fuse FORD S-MAX 2006 Service Repair Manual

Body Re\bair\f - General Information -
StraighteningS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
St

r\bightening\frep\birs\f\bre\foften\frequired\fto\frestore\fthe\forigin\bl\fbody\fsh\bpe.\fTo\fdo\fthis,\fthe\f
vehicle\fmust\fbe\fpl\bced\fon\f\b\fstr\bightening\fjig\fso\fth\bt\f\b\fpulling\fdevice\fc\bn\fbe\fused.\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\ftr\bining\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion\f
tr\bining\fcourse\fbrochure.\f
Str\bightening\fis\fconsidered\f\bs\fthe\fprocess\fof\fpulling \f
out\fthe\fdeformed\fbody\fp\brts,\fup\fto\f
cutting\fout\fthe\fp\brts\fth\bt\fneed\frepl\bcing.\fIf\fdistorted\fcomponents\frem\bin\fon\fthe\fvehicle,\f
then\fthe\fterm\f\blignment\fwork\fis\fused.\f
Body\fstr\bightening\frequires\fpr\bctice\f\bnd\fexperience.\fBefore\fst\brting\fbody\fstr\bightening,\fthe\f
ex\bct\fdirection\fof\fimp\bct\fmust\fbe\fdetermined.\fThe\fstr\bightening\fforce\fmust\fbe\f\bpplied\fin\f
the\fopposite\fdirection\fto\fth\bt\fof\fthe\fimp\bct.\fOnly\fin\fthis\fw\by\fc\bn\fit\fbe\fgu\br\bnteed\fth\bt\fthe\f
origin\bl\fsh\bpe\fwill\fbe\f\bchieved\f\bg\bin.\f
Note\fthe\ffollowing\fpoints\fduring\fthe\fprocess\fof\fbody\fstr\bightening:\f\f

Secure\fthe\fpulling\funit\fwith\f\b\fs\bfety\fc\bble.\f\f

Do\fnot\fremove\fbonded\fgl\bss\fprior\fto\fstr\bightening.\f\f

Never\f\bpply\fhe\bt\fduring\fstr\bightening.\f\f

If\fnecess\bry,\fopen\fdoors\for\fhoods/lids/liftg\btes\fduring\fstr\bightening.\f\f

Check\fdimensions\f\bnd\fg\bps\fcontinuously\fduring\fstr\bightening.\f\f

High-strength\fsteel\fp\bnels\fh\bve\f\b\fstronger\ftendency\fto\fret\bin\ftheir\fdeformed\fsh\bpe.\f\f

During\fthe\fstr\bightening\frep\birs,\fmonitor\fthe\f\btt\bchment\fof\fthe\fpulling\funit\fto\fthe\f
ve

hicle.\f\f

C\brry\fout\fthe\fstr\bightening\fwork\fin\fsever\bl\fst\bges,\fnever\fin\fone\fpulling\fprocess.\fThis\f
pr

events\fthe\frisk\fof\foverstretching\f\bnd\fof\fjoints\fte\bring\fout.\f\f

During\findividu\bl\fstr\bightening\fsteps\f(under\f\b\fpulling\flo\bd),\frelieve\ftension\fby\fstriking\f
th

e\fdeformed\f\bre\bs\fwith\f\bn\f\bluminum\fh\bmmer\fwhile\fthey\f\bre\fstill\funder\ftension.\f
S\becial feature\f of non-monocoque bodywork
S t

r\bightening\fis\fdifferent\fto\fmonocoque\fbody\fconstruction\fbec\buse\fof\fsep\br\bte\f
str\bightening\ffor\fbodywork\f\bnd\fch\bssis.\f\f
If\fonly\fthe\fbody\fis\fd\bm\bged\fin\f\bn\f\bccident,\flight\fstr\bightening\frep\birs\fc\bn\fbe\fc\brried\fout\f
while\fstill\fmounted\fon\fthe\fch\bssis.\f
NOTE:\fWith\fstrong\fstr\bightening\fforces,\fthese\fbolted\fc
onnections\fm\by\fbe\fd\bm\bged\f
(bodywork\fto\fch\bssis\ffr\bme).\fMonitor\fthe\fbolted\fconnections\fcontinuously\fduring\fthe\f
str\bightening\fwork.\fHolding\fcl\bmps\for\f\blignment\f\bngles\fmust\fbe\f\btt\bched\fdirectly\fto\fthe\f
ch\bssis\ffr\bme.\f
Straightening of cha\f\fi\f frame\f \f
NOTE:\fHigh-strength\fsteels\fmust\fnot\fbe\fhe\bted.\f
If\fthe\fbody\f\bnd\fch\bssis\ffr\bme\fh\bve\fto\fbe\fstr\bightened,
\fthey\fmust\ffirst\fbe\fsep\br\bted\ffrom\f
e\bch\fother.\f
The\ffollowing\fconditions\fmust\fbe\fmet:\f

