warning FORD S-MAX 2006 Service Repair Manual

Side Pa\bel Sheet \fetal Repairs - B-Pillar
a\bd Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
WARNING:\f\f

A\fsuit\bbly\fpowerful\fresist\bnce\fspot\fwelding\fdevice\fwith\finverter\ftechnology\fshould\fbe\f
us

ed\ffor\fthis\frep\bir.\fObserve\fthe\fwelding\fequipment\finstructions\fin\fsub-section\f501-25.\f\f

The\fwelded\fjoints\f\bt\fthe\ffront\f\bnd\fre\br\fdoor\f\bpertures\fmust\fonly\fbe\fm\bde\fby\fresist\bnce\f
sp

ot\fwelding.\fMIG\fpuddle\fwelding\fis\fnot\f\b\fpermissible\f\bltern\btive.\f
WARNING:\f\f

The\fB-pill\br\freinforcement\fis\fm\bde\fof\fhigh-strength\fsteel\fpl\bte\f(Usibor\f1500).\f\f

A\fp\brti\bl\frepl\bcement\fin\fthe\f\bre\b\fof\fthe\fB-pill\br\freinforcement\fis\fnot\fpermissible.\fThe\f
re

quired\fcontinuous\fMIG\fweld\fse\bm\fin\fthe\f\bre\b\fof\fthe\fcut\fc\buses\fstructur\bl\fch\bnges\f
which\fresult\fin\fsignific\bnt\floss\fof\fstrength\fin\fthe\fB-pill\br\freinforcement.\f\f

Due\fto\fits\fstrength,\fthe\fB-pill\br\freinforcement\fc\bnnot\f\blw\bys\fbe\fworked\fon\fwith\f
co

nvention\bl\fbody\ftools.\f\f

Addition\bl\fprep\br\btions\f\bre\frequired\ffor\fMIG\fpuddle\fwelding.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt Parts \f

B-pill\br\fouter\fp\bnel\f

B-pill\br\finner\fp\bnel\f

B-Pill\br\freinforcement\f

NVH\felement\f
1. Gener\bl\fnotes\f

Necess\bry\fremov\bl\fwork:\fDoors,\fB-pill\br\f
tr

im\fp\bnel,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. NOTE:\fDue\fto\fthe\finner\freinforcements\f\bnd\f
NV
H\felements,\fthe\fspecified\fdimensions\ffor\f
the\fcuts\fto\fbe\fm\bde\fin\fthe\frocker\fp\bnel\f\bre\b\f
must\fbe\fcomplied\fwith.\f
Outer\fB-pill\br\f NOTE:\fOnly\fcut\fthrough\fthe\fouter\f
p\b

nels\fof\fthe\fB-pill\br\f-\fdo\fnot\fd\bm\bge\f
the\finner\freinforcement\fof\fthe\frocker\f
p\bnel.\f
1. Rocker\fp\bnel\fcut\floc\btions\f
2.
B-Pill\br\fcut\floc\btion.\f
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I\bstallatio\b
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\b n

d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
1.NOTE:\fTo\fst\brt\fwith\fthe\fholes\fneed\fto\fbe\f
pr

e-milled\fwith\f\b\fspheric\bl\fcutter\fwith\f\b\f
sm\bll\fdi\bmeter.\fAfterw\brds\fthese\fholes\f\bre\f
then\fmilled\fout\fto\fthe\frequired\fdi\bmeter\fwith\f
\b\fspindle\fmilling\fcutter.\fThis\fmethod\fis\f
essenti\bl\fin\forder\fto\fensure\fth\bt\fthe\fm\bteri\bl\f
in\fthe\fedge\f\bre\b\fof\fthe\fmilled\fholes\fis\fnot\f
we\bkened.\f
B-Pill\br\freinforcement\f
Mill\fout\fthe\fholes\ffor\fpuddle\fwelding\f(10\f
mm

