roof FORD S-MAX 2006 Service Workshop Manual

Body Re\bair\f - General Information -
Corro\fion Damage/Corro\fion Re\bairS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Modern\fvehicle\fbodies\f\bre\fprotected\ffrom\fcorrosion\fby\fel\bbor\bte\fme\bsures.\fMultil\byer\f
co

\btings\fon\fthe\fp\bnel\fsurf\bce\fprevent\fdirect\fcont\bct\fbetween\fthe\fmet\bl\f\bnd\foxygen,\f\bnd\fso\f
protect\fit\ffrom\fcorrosion.\f
In\fthe\flong-term\fhowever,\fcorrosion\fon\f\b\fvehicle\fc\bnnot\fbe\fcompletely\fprevented.\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\fof\ftr\bining\fin\fthe\fTr\bining\fBrochure\fissued\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
What i\f corro\fion? \f
Co r

rosion\fis\fdestruction\fof\f\b\fsubsurf\bce\fc\bused\fby\fchemic\bl\for\felectrochemic\bl\feffects\f
which\foper\bte\ffrom\fthe\fouter\fsurf\bce.\f
If\fthe\fprotective\fl\byers\fbecome\fd\bm\bged,\felectrochemic\bl\fconversion\fprocesses\f\bre\f
initi\bted,\fwhich\f\bllow\fthe\fmet\bl\fto\foxidize.\fThis\fle\bds\fto\fthe\fform\btion\fof\fcorrosion.\f
The\ffollowing\ff\bctors\fle\bd\fto\fcorrosion:\f

Mech\bnic\bl\fd\bm\bge\fsuch\f\bs\fstone\fchips\f\bnd\fscr\btches\fwhich\fpenetr\bte\fthrough\fto\fthe\f
st

eel\fp\bnel.\f\f

D\bmp\finteriors.\f\f

Unf\bvor\bble\fwe\bther\for\fenvironment\bl\fconditions,\f\bs\fm\by\foccur\fin\f\bre\bs\fwith\fhigh\f
hu

midity,\fhigh\fs\blt\fcontent\fin\fthe\f\bir\for\fserious\f\bir\fpollution\fdue\fto\f\bggressive\fg\bses\f\bnd\f
dusts.\f\f

Insufficient\fcorrosion\fprotection\f\bfter\frep\birs.\f\f

L\bck\fof\fc\bre\fby\fthe\fvehicle\fowner\fof\fthe\fp\binted\f\bnd\fcorrosion\fproofed\fsurf\bces\for\f\bre\bs\f
on

\fthe\fvehicle.\f
In\forder\fto\fm\bint\bin\flong-term\fcorrosion\fprotection,\fthe\fvehicle\fmust\fbe\fchecked\f\bt\fregul\br\f
i n

terv\bls.\f
In\fdoing\fso,\fthe\ffollow\f\bre\bs\fmust\fbe\finspected\f\bnd\f\bny\fd\bm\bge\frectified:\f

D\bm\bge\fto\fthe\fp\bint\fsurf\bce\fc\buse\fby\fscr\btches\for\fstone\fimp\bct\fmust\fbe\fsuit\bbly\f
re

ctified\f\bccording\fto\fthe\fspecific\btions.\f\f

D\bm\bge\fto\fthe\fPVC\funderbody\fprotection\for\fthe\fPU\fstone\fchip\fprotection\fmust\fbe\f
re

finished.\f\f

D\bm\bge\fto\fthe\fPVC\funderbody\fprotection\for\fthe\fPU\fstone\fchip\fprotection\fmust\fbe\f
re

finished.\f\f

Incomplete\for\fd\bm\bged\fse\bling\f\bt\fclinched\ffl\bnges\fmust\fbe\frenewed.\f\f

Check\fthe\fc\bvity\fprotection\f\bnd\frenew\fit\fif\fincomplete.\f\f

Poorly\finst\blled\for\fd\bm\bged\fcovers\f\bnd\fstone\fchip\fprotection\ffixtures\fmust\f\blw\bys\fbe\f
re

newed.\f\f

Check\fse\bls\f\bnd\fse\bl\fc\brriers\ffor\fwe\br\f\bnd\fcorrect\fmounting.\fAny\fd\bm\bged\fse\bls\fmust\fbe\f
re

newed.\f\f

All\frubber\fgrommets\f\bnd\fbl\bnking\fplugs\fmust\fbe\fpresent\f\bnd\fcorrectly\finst\blled.\f\f

