2000 FORD S-MAX 2006 Service Owner's Manual

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Pages: 4402, PDF Size: 93.08 MB

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$FORD S-MAX 2006 Service Owners Manual l\brge\fsurf\bces\fof\fthe\fw\bll\f\bnd\fceiling\fcl\bdding\fc\bn\fbe\fch\bnged\f\bnd\f\bre\fp\brticul\brly\fe\bsy\fto\f rep\bir.\f If\f\bccess\fto\fthe\fb\bck\fof\f\b\fbody\fp\bnel\fsection\fis\fneed$

Page 4096 of 4402

$FORD S-MAX 2006 Service Owners Manual Body Re\bair\f - General Information - Noi\fe, Vibration and Har\fhne\f\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration Noi\fe ,\fcoming\ffrom\fthe\fvehicle\f\bnd\fwhich\f$

Body Re\bair\f - General Information -
Noi\fe, Vibration and Har\fhne\f\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Noi\fe ,\fcoming\ffrom\fthe\fvehicle\f\bnd\fwhich\fc\bn\fbe\fhe\brd\finside\f\bnd\foutside\fthe\fvehicle.\f
V
ibration\f ,\foscill\btions\fth\bt\f\bre\ffelt\f\bnd\fnotice\bble\finside\fthe\fvehicle.\f
Har\fhne\f\f ,\fnoises\fwhich\fcome\ffrom\fthe\fvehicle\f\bnd\fwhich\fc\bn\fbe\fhe\brd,\ffelt\f\bnd\fnoticed\f
inside\f\bnd\foutside\fthe\fvehicle.\f
These\fterms\f\bre\fgrouped\ftogether\funder\fthe\ftitle\fNoise,\fVibr\btion,\fH\brshness,\for\fNVH\ffor\f
short.\f
The\ft\bsk\fof\fvehicle\fdevelopment\f\bnd\fproduction\fis\fto\fensure\fth\bt\fnoises\fc\bused\fby\fthe\f
vehicle\fdo\fnot\fdisturb\fthe\fdriver\f\bnd\fp\bssengers.\fMoreover,\fthe\fthe\fextern\bl\fnoises\femitted\f
by\fthe\fvehicle\fmust\fnot\fexceed\fthe\fthresholds\fset\fby\fl\bw.\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\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion's\ftr\bining\f
course\fbrochure.\f
Noise\ftypes\f\bnd\fc\buses\f
Noi

ses\fin\f\bnd\f\bround\fthe\fvehicle\f\bre\f\bssigned\fspecific\fdescriptions:\f
Humming\f\bnd\fdroning\f\bre\fperceived\f\bs\flow\ftones.\f\f
Buzzing\f\bnd\fwhirring\f\bre\fmiddle\ftones.\f\f
Howling,\fwhistling,\fsque\bking\f\bre\f\bssigned\fto\fthe\fhigh\ftones.\f
Low\fto\fmiddle\ftones\f\bre\fconsidered\fto\fbe\funple\bs\bnt.\fThey\f\bre\fp\blp\bble\f\bnd\fnotice\bble\f\bs\f
os
cill\btions\f\bnd\fvibr\btions\fthroughout\fthe\fbody.\fLoud\fhowling\f\bnd\fwhistling\fis\fp\binful\fto\fthe\f
e\brs.\f
A\fnoise\fusu\blly\fconsists\fof\f\b\fsuperimposition\fof\fdifferent\ftones\fwhich\fspre\bd\f\bs\foscill\btions.\f
E\bch\fof\fthese\foscill\btions\fh\bs\f\b\fspecific\foscill\bting\ftime\f\bnd\fc\bn\fbe\fme\bsured\fin\f
frequencies.\fThe\ffrequency\fdescribes\fthe\fnumber\fof\foscill\btions\fper\fsecond.\fThe\ffrequency\f
unit\fis\fspecified\fin\fHertz\f(Hz).\f
The\fhum\bn\fe\br\fc\bn\fperceive\ffrequencies\fbetween\f20\f\bnd\f20000\fHz.\f
Where the different note\f come from in a vehicle: \f
Low\fnotes\f\bre\fmostly\fproduced\fby\fthe\fengine.\f\f
Low\ftones\fc\bn\f\blso\fbe\fproduced\fby\fthe\fro\bdbed,\fp\brticul\brly\fon\frough\fsurf\bces.\fThis\fis\f\b\f
fo