\fdi\bmeter).\f
2. WARNING:\fThe\fB-pill\br\freinforcement\fis\f
c o

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\fwelding\ffl\bnges\f
on\fthe\ffront\f\bnd\fre\br\fusing\f\b\ffibre\fgrinding\f
disc.\fAny\fcont\bmin\btion\fdue\fto\fp\brts\fof\fthe\f
co\bting\fin\fthe\fwelding\fb\bth\fwill\fwe\bken\fthe\f
welded\fjoint.\f B-Pill\br\freinforcement\f
Cle\bn\fthe\fcont\bct\f\bre\bs.\f
\f\f
\f
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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\fwelding\ffl\bnges\f
on\fthe\ffront\fusing\f\b\ffibre\fgrinding\fdisc.\fAny\f
cont\bmin\btion\fdue\fto\fp\brts\fof\fthe\fco\bting\fin\f
the\fwelding\fb\bth\fwill\fwe\bken\fthe\fwelded\f
joint.\f A-pill\br\freinforcement\f
Cle\bn\fthe\fcont\bct\f\bre\b.\f
4. NOTE:\fFit\fthe\fB-pill\br\finner\fp\bnel,\fB-pill\br\f
re
inforcement\f\bnd\fB-pill\br\fouter\fp\bnel\fin\fthe\f
vehicle\f\bnd\fsecure.\fT\bck-weld\fthe\fB-pill\br\f
inner\fp\bnel\f\bnd\fthe\fthe\fB-pill\br\f
reinforcement\fon\fthe\finside\fwith\fMIG\fspot\f
welds\fon\fthe\finside\fof\fthe\frocker\fp\bnel\f\bnd\f
on\fthe\finner\fp\brt\fof\fthe\froof\ffr\bme.\fT\bke\fthe\f
B-pill\br\fouter\fp\bnel\fb\bck\foff\f\bg\bin.\f
B-pill\br\f
MIG\fwelding\ffrom\fthe\finside\f(t\bck-
we

lding)\f
5. B-Pill\br\freinforcement\f 1. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\frocker\fp\bnel\freinforcement.\f
\f
\f\f
\f
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8. Outer\fB-pill\br\f
Continuous\fMIG\fweld\fse\bm.\f
9.

Outer\fB-pill\br\f 1. Continuous\fMIG\fweld\fse\bm.\f
WARNING:\fThe\fwelded\fjoints\f\bt\f
t h

e\ffront\f\bnd\fre\br\fdoor\f\bpertures\fmust\f
only\fbe\fm\bde\fby\fresist\bnce\fspot\f
welding.\fMIG\fpuddle\fwelding\fis\fnot\f\b\f
permissible\f\bltern\btive.\f
2. Resist\bnce\fspot\fweld.\f
\f
\f\f
\f
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Paint - \beneral \fnformation - SymbolsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
\beneral
V\b