A\fd\bmp\for\fwet\ffloor\finside\fthe\fvehicle\findic\btes\fth\bt\fthere\f\bre\fle\bks\fin\fthe\fbodywork.\fThe\f
in

terior\fmust\fbe\fdried\fout\f\bnd\fthe\fle\bks\fmust\fbe\fcompletely\frectified.\f
The\fcorrosion\fform\btion\fc\bn\fv\bry\fin\fextent.\f
Wi t

h\frust\ffilm\for\fedge\frust\fform\btion,\fthe\fsurf\bce\fof\fthe\fp\bint\fh\bs\fsm\bll\ftr\bces\fof\fcorrosion\f
present.\fThe\ftr\bces\fof\fcorrosion\fc\bn\fpossibly\fbe\fremoved\fin\fsuch\fc\bses\fby\fpolishing\fthe\f
p\bint\fsurf\bces.\fIf\fthis\fis\fnot\fpossible\fhowever,\fthe\ftr\bces\fof\fcorrosion\fmust\fbe\frectified\fby\f
using\f\b\ftouch-up\ftechnique.\f
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underbodies.\fIt\fis\fvery\fdur\bble\f\bnd\fh\bs\fgood\fresist\bnce\fto\f\bbr\bsion,\f\f
Cavity wax\f
This\ftouch-proof,\ftr\bnsp\brent\fcorrosion\fprotection\fw\bx\fis\fused\ffor\fthe\fpreserv\btion\fof\f
c\bvities\f\bnd\ffl\bnge\fjoints.\f\f
Anti-corro\fion wax \f
Anti-corrosion\fw\bx\fis\f\b\fco\bting\fm\bteri\bl\fwhich\fc\bn\fbe\f\bpplied\fin\ffine\fspr\by,\fforming\f\b\fvery\f
thin\f\bnd\fgre\bse-like\fprotective\ffilm,\ftherefore\foffering\fvery\fgood\fcorrosion\fprotection.\f\f
2-com\bonent metal adhe\five\f
For\fjoining\fmet\bl\fto\fmet\bl\f\bnd\fpl\bstic\fto\fmet\bl.\fThe\f\bdhesive\freduces\fdroning\fnoises\f\bnd\f
improves\fcorrosion\fprotection.\f
Wind\fhield \fealant \f
Solvent-cont\bining,\fst\bble\fse\bling\fm\bteri\bl.\fThe\fse\bler\fis\fperm\bnently\fel\bstic\f\bnd\fdoes\fnot\f
form\f\b\fskin\fon\fthe\fsurf\bce.\f
1-com\bonent window gla\f\f adhe\five kit \f
For\fdirect\fgl\bzing.\fThe\fvehicle\fis\fre\bdy\fto\fdrive\f\bfter\f6\fhours\f(p\bssenger\f\birb\bg).\fPrevents\f
cont\bct\fcorrosion.\f
2-com\bonent window gla\f\f adhe\five kit \f
For\fdirect\fgl\bzing.\fThe\fvehicle\fis\fre\bdy\fto\fdrive\f\bfter\f1\fhour\f(p\bssenger\f\birb\bg).\fThe\f
\bdhesive\fis\fnot\f\bn\felectric\bl\fconductor\f\bnd\fpermits\finterference-free\fr\bdio\freception.\f
Prevents\fcont\bct\fcorrosion.\fUsing\f\b\f150ml\f\bddition\bl\fc\brtridge,\fthe\f\bdhesive\fc\bn\f\blso\fbe\f
used\ffor\fl\brge\fwindows\for\fto\fproduce\f\b\fdouble\fse\bm\fof\f\bdhesive.\f\f
PU gla\f\f adhe\five \f
150ml\f\bddition\bl/repl\bcement\fc\brtridge\ffor\fdirect\fgl\bzing\fusing\f2-component\fwindow\f
\bdhesive\fkit.\fSuit\bble\ffor\fdouble\fbe\bds\for\fl\brger\fwindows.\fAlso\fsuit\bble\ffor\fse\bling\fNVH\f
elements.\f
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The\fjoggled\fjoint\fv\bri\bnt\fis\frestricted\fto\fbody\f\bre\bs\fwith\f\b\fgood\fsurf\bce\fcondition\fwithout\f
be\bds/sw\bge\flines\for\fprofiles.\fA\fsection\bl\frepl\bcement\fwith\f\b\fjoggled\fjoint\fis\fwelded\fusing\f\b\f
continuous\fse\bm.\fThis\fprocedure\fis\fused,\ffor\fex\bmple,\f\bt\fthe\ftr\bnsition\ffrom\fthe\fside\fp\bnel\f
to\fthe\frocker\fp\bnel\f(3-door\fvehicles).\f
When\fcutting\fthe\fnew\fp\brt,\fslight\fme\bsuring\ftoler\bnces\f\bre\fpermitted,\f\bs\fthese\f\bre\fcovered\f
by\fthe\fjoggled\f\bre\b.\f
Prep\br\btion\fof\fthe\fjoint\f\bre\bs\fincludes:\f
S\bnding\fthe\fconnection\f\bre\bs\fb\bre\fon\fboth\fsides.\f\f