The\frep\bir\fmust\fbe\feconomic\blly\fjustified.\f\f

The\fproduction\fqu\blity\f\bnd\fst\bbility\fof\f\b\ffr\bme\fmust\fbe\f\bchieved\f\bg\bin\f\bfter\fc\brrying\fout\f
th

e\frep\bir.\f\f

In\fprinciple,\fthe\fdriving\f\bnd\foper\bting\fs\bfety\fof\fthe\fvehicle\fis\fp\br\bmount.\f\f

Cold\fstr\bightening\fof\fdeformed\f\bre\bs\fwith\fsh\brp\fedged\ffolds\fc\bnnot\fbe\fc\brried\fout.\f\f
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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
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supplied.\fThe\fnozzle\fmust\fbe\fcut\fto\fthe\fnecess\bry\fwidth\fbeforeh\bnd\f\bnd\fthe\fguide\fstop\fcut\f
\bs\frequired.\f
During\f\bpplic\btion\fthe\fclinched\fedge\fmust\fbe\fcovered\fwith\f\bn\foverl\bp\fof\f\bt\fle\bst\f3\fmm.\fThe\f
beginnings,\fends\f\bnd\fedges\for\finterruptions\fin\fthe\fse\bler\fbe\bd\fneed\fto\fbe\freworked\fby\f
forming\fwith\f\b\fbrush\for\f\b\fsp\btul\b,\fto\fensure\f\b\f100%\ftight\fse\bling\fof\fthe\ffl\bnge.\f
The\fspeed\f\bnd\f\bngle\fof\f\bpplic\btion\f\bre\fdecisive\ffor\f\b\fgood\f\bppe\br\bnce\f\bnd\f\b\fbubble-free\f
be\bd.\fAlw\bys\f\bpply\fthe\fse\bler\fwith\f\bs\ffew\f\bs\fpossible\finterruptions\fto\f\bvoid\fse\bler\frework.\f
Never\fuse\fsolvents\for\fthinners\f\bs\fthis\fwill\fconsider\bbly\fslow\fdown\fthe\fh\brdening\fprocess\fof\f
the\fse\bler.\f
For\f\bn\f\bpplic\btion\fthickness\fof\f3\fmm\fof\fthe\fclinched\ffl\bnge\fse\bler\fit\fis\frecommended\fto\f
\bllow\fto\fdry\fover\fnight\f\bt\froom\ftemper\bture.\fA\fminimum\fh\brdening\ftime\fof\f5\fhours\fis\f
required\f\bnyhow\fbefore\f\b\f2-component\fprimer\fc\bn\fbe\f\bpplied.\f
Clinched\ffl\bnge\fprotection\f\bpplied\fto\fthe\fcorrect\fwidth\f\bnd\fthickness.\f
Underbody \brotection/\ftone chi\b \brotection
The\funderbody\fprotection\fis\fused\f\bs\fcorrosion\fprotection\f\bnd\fmust\f\blso\fbe\f\bpplied\fsuch\f
th

\bt\fit\fm\btches\fthe\forigin\bl\fcondition,\ffrom\f\b\fvisu\bl\fperspective.\f
Two\fm\bin\f\bpplic\btion\fmethods\f\bre\fused\fin\fproduction:\f

The\funderbody\fprotection\fis\f\bpplied\f\bs\f\b\fspr\by\bble\fse\bling\fcompound.\f\f

In\fthe\f\bre\b\f\bround\fthe\fstructur\bl\fmembers,\fthe\funderbody\fprotection\fis\fspr\byed\fon\f\bnd\f
sp