rious\fsymbols,\fsigns,\finstructions\f\bnd\fillustr\btions\f\bre\fused\fin\fthis\fliter\bture.\fW\brnings\f
\bnd\fc\butions\fh\bve\fdifferent\fme\bnings\f\bnd\frequire\fdifferent\fw\bys\fof\fproceeding.\f
Di\bgr\bmm\btic\frepresent\btions\f\bre\fprovided\fwith\finstruction\bl\fsigns\ffor\fimproved\fcl\brity.\f
These\f\bre\fbriefly\fexpl\bined\fbelow:\f
WARNING:\fThis\fc\bption\fis\fused\fwhen\ff\bilure\fto\ffollow\f i
nstructions\fex\bctly\for\ff\bilure\fto\f
follow\fthem\f\bt\f\bll\fm\by\fresult\fin\f\b\fh\bz\brd\fto\fpersons\for\fin\fpersons\fbeing\finjured.\f
CAUTION:\fThis\fc\bption\fis\fused\fwhen\fincorrectly\ffollowing\fthe\ftest\fprocedures\for\f
instructions\for\ff\bilure\fto\ffollow\fthem\f\bt\f\bll\fcould\fle\bd\fto\fd\bm\bge\fto\fthe\fvehicle\for\f
components.\f
NOTE:\fThis\fc\bption\fis\fused\fwhen\f\bttention\fneeds\fto\fbe\fdr\bwn\fto\fspeci\bl\for\fextr\b\f
inform\btion.\f
When\fre\bding\fthis\fh\bndbook,\fyou\fwill\fcome\f\bcross\fthe\fp
oints\fWARNING,\fCAUTION\fAND\f
NOTE.\fThese\finstructions\f\bre\f\blw\bys\fgiven\fimmedi\btely\fbefore\fthe\fcorresponding\fjob\fsteps.\f
Hazardous materials designations
M\bny\f\bccidents\foccur\fbec\buse\fof\fignor\bnce.\fIn\fthe\f\bre\b\fof\fperson\bl\fhe\blth\fprotection,\fit\fis\f
p\brticul\brly\fimport\bnt\fto\fcle\brly\femph\bsize\fsources\fof\fd\bnger\f\bnd\ftheir\feffects\fon\fhum\bn\f
org\bns.\f\f
Only\fwith\fknowledge\fof\fh\bz\brdous\fm\bteri\bl\fdesign\btions\fc\bn\fit\fbe\fcert\bin\fth\bt\fthe\f
necess\bry\fprec\butions\f\bre\ft\bken\fwhen\fh\bndling\fsubst\bnces\fwhich\f\bre\fh\brmful\fto\fhe\blth.\f
NOTE:\fP\by\f\bttention\fto\fthe\fm\bnuf\bcturer's\fd\bt\b\fon\fthe \f
cont\biners\f\bnd\fgiven\fin\fthe\fS\bfety\f
D\bt\b\fSheet.\f
H\bz\brdous\fm\bteri\bl\fsymbols\f
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Paint - \beneral \fnformation - Health and
Safety PrecautionsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
\beneral instructions for the paint shop and handling paint materials
H\b

z\brdous\f\bre\bs\fin\frep\bir\fp\bint\fshops:\f\f

D\bnger\ffrom\ffires,\fexplosions\f\bnd\fhot\fsurf\bces.\f\f

D\bngers\fto\fhe\blth\f\bnd\fs\bfety\ffrom\fthe\feffects\fof\fh\brmful\fsubst\bnces\fbec\buse\fof\ftheir\f
\bbs

orption\fthrough\fthe\fskin\f\bnd/or\finh\bl\btion.\f\f

D\bngers\fc\bused\fby\felectricity,\fcompressed\f\bir,\fpower\ftools\f\bnd\fnoise.\f\f
WARNING:\fDuring\fp\binting\fwork\fthere\fis\f\bn\fincre\bsed\fd\bnger\fof\ffire\for\fexplosion.\f
Pre

vent\f\bny\fsp\brks\fbeing\fcre\bted.\fFire,\fn\bked\flights\f\bnd\fsmoking\f\bre\fforbidden.\f\f
Me\bsures:\f

We\br\fprotective\ffootwe\br\fm\bde\ffrom\f\bnti-st\btic\fm\bteri\bl.\f\f

Only\fuse\ftools\fm\bde\fof\fwood,\fbr\bss\for\fcopper\fto\fcle\bn\fst\bnds\f\bnd\fextr\bction\fducts.\fDo\f
no

t\fuse\ftools\fm\bde\fof\fsteel.\f
Only\ffill\for\fdec\bnt\fp\bint\fm\bteri\bls\fin\f\b\fspeci\blly\fm\brked\f\bre\b.\f\f
A s

\fwell\f\bs\fthese\fgener\bl\finstructions\fon\fthe\fd\bngers\fin\frep\bir\fp\bint\fshops,\f\bll\fn\btion\bl\f\bnd\f
intern\btion\bl\fregul\btions\fmust\fbe\fobserved:\f

He\blth\f\bnd\fS\bfety\f\bt\fWork\fAct\f\f

Ordin\bnce\fon\fH\bz\brdous\fSubst\bnces\f\f

Technic\bl\fRules\ffor\fH\bz\brdous\fSubst\bnces\f\f

Regul\btions\ffor\fthe\fPrevention\fof\fIndustri\bl\fAccidents\f\f

EU\fDirective\fon\fH\bz\brdous\fSubst\bnces,\f98/24/EU\f\f

EU\fDirective\fon\fNoise,\f2003/10/EU\f\f

EU\fDirective\fon\fVol\btile\fOrg\bnic\fCompounds\f(VOC),\f1999/13/EU,\f2001/81/EU,\f
20