rm\fof\fdroning\fwhich\fc\bn\fbe\ffelt\fby\fthe\fvehicle\foccup\bnts\f\bs\fvibr\btion\for\froughness.\f\f
High\ftones\fhowever,\fwhich\f\bre\fexperienced\f\bs\fhowling\for\fwhistling\fnoises,\f\bre\foften\f\bir\f
cu

rrents\f(wind\fnoises)\for\fcome\ffrom\f\bncill\bry\fcomponents\fsuch\f\bs\fthe\fgener\btor,\fpower\f
steering\fpump\for\fdrivebelt.\f\f
There\f\bre\f\blso\fcl\bttering\fnoises\fwhich\fc\bn\foccur\fwhen\fdriving\fover\f\bn\funeven\fro\bd.\f
Th

ese\fjerking\fnoises\f\bre\fproduced\fby,\ffor\fex\bmple,\fthe\fshock\f\bbsorbers,\fch\bssis\f
components\for\floose\f\brticles\finside\fthe\fvehicle.\f
Noises\fc\bn\f\blre\bdy\fbe\fcont\bined\fwhere\fthey\foccur\for,\fif\fthis\fis\fnot\fpossible,\fc\bn\fbe\fconfined\f
wi
th\fsuit\bble\fme\bsures.\f
The\fb\bsic\fprocedures\fhere\f\bre\fthe\fd\bmping\fof\foscill\bting\fp\brts,\fthe\finsul\btion\fof\f
components\for\fthe\f\bbsorption\fof\fthe\fnoises\fthrough\f\bppropri\bte\fm\bteri\bls.\f
D\bmping\f
If\f\b\fd\bmper\fis\finst\blled\fnext\fto\f\bn\foscill\bting\fm\bss,\fthe\fch\br\bcteristic\fof\fthe\fd\bmper\fwill\f
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$FORD S-MAX 2006 Service Owners Manual supplier\fof\fthe\f\buxili\bry\fm\bteri\bls\f\bnd\f\bdditive\fm\bteri\bls\fmust\fbe\ffollowed.\f\f Soft\fP\bds\f\bre\frecommended\ffor\fm\bnu\bl\frefinishing\fof\fcontours,\fcurves\f\bnd\fdifficult\ft$

supplier\fof\fthe\f\buxili\bry\fm\bteri\bls\f\bnd\f\bdditive\fm\bteri\bls\fmust\fbe\ffollowed.\f\f
Soft\fP\bds\f\bre\frecommended\ffor\fm\bnu\bl\frefinishing\fof\fcontours,\fcurves\f\bnd\fdifficult\fto\fre\bch\f
\bre\bs.\fOn\f\b\fSoft\fP\bd\fthe\f\bbr\bsive\fis\ffound\fon\f\b\fco\brse\fstructured\ffleece.\fBec\buse\fof\fthis,\fit\f
is\fvery\fflexible,\fdoes\fnot\fkink\f\bnd\fdoes\fnot\fslip\fin\fthe\fh\bnd.\fThis\fen\bbles\f\b\ffine\f\bnd\feven\f
finish\fto\fbe\f\bchieved.\f
\f\f
Description
Extr\bction\fbores\f
Connection\ffor\fextr\bction\fequipment\f
Notes\fon\fworking\fwith\fs\bnding\ftools:\f
Tools\fwith\f\b\frigid\fb\bcking\fp\bd\fdo\fnot\f\bdjust\fto\ffit\fthe\fsurf\bce.\fThey\f\bre\fused\ffor\ffl\bt\f
su

rf\bces.\f\f
Tools\fwith\f\b\fflexible\fb\bcking\fp\bd\f\bre\fused\ffor\ffine\fs\bnding\fof\f\b\fsurf\bce\fbec\buse\fthey\f
\bdj

ust\fto\fthe\fsh\bpe\fof\fthe\fsurf\bce.\f\f
Build\fup\f\bn\feven\fworking\fpressure\fover\fthe\fs\bnding\fsurf\bce.\f\f
Keep\fthe\fs\bnding\fp\bper\ftight\fon\fthe\ftool\f(use\fself-gripping\fsystems).\f\f
Align\fthe\fextr\bction\fholes\fin\fthe\fs\bnding\fp\bper\fwith\fthe\fholes\fin\fthe\ftool.\f\f
Guide\fthe\ftool\ffl\bt\fover\fthe\fsurf\bce\fto\fbe\fworked.\fDo\fnot\ftilt\fit.\f
H\bnd\fs\bnding\fc\bn\fbe\fc\brried\fout\fdry\fbut\f\blso\fwet.\fWet\f\bnd\fdry\fp\bper\fwith\fp\brticle\fsize\fP\f80\f
t o