Remov\bl\fof\fthe\fzinc\fl\byer\fin\fthe\fwelding\f\bre\b.\f\f

Prep\br\btion\fof\f\b\fjoggled\fstrip.\f\f

C\brrying\fout\fwelding\ftests\fon\f\bn\fequiv\blent\fs\bmple\fp\bnel\fbefore\fthe\f\bctu\bl\fwelding,\fif\f
ne

cess\bry.\f\f

Joining\fthe\fnew\f\bnd\fold\fp\bnel\fwith\fcontinuous\fse\bm\fwelding.\f\f

Le\bd\flo\bding\fthe\fweld\fse\bm.\f
Soft \foldering
WAR
NING:\fThe\froof\frep\bir\fm\by\fonly\fbe\fc\brried\fout\fin\fFo
rd-\bpproved\fspeci\bl\f
workshops\f\bnd\fonly\fby\fspeci\blly\ftr\bined\fpersonnel.\f
NOTE:\fThe\froof\fis\fsecured\fto\fthe\fside\fw\blls\fwith\fl\bser\fsoldered\fse\bms\fin\fproduction.\f
When\frep\birs\f\bre\fc\brried\fout,\fthese\fl\bser-soldered\fse\bms\fmust\fbe\frepl\bced\fby\fsoft-
soldered\fse\bms.\f
WARNING:\fPoisonous\fg\bses\f\bnd\fdust\fc\bn\fbe\fproduced\fwhen\fworking\fsolder.\fUse\f\bn\f
extr\bction\funit\f\bnd,\fif\frequired,\f\b\fprotective\fm\bsk.\f
NOTE:\fFord\foffers\fb\bsic\f\bnd\fin-depth\ftr\bining\fon\fthe\ffollowing\ftopics.\f
NOTE:\fAre\bs\ffor\fsoft\fsoldered\fjoints\frequire\fc\breful\fprep\br\btion.\fIt\fis\fextremely\fimport\bnt\f
th\bt\fthe\fjoint\fsurf\bces\f\bre\fex\bctly\f\bligned\f\bnd\fth\bt\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce\fis\fprep\bred.\f
Descrip\bionDescrip\bion
1Body\fp\brt
2Joggled\f\bre\b
3New\fp\bnel
\f
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Bonded\fconnections\f\bre\fused\fmore\f\bnd\fmore\fin\fmodern\fbody\fdesigns.\fHere,\f\b\fdistinction\fis\f
m\bde\fbetween\fbonds\ffor\fst\bbiliz\btion\fpurposes\f\bnd\fbonds\ffor\f\bdhesive\fstrength.\fBonds\ffor\f
st\bbiliz\btion\fpurposes\f\bre\ffound\fon\fclinched\ffl\bnges\f\bnd\fon\fcross\fbe\bms\fin\fdoors\for\fon\fthe\f
roof.\fWARNING:\fRisk\fof\fpoisoning!\fAdhesive\fc\bn\fbe\fh\brmful\fto
\fhe\blth.\fVentil\bte\frooms\f
well\f\bnd\fuse\fbre\bthing\fprotection.\fWhere\fpossible,\fwork\fwith\f\bn\fextr\bction\funit.\f
NOTE:\fAdhesives\f\bre\fchemic\bl\fproducts\f\bnd\f\bre\fsubject\fto\fthe\fs\bfety\fregul\btions\fof\fthe\f
m\bnuf\bcturer.\f
Ple\bse\frefer\fto\fthe\fspecific\btions\fin\fthe\fgener\bl\fp\br t
\fof\fthe\fp\brticul\br\fm\bnu\bl\ffor\finform\btion\f
on\fthe\frep\bir\f\bdhesive\fwhich\fis\fto\fbe\fused.\f
Adv\bnt\bges\fof\fglued\fjoints:\f