04/42/EU\f\f

S\bfety\finstructions\fof\fequipment\f\bnd\ftool\fm\bnuf\bcturers\f
Personal protection
Be
sides\fthe\fbody\f\bnd\flimbs,\fsever\bl\forg\bns\fvit\bl\fto\flife\f\bre\fin\fvery\fp\brticul\br\fd\bnger.\f
Bec\buse\fd\bm\bge\fis\fmostly\firrep\br\bble,\fspeci\bl\f\bttention\f\bnd\fcomprehensive\fprotection\f\bre\f
necess\bry.\f
WARNING:\fSolvents\fc\buse\fd\bm\bge\fto\fthe\fhe\blth\fthrough\f i
nh\bl\btion.\fSpl\bshes\fin\fthe\f
eyes\for\fon\fthe\fskin\fc\bn\fc\buse\fbodily\fh\brm.\fWhen\fworking\fwith\fsolvents,\f\blw\bys\fuse\f
suit\bble\fme\bns\fof\fprotection.\f
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WARNING:\fV\bpor\for\fspr\by\fmist\fcont\bining\fisocy\bn\bte\f\bs\f\b\fp\bint\fb\bse\for\fh\brdener\f
c\bn\fc\buse\ftoxic\frespir\btory\fdise\bse\f(conditions\fsimil\br\fto\f\bsthm\b)\fle\bding\fto\fperm\bnent\f
d\bm\bge,\feven\fwhen\finh\bled\fin\fthe\flowest\fconcentr\btions.\f
Filter\fm\bsks\fwith\fw\bdding,\fsponge\for\fcolloid\ffilters\f\b
nd\f\blso\fp\bper\fm\bsks\f\bre\f\bll\funsuit\bble\f
for\fworking\fwith\fco\bting\fm\bteri\bls\fbec\buse\fthey\fdo\fnot\fstop\fsolvent\fv\bpors.\f\f
The\finstructions\ffor\fuse\fprovided\fby\fthe\fm\bnuf\bcturer\fmust\fbe\fobserved\fwhen\fworking\fwith\f
bre\bthing\fprotection\fequipment.\f\f
Skin protection
Spr\by\fp\binters\fwho\f\bre\fsubject\fto\fconsider\bble\fexposure\fto\fco\bting\fm\bteri\bls\fmust\fwe\br\f
su
it\bble\fprotective\fwork\fclothing\f(fl\bme-proof\f\bnd\f\bnti-st\btic).\f
NOTE:\fAlso,\fwhen\fworking\fwith\fw\bter\fb\bsed\fm\bteri\bls,\f c
omprehensive\fskin\fprotection\f
must\fbe\fworn,\fbec\buse\fthese\fm\bteri\bls\f\bre\fvery\fe\bsily\f\bbsorbed\fthrough\fthe\fskin.\f
The\fprotective\fclothing\fmust\fbe\fch\bnged\f\bt\fthe\fproper\f
interv\bls.\fItems\fof\fclothing\fwhich\f
\bre\fcont\bmin\bted\fwith\fco\bting\fm\bteri\bls\fc\bn\fe\bsily\fc\btch\ffire.\f\f
When\fselecting\fprotective\fclothing,\fit\fmust\fbe\ft\bken\finto\f\bccount\fth\bt\fcloth\fcont\bining\f\b\f
high\fproportion\fof\fe\bsily\fmelted\fpl\bstic\fthre\bd\fconsider\bbly\fincre\bses\fthe\fdegree\fof\fburns\f
injury\f(melted\fpl\bstic\fon\fthe\fskin!).\fThis\fmust\f\blso\fbe\ft\bken\finto\f\bccount\fin\fthe\fchoice\fof\f
underwe\br.\f\f
For\f\bre\bs\fof\fskin\fwhich\f\bre\fnot\fcovered\fby\fprotective\fclothing,\fsuit\bble\fskin\fprotection,\fskin\f
cle\bning\f\bnd\fskin\fc\bre\f\bgents\fmust\fbe\fused.\f
Eye protection
Working\fwith\fport\bble\fh\bnd\fs\bnding\fm\bchines\fon\fwhich\fthe\ftools\fmove\fungu\brded,\f\bt\f
sp
eed\f\bnd\fwith\fpower\fis\ffund\bment\blly\fd\bngerous.\f
Goggles\fmust\fbe\fworn\fnot\fonly\fwhen\fs\bnding,\fbut\f\blso\fwhen\fworking\fwith\fp\bints\f\bnd\ftheir\f
\bdditives.\fThese\fcont\bin\fsubst\bnces\fwhich\f\bre\fh\brmful\fto\fthe\feyes.\fD\bm\bge\fr\bnging\ffrom\f
irrit\btion\fof\fthe\fcorne\b\fto\fincur\bble\fillnesses\f\bre\fpossible.\f
The\fprotective\fgoggles\fmust\fbe\finert\ftow\brd\fspl\bshes\fof\fsolvent,\f\bnd\ffully\fenclose\fthe\f\bre\bs\f
\bt\fthe\fside\fof\fthe\feyes\fon\fboth\fsides.\fThe\fbest\fprotection\fduring\fspr\by\fp\binting\fis\foffered\fby\f
full\fm\bsk\frespir\btors\for\fhelmet\frespir\btors\fwith\f\b\fbuilt-in\fvisor.\f
Ear protection
Noise\fdisturb\bnce\fin\frep\bir\fp\bint\fshops\fc\bused\fby\fv\brious\fsources\fis\fp\brticul\brly\fhigh.\f
S\b
nding\f\bnd\fcompressed\f\bir\fm\bchines,\fp\bint\fc\bbin\fextr\bctor\ff\bns\f(compressors)\f\bnd\f
extr\bctor\fducts\fin\fthe\fwork\frooms\f\bre\fthe\fc\buses\fof\fthe\fhigh\flevels\fof\fnoise.\f\f
WARNING:\fAvoid\fd\bm\bge\fto\fyour\fhe\bring!\fWe\br\fe\br\fprotec
tion.\f
Suit\bble\fe\br\fprotection\fis\foffered\fby\fe\br\fplugs\for\fe\br
\fdefenders.\f\f
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Vehicles\fwith\f2.0L,\f2.3L\for\fdiesel\fengine\f
All\fvehicles\f
not\fforcibly\fbent.
17.Torque:\b 110\fNm\f
18. Torque:\b 80\fNm
\f
19. General\bEquipment:\b Tr\bnsmission\fj\bck\f
20.
WARNING:\f
This\fstep\f
requires\fthe\f\bid\f
\f
\f\f
\f\f
\f\f
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Installation of\f\bnother\f
te
c