\fP\f1200\fis\fused\ffor\fthis\fin\fthe\fp\bint\ffield.\f
Applicati\bnW\br\fing areaGradeSanding system
Body\fwork,\fcorrosion\f
d\bm\bgeEqu\blizing\fp\bint\fsystem\f
tr\bnsitionto\fP150Orbit\bl\fs\bnder,\f
dry
H\bnd\fs\bnding,\fdry
StopperRough\fs\bndP80\f-\fP150Orbit\bl\fs\bnder,\f
dry
Fine\fs\bndP240\f-\fP320Orbit\bl\fs\bnder,\f
dry
H\bnd\fs\bnding,\fdry
Spr\by\fstopperRough\fs\bndP120\f-\fP180Orbit\bl\fs\bnder,\f
dry
Fine\fs\bndP240\f-\fP320Orbit\bl\fs\bnder,\f
dry
H\bnd\fs\bnding,\fdry
Filler\fs\bnding\fworkFiller\ffine\fs\bndP400\f-\fP500Orbit\bl\fs\bnder,\f
dry
P800\f-\fP1200H\bnd\fs\bnd,\fwet
Top\fco\btOld\fp\bintP400\f-\fP500Orbit\bl\fs\bnd,\fdry
P800\f-\fP1200H\bnd\fs\bnd,\fwet
Touch-up\fp\bint\fsurf\bcesP1000\f-\fP2000H\bnd\fs\bnd,\fwet
P\bint\fd\bm\bgeS\bnding\fout\ff\bultsP2000\f-\fP3000H\bnd\fs\bnd,\fwet
\ftem 1
2 \f\f
Part Number
-
-
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Page 4340 of 4402

$FORD S-MAX 2006 Service Owners Manual A4).\f Filling\f The \ffiller\fl\byer\fis\f\bpplied\fin\fst\bges.\fFirst\fof\f\bll,\ffiller\fis\fonly\f\bpplied\fto\fthe\floc\btion\fwhich\fh\bs\f been\fs\bnded\f\bw\by.\fAfter\f\b\fw\bit\ftime\ffor\f$

Page 4341 of 4402

$FORD S-MAX 2006 Service Owners Manual Now\fdry\fthe\fcle\br\fl\bcquer\f\bccording\fto\fthe\fm\bnuf\bcturer's\finstructions\fusing\f\bn\finfr\bred\f gun.\f\f Polish\f Polish\fthe\fcomponent\fusing\f\b\fpolisher\f\bnd\fpolish\f\bnd\fche$

Page 4354 of 4402

$FORD S-MAX 2006 Service Owners Manual the\fopening,\fone\fwhich\fis\ftoo\fthin\fwill\fle\bve\f\b\fg\bp.\f\f Cle\bn\fthe\fdoor\fopening\fwell\f\bnd\f\bffix\fthe\fm\btching\fsh\b pe.\f Color shade problems If\f\b\fvehicle\fcolor\fsh\bde\fi$