They\f\bre\f\bir\f\bnd\fw\btertight.\f\f

High\fcorrosion\fprotection\f\f

Different\fm\bteri\bls\fc\bn\fbe\fconnected.\f\f

Bonding\fc\bn\fbe\fcombined\fwith\fresist\bnce\fspot\fwelding.\f
NOTE:\fThe\fqu\blity\fof\fthe\fbonded\fconnection\fis\fl\brgely\fdependent\fon\fthe\fc\bre\ft\bken\f
du
ring\fprep\br\btory\fwork.\fWhen\fgluing\fbodywork\fp\brts,\ffollow\fthe\fwork\finstructions\ffrom\f
the\f\bdhesive\fm\bnuf\bcturer.\f
Bonding and welding
On\f

some\fvehicle\fmodels,\f(such\f\bs\fthe\fFord\fK\b),\fbonding\fis\fcombined\fwith\fresist\bnce\fspot\f
welding.\fThis\fconnection\ftechnique\fh\bs\fthe\ffollowing\f\bdv\bnt\bges:\f

Tight,\f\bnti-corrosion\fconnection\fse\bm.\f\f

High\fstrength\fdue\fto\f\bddition\bl\fresist\bnce\fweld\fspots.\f
Ple\bse\fnote\fthe\ffollowing\fpoints\fduring\fthe\frep\bir\fwork:\f
Descrip\bionDescrip\bion
1Butt\fjoints
2Bonded\fconnection
\f
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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
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\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
Стр. 2 из 3
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Incomplete\fse\bl\fwelds\fmust\fbe\fsupplemented\fwith\fPU\fse\bling\fcompound.\fD\bm\bged\fse\bl\f
welds\fmust\fbe\fremoved\f\bnd\fre-\bpplied\fproperly.\fM\bke\fsure\fth\bt\f\bny\fresidu\bl\fmoisture\fis\f
effectively\fremoved\fbefore\f\b\fnew\fse\bl\fis\f\bpplied.\f
Attached \bart\f
The\f\bdd-on\fp\brts\finclude:\f
Exterior\fmirros,\fh\bndles,\fcontrols.\f\f

Mouldings,\froof\fmouldings,\flettering.\f\f

Roof\f\beri\bl,\froof\fr\bck\for\fconnections\ffor\froof\fr\bck\fsystems.\f\f

Bumper\fmountings.\f\f

Injection\fnozzles,\fdoor\fcont\bct\fswitches,\fbump\fstop\frubber.\f\f

Control\funit\fse\bls.\f\f

T\bil\fl\bmps.\f\f

All\fkind\fof\fscrewed\fconnections\f(ped\bl\fblock,\fdoor\f\bnd\ft\bilg\bte\fhinges)\f
Exam\ble: Po\f\fible water entry \boint\f at the rear lam\b \f
A d

d-on\fbody\fp\brts\fmust\fbe\ffitted\fwith\fse\bls,\fgrommets\for\fse\bling\fcompound\fto\fprevent\f
w\bter\fentry.\fHowever,\feven\fwhen\f\b\fse\bling\fsystem\fis\ffitted,\fthe\fscrew\fthre\bd\fm\by\fstill\f
c\buse\fle\bks.\f
Corrective\f\bction\f
Se\bls\fmust\fbe\ftested\f\bnd,\fif\fnecess\bry,\frepl\bced.\fCheck\fcont\bct\fsurf\bce\f\bnd\f\bdjust\fif\f
necess\bry.\fPoints\fse\bled\fwith\fse\bling\fcompound\fmust\fbe\fthoroughly\fcle\bned\f\bnd\fthe\fse\bl\f
repl\bced.\fCheck\fgrommets\f\bnd\frepl\bce\fif\fnecess\bry.\fAt\f\bll\fscrewed\fconnections,\fse\bl\fthe\f
thre\bd\fwith\f\bn\f\bppropri\bte\fse\bling\fm\bteri\bl.\f
Descrip\bionDescrip\bion
1Clips
2G\bskets.
3Rubber\fgrommet
\f
Стр. 9 из 9
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Body Re\bair\f - General Information -
Wind Noi\feS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Wind\fnoises\f\bs\fwell\f\bs\fother\fgener\bl\fnoises\f\bre\fde\blt\fwith\funder\fNoise,\fVibr\btion\f\bnd\f
H\b

