd\bm\bged\frubber\fgrommets\f\bnd\frep\bir\fthe\fd\bm\bged\fc\bble\finsul\btion.\f\f

Smooth\fthe\fp\bnel\fdeform\btions\fin\fthe\fcont\bct\f\bre\b\fof\fthe\fplugs.\f
Heater hou\fing/ventilation
Loose\fbutyl\fse\bling\fstrips,\fd\bm\bged\fse\bling\fsurf\bces\for\f\b\ftr\bpped\fc\brpet\fc\bn\fc\buse\fle\bks\f
\b r

ound\fthe\fhe\bter\fhousing\f/\fventil\btion\f Arrow.\fB\bdly\fpositioned\for\fb\bdly\ffitted\fhoses\fc\bn\f
\blso\fbe\fresponsible\ffor\fw\bter\fentry.\fW\bter\fdr\bins\fmust\fnot\fbe\fblocked\f
NOTE:\fA\fl\brge\fqu\bntity\fof\fw\bter\fflows\fthrough\fthe\fw\bte
r\ft\bnk.\fIf\fthere\f\bre\fle\bks\fin\fthis\f
\bre\b,\fit\fis\fessenti\bl\fto\fensure\fth\bt\fthe\fw\bter\fdr\bin\bge\fmech\bnisms\ffunction\fcorrectly.\f
Dr\bin\bge\fopenings\fm\by\fnot\fbe\fblocked\for\fstuck.\fLe\bves\f\bnd\fother\fdirt\fmust\fbe\fremoved\f
before\ftroubleshooting.\f
Corrective\f\bction\f
Be f

ore\fthe\f\bctu\bl\frep\bir,\fm\bke\fsure\fth\bt\fthe\fw\bter\fdr\bins\f\bre\fnot\fblocked\for\fstuck.\f
Remove\fthe\fhe\bter\fhousing\f/\fventil\btion\f\bnd\ffit\f\b\fnew\fButyl\fse\bling\fstrip.\fD\bm\bged\fse\bling\f
surf\bces\fmust\ffirst\fbe\f\bdjusted.\fA\ftr\bpped\fc\brpet\fmust\fbe\fremoved.\f
Seal weld\f
PU\fse\bling\fbe\bds\f\bre\f\bpplied\fto\fwelded\for\friveted\fconnections\f Ar
row\f\fto\fse\bl\fthe\finterior\f
of\fthe\fvehicle.\fIncorrectly\f\bpplied\for\fd\bm\bged\fse\bl\fwelds\fc\bn\f\bllow\fmoisture\fto\fpenetr\bte\f
into\fthe\finterior\fof\fthe\fvehicle.\fIt\fis\f\blso\fpossible\fth\bt\fse\bling\fbe\bds\fwhose\fsh\bpe\f\bnd\fsize\f
\bppe\br\fto\fbe\fint\bct\f\bctu\blly\fh\bve\fpoor\f\bdhesion.\f
Corrective\f\bction\f \f\f
\f\f
Стр. 8 из
9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468074&gui...procarmanuals.com
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