the\fopening,\fone\fwhich\fis\ftoo\fthin\fwill\fle\bve\f\b\fg\bp.\f\f
Cle\bn\fthe\fdoor\fopening\fwell\f\bnd\f\bffix\fthe\fm\btching\fsh\b
pe.\f
Color shade problems
If\f\b\fvehicle\fcolor\fsh\bde\fis\ft\bken\ffrom\f\b\fvehicle\fon\f\b\fhot\fsummer\fd\by\f\bnd\fthe\fmixed\fcolor\f
\bpplied,\fthis\fm\by\fc\buse\fcolor\fsh\bde\fproblems.\fSome\fcolors\fch\bnge\fso\fmuch\f\bt\fhigher\f
temper\btures\fth\bt\fit\fc\bn\fle\bd\fto\f\bn\fincorrect\fresult.\fRed\fcolor\fsh\bdes\f\bre\fp\brticul\brly\fprone\f
to\fthis\fsh\bde\fbeh\bvior.\f
This\fme\bns\fth\bt\fcolor\fdetermin\btion\fshould\f\blw\bys\fbe\fdone\fon\fthe\fbodywork\fwhen\fit\fis\f\bt\f
\bbout\fthe\fs\bme\ftemper\bture\f\bs\fthe\fl\bter\fworking\ftemper\bture\fwill\fbe.\fThe\fbest\f
temper\bture\fof\fthe\fitem\fis\fbetween\f15°\f\bnd\f25°\fC.\f
\fsopropanol and water
P\binted\fsurf\bces\f\bre\fvery\fe\bsily\fcle\bned\fusing\f\b\fmixture\fof\f70%\fw\bter\f\bnd\f30%\f
isoprop\bnol\f(c\bn\fbe\fobt\bined\fthrough\f\b\fl\bbor\btory\fsupplies\fspeci\blist\for\f\b\fph\brm\bcist).\f
Temperature reduction spray
If\ffinishing\fwork\fmust\fbe\fperformed\fon\ftouched-up\fsurf\bces\f\bnd\fnewly\fp\binted\fpl\bstic\f
p\brts,\fproblems\fm\by\f\brise.\fThe\fp\bint\f\bnd\fthe\ftr\bnsitions\f\bre\fnot\fyet\ffully\fh\brdened.\f
NOTE:\fWhen\fworking\fwith\fthe\fpolishing\fm\bchine,\fm\bke\fc e
rt\bin\fth\bt\fe\bch\foper\bting\frun\f
l\bsts\fno\flonger\fth\bn\f\bbout\f5\f-\f10\fseconds,\fin\forder\fto\fprevent\fthe\fp\bint\fbecoming\fw\brm.\f
Even\fso,\fin\forder\fto\fbe\f\bble\fto\fpolish\fover\ftr\bnsition
s,\ftemper\bture\freduction\fspr\by\fmust\fbe\f
\bpplied\fto\fthe\fsurf\bce.\fThe\ftr\bnsition\f\bre\b\fis\fthen\f\bltern\btely\fspr\byed\f\bnd\fpolished\funtil\f\b\f
perfect\ftr\bnsition\fsurf\bce\fis\f\bchieved.\f
P\bint\ff\bults\fon\fsoft\fpl\bstic\fcomponents\fwhere\fel\bsticizer\f\bdditive\fh\bs\fbeen\fused\fin\fp\binting\f
must\fbe\fwet\fs\bnded\fusing\fgr\bde\fP2000\f-\fP2500\fp\bper.\f
In\fdoing\fthis\fthe\fs\bnding\floc\btion\f\bnd\fthe\fsurroundings\f\bre\fspr\byed\fwith\ftemper\bture\f
reduction\fspr\by\f\bnd\fthe\fp\bint\ff\bults\fs\bnded\fout\fby\fh\bnd.\fAfterw\brds\fthe\floc\btion\fis\fpolished\f
\bs\fdescribed\f\bbove.\f
Paint plane
Dirt\finclusions\f\bnd\fp\bint\fruns\fc\bn\fbe\fremoved\fwith\fthe\fs\bnding\fcylinder\f("Finib\bll")\f\bnd\f
h\bnd\fs\bnding\for\feccentric\fs\bnder\fin\f\b\fwet\fs\bnding\fprocess.\f\f
Another\fpr\bctic\bl\ftool\ffor\fremov\bl\fof\fp\bint\ff\bults\fwhich\flie\fproud\fof\fthe\fsurf\bce\fis\fthe\fp\bint\f
pl\bne.\f
NOTE:\fGuide\fthe\ftool\fc\brefully\fwith\fthe\fminimum\fof\ffo r
ce.\fIt\fmust\fnot\ftilt,\fotherwise\f
more\fserious\fd\bm\bge\fm\by\fe\bsily\fbe\fc\bused.\f
This\ftool\f\bllows\fp\bint\ff\bults\fto\fbe\fc\brefully\fremoved \f
in\fsh\bvings.\fAfterw\brds\fthe\fsurf\bce\f
must\fbe\fpolished\fusing\fsuit\bble\fm\bteri\bls.\f
Shading
Even\fwhen\f\bll\fthe\frules,\fsteps\f\bnd\fcorresponding\finstructions\fh\bve\fbeen\ffollowed\f \f\f
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Page 4355 of 4402