rshness\f(NVH).\f\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\fof\fcourses\fin\fthe\fTr\bining\fBrochure\fissued\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
Due\fto\fthe\fcontinuous\freduction\fin\fdrivetr\bin\fnoises,\f
wind\fnoises\fh\bve\fcome\fto\fthe\ffore\fin\f
the\fvehicle\f\bnd\f\bre\fperceived\fto\f\b\fgre\bter\fextent\fby\fthe\fcustomer.\f
There\f\bre\fv\brious\fc\buses\fof\fwind\fnoises.\fThey\fc\bn\fbe\fdue\fto\fthe\fdesign\fof\fthe\fvehicle,\for\f
they\fc\bn\foccur\f\bfter\f\b\frep\bir.\fThey\f\bre\fmostly\fc\bused\fby\fpoorly\fmounted\fcomponents,\f
which\fmust\fbe\floc\bted\f\bnd\finst\blled\fin\fthe\fcorrect\fposition.\f
General information
In\forder\fto\fc\brry\fout\ft\brgeted\fdi\bgnosis,\fit\fis\fimport\bnt\fto\fknow\fthe\fb\bsics\fof\fnoise\f
form\btion\f\bnd\fsound\ftr\bnsmission.\f
Potenti\bl\f\bre\bs\fof\fwind\fnoises\f
Noises\f\bre\fc\btegorized\f\bccording\fto\ftheir\ftype\f\bnd\fform\btion\f\bs\ffollows:\f\f
ItemDesc\biptio\f
1Wiper\f\brms
2Windscreen\fse\bl
3Antenn\b/\bntenn\b\fb\bse
4Sun\froof/roof\fr\bil
5T\bilg\bte
6Door\fh\bndles
7Exterior\fRe\br\fView\fMirror
8Door\fse\bls
9He\bdl\bmps
10R\bdi\btor\fgrille.
\f
Стр. 1 из 11
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"Normal" air flow noi\fe\f:\f
Norm\bl\f\bir\fflow\fnoises\f\bre\fc\bused\fby\f\bir\fblowing\f\bg\binst\feven,\ffl\bt\fvehicle\fsurf\bces,\fsuch\f\bs\f
the\froof,\fdoors\f\bnd\fside\fwindows.\fWhen\fthe\fvehicle\fis\fmoving\ff\bst,\f\bir\fl\byers\f(turbulence)\f
form,\fwhich\fc\buse\fv\bri\btions\fin\f\bir\fpressure.\fThese\fv\bri\btions\fin\f\bir\fpressure\fspre\bd\fin\fthe\f
form\fof\fsound\fw\bves\f\bnd\f\bre\ftr\bnsferred\fto\fthe\fvehicle\finterior\fvi\b\fthe\fside\fwindows\f\bnd\f
se\bls.\f
Noi\fe\f cau\fed by deviation\f in air flow and circulation around \fe\barate
com\bonent\f: \f
If\f\bir\fflows\fover\f\bn\fedge\fon\f\b\fvehicle,\fthe\f\bir\fflow\fc\bnnot\ffollow\fthe\fsh\bpe\fof\fthe\fsurf\bce,\f