hnici\bn.\f
CAUTION:\f
M\bke\fsure\fth\bt\f
no\fcomponents\f
c\btch.\f
NOTE:\fThis\fstep\f
is\fonly\fnecess\bry\f
when\finst\blling\f\b\f
new\fcomponent.
Remove\fthe\f
following\fitems:\f
1.Torque:\b
140\fNm
45°\f
2.
Torque:\b
Nm\f
3.
Torque:\b
150\fNm
90°\f
4.
Torque:\b
150\fNm
90°\f
21.WARNING:\f
This\fstep\f
requires\fthe\f\bid\f
of\f\bnother\f
technici\bn.\f
CAUTION:\f
M\bke\fsure\fth\bt\f
no\fcomponents\f
c\btch.\f
Remove\fthe\f
following\fitems:\f
1.Torque:\b
Nm\f
2.
Torque:\b
150\fNm
90°\f
3.
Torque:\b
150\fNm
90°\f
1. To\finst\bll\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
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16. \f\f1.
Torque:\b
25\fNm
2.Torque:\b
10\fNm
17.Torque:\b 80\fNm\f
18. General\bEquipment:\b Tr\bnsmission\fj\bck\f
19.
WARNING:\f
This\fstep\f
requires\fthe\f\bid\f
of\f\bnother\f
\f\f
\f
\f\f
\f\f
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