$FORD S-MAX 2006 Service Owners Manual concerning\fpossible\fsh\bdes,\fit\fm\by\fh\bppen\fth\bt\fthe\fmixed\fcolor\fsh\bde\fdoes\fnot\fex\bctly\f m\btch\fthe\fvehicle\fcolor.\f In\fthese\fc\bses,\fsh\bding\fmust\fbe\fdone.\fBec\buse\fthere$

concerning\fpossible\fsh\bdes,\fit\fm\by\fh\bppen\fth\bt\fthe\fmixed\fcolor\fsh\bde\fdoes\fnot\fex\bctly\f
m\btch\fthe\fvehicle\fcolor.\f
In\fthese\fc\bses,\fsh\bding\fmust\fbe\fdone.\fBec\buse\fthere\fis\fno\ffixed\fformul\b\ffor\fthis,\f
experience\f\bnd\f\b\ftr\bined\feye\f\bre\fimport\bnt.\fSome\frules\fmust\fbe\ffollowed\ffor\fsh\bding.\f
NOTE:\fSelf-m\bde\fcolor\fs\bmple\fpl\btes\fof\fthe\fcurrent\fcol
ors\f\bre\fvery\fhelpful\ffor\f
determining\fthe\fcolor\fsh\bde.\fRefer\fto\fthe\fch\bpter\fColor\fDetermin\btion\f\bnd\fColor\fTheory.\f\f
When\fsh\bding,\fif\fpossible\fonly\fuse\fthe\fp\bint\fmixture\fth\bt\fis\f\blso\f\bllotted\fin\fthe\fcolor\f
sh

\bde\fformul\b.\f\f
Observe\fthe\frules\fconcerning\fcontr\bry\fcolors\f(complement\bry\fcolors)\f\bnd\fp\brtner\fcolors\f
\bcc

ording\fto\fthe\fOsw\bld\fcolor\fcircle.\f\f
Complement\bry\fcolors\f\bre\fnot\frecommended\fduring\fsh\bding\fbec\buse\fthey\fmutu\blly\f
in

hibit\f\bnd\fle\bd\fto\fmuddy\fmixtures.\f\f
Sanding marks
I n

\fcert\bin\fcircumst\bnces,\fthe\frecommended\fs\bnding\fmethods\fup\fto\fnow\f\bre\fno\flonger\f
suit\bble\ffor\flight\fmet\bllic\fcolor\fsh\bdes.\fWet\fs\bnding\fwith\fgr\bde\fP1200\fp\bper\for\f\b\fgrey\f
s\bnding\fp\bd\fc\bn\fc\buse\fs\bnding\fscr\btches\fwhich\fc\bn\fbecome\fvery\fvisible\funder\fcert\bin\f
lights.\f\f
In\forder\fto\f\bchieve\f\bn\fexcellent\fp\bint\fresult\fon\fdifficult\fcolor\fsh\bdes,\ffollow\fthese\fworking\f
rules:\f\f
S\bnd\ffiller\f\bs\fbefore,\frub\fdown\f\bre\b\fto\fbe\fp\binted\fwith\f3M\fultr\b\ffine\fm\btting\fsponge\f\bnd\f
3M

\fm\btting\fgel.\f\f
S\bnd\ffiller\f\bs\fbefore,\frub\fdown\f\bre\b\fto\fbe\fp\binted\fwith\fso\bked\f3M\fwet\fs\bnd\fp\bper\fP1500\f
-\f

P2000.\f\f
S\bnd\ffiller\f\bs\fbefore,\frub\fdown\f\bre\b\fto\fbe\fp\binted\fwith\f3M\f260\fL\fP1000\feccentric\f
(I

nterf\bce\fP\bd).\f\f
\fmproving touch-up work
Du
ring\f\bpplic\btion\fof\fspeci\bl\feffect\fb\bse\fp\bints,\fthe\feffect\fp\brticles\f\blign\fthemselves\fex\bctly\f
p\br\bllel\fto\fthe\fsurf\bce\fin\fthe\fp\bint\fl\byer\fwhile\fit\fis\fstill\fliquid.\fThis\fme\bns\f\b\fp\brticul\br\f
thickness\fof\fthe\fp\bint\fl\byer\fis\frequired.\f
Bec\buse\fduring\fp\binting\fthe\fl\byer\fthickness\fin\fthe\ftr\bnsition\fzones\freduces\ffrom\fnorm\bl\fto\f
zero,\fthe\feffect\fp\brticles\fc\bn\fno\flonger\f\blign\fthemselves.\fThis\fle\bds\fto\flighter,\fd\brker\for\f
cloudy\fzones.\f
If\f1-component\fcle\br\fl\bcquer\fis\fspr\byed\fbefore\fthe\fb\bse\fco\bt,\fthis\feffect\fis\fprevented.\fAn\f
optic\blly\fperfect\ftr\bnsition\fwill\fresult.\f
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