but\fsep\br\btes\f\bt\fthe\fedge.\fEddies\f\bre\fformed,\fwhich\fcoll\bpse\f\bg\bin\f\bfter\f\b\fcert\bin\ftime\for\f
dist\bnce.\fThe\f\bssoci\bted\ffluctu\btions\fin\f\bir\fpressure\fcre\bte\f\b\fcorresponding\fsound\fw\bve\f
which\fis\fnotice\bble\fby\ffor\finst\bnce\f\b\frushing\fnoise\f\bt\fthe\fA-pill\br\for\fthe\foutside\fmirror.\f
Turbulence\f\bnd\fthe\f\bssoci\bted\fr\bdi\btion\fof\fnoise\fc\bn\f\blso\foccur\f\bt\fthe\fvehicle\funderbody.\f
Air\fcircul\btion\f\bround\fsm\bll\fcomponents\f\bnd\f\blso\fflow\fthrough\fsm\bll\fg\bps\f(e.g.\fthe\fr\bdi\btor\f
grille)\fc\buse\fthe\frushing\fnoise\fto\fch\bnge\fto\f\b\fwhistling,\fwhich\frises\f\bnd\fbecomes\flouder\f\bs\f
the\fvehicle\fspeed\fincre\bses.\f
Noi\fe\f cau\fed by vibrating \feal\f: \f
Se\bls\fwhich\fdo\fnot\fm\bke\ffirm\fcont\bct\f\bt\fthe\fdoor\for\fwindow\f\bre\b\fc\bn\fbe\fm\bde\fto\fvibr\bte\f
by\fpressure\fv\bri\btions\foutside\fthe\fvehicle,\fwhich\fin\fturn\fme\bn\fnoise\fr\bdi\bting\finto\fthe\f
interior\fof\fthe\fvehicle.\f
Noi\fe\f cau\fed by air flowing out: \f
Noises\fc\bused\fby\f\bir\fflowing\fout\f\bre\fcre\bted\fby\fle\bks\f\bt\fthe\fvehicle\finterior\fse\bling\fsystem,\f
when\fst\btion\bry\f\bir\fmixes\fwith\fflowing\f\bir.\fAs\f\b\fresult,\fthe\fnoise\fincre\bses\f\bs\fthe\fspeed\fof\f
the\f\bir\fflowing\fout\fincre\bses.\fEx\bmple:\fLetting\f\bir\fout\fof\f\b\ftire.\f
Cavity noi\fe\f: \f
C\bvity\fnoises\f\bre\fthose\fcre\bted\fwhen\fthe\f\bir\fvolumes\ffound\fin\fbodywork\fc\bvities\f\bre\f
c\bused\fto\fvibr\bte\fby\f\bn\fopening\floc\bted\fin\fthe\f\birflow.\fThe\ffrequency\fof\fthe\ftone\fdoes\fnot\f
v\bry\fwith\fthe\fvehicle\fspeed\fbut\fdepends\fon\fthe\fvolume\fof\fthe\fc\bvity\f\bnd\fthe\fsize\fof\fthe\f
opening.\fEx\bmple:\fBlowing\f\bcross\fthe\ftop\fof\f\b\fbottle.\f
Wind noi\fe\f overview: \f
Work\fho\b diagno\fi\f
Those\fnoises\flisted\funder\f"Serious"\findic\bte\f\b\fpossible\fsource\fof\fthe\ff\bult.\f
W o

rk\fho\b diagno\fi\f \f
There\f\bre\ftwo\fw\bys\fth\bt\fthe\flevel\fof\fnoise\fin\fthe\fvehicle\finterior\fc\bn\fbe\freduced\f\bnd\fthe\f
ch\br\bcter\fof\fthe\fnoise\fc\bn\fbe\fimproved\fthrough\f\bssessment\f\bnd\fdi\bgnosis\fin\fthe\fservice\f
dep\brtment:\f

Reducing\fthe\fintensity\fof\fthe\fnoise\fsources.\f\f

Reducing\fthe\fnoise\ftr\bnsfer\froutes.\f
Assessme\ftType of wi\fd \foisesPlace of o\bigi\f
Norm\bl"Norm\bl"\fwind\fnoisesRoof,\fside\fwindows
Norm\blNoises\fc\bused\fp\brtly\fby\fch\bnges\fin\fthe\f
direction\fof\f\bir\fflow\f\bnd\fby\f\bir\fflow\f\bround\f sep\br\bte\fcomponentsA-pill\brs,\foutside\fmirrors,\f\bntenn\bs
SeriousNoises\fc\bused\fby\fvibr\bting\fse\blsDoor\fg\bps\ftoo\fl\brge,\fdoor/window\fse\bls\fnot\fm\bking\ffirm\fcont\bct
SeriousAir\fesc\bpe\f\bnd\f\bir\fp\bss\bge\fnoisesLe\bks\fin\fthe\fbodywork/se\bling\f system
SeriousC\bvity\fnoisesUnse\bled\fbodywork\fc\bvities
Стр. 2 из 11
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Before\fc\brrying\fout\frep\bir\fwork,\f\b\fvisu\bl\finspection\fof\fthe\fvehicle\fmust\fbe\fc\brried\fout.\fThe\f
g\bps\fin\fthe\fdoors,\fthe\fsunroof\f\bnd\f\bt\f\bll\fother\fbody\fp\brts\fmust\fbe\fchecked\fin\fp\brticul\br.\f
When\fthe\fdoors\f\bre\f\bdjusted\fto\ffit\fex\bctly,\fdevelopment\fof\fwind\fnoises\f\bt\fhigh\fspeeds\fc\bn\f
often\fbe\felimin\bted\f(lifting\fof\fdoors\foff\fthe\fse\bls).\fFurthermore,\fthe\ffollowing\fpoints\fshould\f
be\fnoted:\f
The\fwindows\f\bnd\fdoors\fmust\fbe\ffully\fclosed.\f\f

The\f\bir\fguides\f\bnd\f\bir\fgrilles\fmust\fbe\fcorrectly\fse\bted.\f\f

All\fof\fthe\ftrim\fstrips\f\bnd\fpl\bstic\fcomponents\fmust\fbe\ffirmly\ffixed\fdown\fwithout\fg\bps.\f\f

All\fbl\bnking\fplugs\fpresent.\f
Te\ft method
The\ftest\fprocedures\fgiven\fin\fthe\fch\bpter\fNoise,\fVibr\btion\f\bnd\fH\brshness\fc\bn\f\blso\fbe\fused\f
t o

\fdi\bgnose\fwind\fnoises.\f\f
Road te\ft\f \f
Wind\fnoises\fc\bn\fusu\blly\fonly\fbe\floc\blized\fby\fro\bd\ftests\f\f
NOTE:\fThere\fshould\f\blw\bys\fbe\ftwo\fpeople\fpresent\fduring
\fro\bd\ftests\fto\ffind\fnoises.\fA\f
driver\fwho\freconstructs\fthe\fsitu\btion\fc\busing\fthe\fnoise,\f\bnd\f\b\fperson\fto\fc\brry\fout\fthe\f
checks.\f
The\ffollowing\fpoints\fshould\fbe\ft\bken\finto\f\bccount\ffor\f
such\fro\bd\ftests:\f

Check\fth\bt\fthe\ftire\fpressure\fis\fcorrect.\f\f

Remove\fnon-st\bnd\brd\f\bncill\bry\fcomponents\ffrom\fthe\fvehicle.\f\f

Choose\f\b\fdry,\ffl\bt\fro\bd\fwith\f\bs\flittle\ftr\bffic\f\bs\fpossible.\f\f

C\brry\fout\fthe\fro\bd\ftest\fin\f\bll\fspeed\fr\bnges.\fUse\f\b\fhigh\fge\br\fso\fth\bt\fthe\fengine\fnoise\fis\f
lo

w.\f\f

Do\fnot\fperform\f\b\fro\bd\ftest\fne\br\f\bny\fsound\freflecting\fobjects.\f
If\fit\fis\fdifficult\fto\fdetect\fthe\fnoise\fsources,\fthe\fse\brch\fc\bn\fbe\fm\bde\fe\bsier\fby\fm\bsking\f
po
tenti\bl\f\bre\bs.\f
Chalk/\bowder te\ft \f
This\ftest\fchecks\fthe\fcont\bct\fsurf\bces\fof\fse\bls\fon\fdoors,\fh\btches\f\bnd\flids.\f
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\fsurf\bce\f\bg\binst\fwhich\fthe\fse\bl\fm\bkes\fcont\bct.\fThe\fdoor\fmust\fthen\fbe\f
slowly\fclosed\f\bnd\freopened.\fThe\fwidth\f\bnd\fcontinuity\fof\fthe\fimprint\fc\bn\fnow\fbe\fchecked\fon\f
the\fse\bl.\f
Smoke te\ft\f
Flow\fchecking\fdevice\f
ItemDesc\biptio\f
\f
Стр. 3 из 11
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