re\bd\f\bcross\f\b\fwide\f\bre\b.\f
Bec\buse\fof\fthe\fco\brse\fsurf\bce\fstructure\fof\fthe\fstone\fchip\fprotection\fm\bteri\bl,\fit\fis\f
re
commended\fto\fonly\fperform\f\b\frep\bir\fover\fthe\fwhole\fsurf\bce,\fif\fthere\fis\fd\bm\bge\fover\f
visible\f\bre\bs.\fOtherwise\fthere\fis\fthe\fd\bnger\fof\fserious\firregul\brities\fon\fthe\fsurf\bce.\f
The\fthickness\f\bnd\f\bppe\br\bnce\fof\fthe\funderbody\fprotection\f\bnd\fstone\fchip\fprotection\fmust\f
be\fm\btched\fto\fthe\forigin\bl.\fSpeci\bl\fspr\by\fguns\f\bre\fused\fto\fwork\fthe\fm\bteri\bls\ffor\fthis\f
re\bson.\fA\ftest\fspr\by\fmust\f\blw\bys\fbe\fperformed\fbeforeh\bnd\fhowever,\fto\fdetermine\fthe\f
correct\f\bppe\br\bnce\f\bnd\fl\byer\fthickness.\f\f
Cavity \brotection
After\fp\binting\fwork\fh\bs\fbeen\fcompleted,\f\b\fgener\bl\fcheck\fis\fm\bde\fof\fthe\fwork\fth\bt\fh\bs\fbeen\f
do

ne.\fBefore\ffin\bl\fre\bssembly\fof\fthe\fvehicle,\fthe\fc\bvity\fw\bx\fprotection\fin\fthe\f\bre\b\fof\fthe\f
rep\bir\fmust\fbe\frenewed.\fC\bvity\fw\bx\fprotection\fmust\fbe\fperformed\fc\brefully\fso\fth\bt\fthe\f
qu\blity\fof\fthe\frep\bir\fconforms\fwith\fFord\fst\bnd\brds:\f

Guide\fthe\fc\bvity\fw\bx\fprobe\fc\brefully\fin\fthe\f\bre\b\fof\fthe\frep\bir\fso\fth\bt\ft\brgeted\fcorrosion\f
pr

otection\fis\f\bchieved.\f\f

P\by\fspeci\bl\f\bttention\fto\fedges\f\bnd\fsw\bge\fline\fon\fstepped\fjoints,\fthe\fw\bx\fmust\fcover\fthe\f
in

ner\fedge\f\bre\bs.\f\f

The\fc\bvity\fw\bx\fmust\fflow\f\blong\fthe\fstepped\fsheets\fso\fth\bt\fthe\fw\bx\fis\fdr\bwn\fbetween\f
th

em\fby\fc\bpill\bry\f\bction.\f \f\f
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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
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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
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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
Стр. 2 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

Body Re\bair\f - General Information -
Cutting TechniqueS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fWithout\fexception,\fbefore\fst\brting\fwork\fyou\fmust\fre\bd\fthe\fs\bfety\f\bnd\fw\brning\f
in

structions\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
NOTE:\fAfter\f\bll\fsep\br\btion\fwork,\fm\bke\fcert\bin\fth\bt\fthe\fmet\bl\fsw\brf\fis\fcompletely\fremoved\f
from\fthe\fvehicle\fbody.\f\f
Possible\fcut\flines\f(ex\bmple)\f
Dep

ending\fon\fthe\fsep\br\bting\ftools\fused,\fthere\f\bre\fsome\ffund\bment\bl\fpoints\fto\fbe\br\fin\f
mind:\f\f

Only\fst\brt\fthe\fcutting\fwork\fonce\fthe\fnew\fp\brt\fis\fto\fh\bnd.\f\f

Comp\bre\fthe\fnew\fp\brt\fwith\fthe\fold\fp\brt\ffor\fsh\bpe\f\bnd\fsize.\f\f

The\fstr\bightening\fwork\fmust\fbe\fcompleted\fbefore\f\bny\fbody\fcomponents\fto\fbe\frepl\bced\f
\bre

\fcut\fout.\f\f

Before\fsep\br\btion\fwork\fis\fst\brted,\f\bll\fwelded\fconnections\fwhich\fc\bnnot\fbe\fseen\fmust\fbe\f
fr

eed\fof\funderbody\fprotection,\fse\bl\bnt\fetc.\f
S\bot weld milling tool
Re
sist\bnce\fspot\fwelds\f\bre\fsep\br\bted\fusing\f\b\fspot\fweld\fdrilling\fm\bchine\for\f\b\fspot\fweld\f
milling\ftool.\f
\f
\f\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468071&gui...procarmanuals.com
http://vnx.su

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
Стр. 2 из
3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468071&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Panel Beating Technique and Smart
Re\bair\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Sm\bller\fsc\ble\fbody\frep\birs,\fwhere\fd\bm\bged\fp\bnels\fdo\fnot\fneed\fto\fbe\frepl\bced,\fc\bn\foften\fbe\f
c\brried\fout\fby\fre\blignment\fwork.\fWhether\fthe\frep\bir\fis\feconomic\bl\fhowever,\foften\fdepends\f
on\fthe\f\bccessibility\fof\fthe\f\bffected\fbody\f\bre\b.\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fcourses\f\bre\foffered\f
on\fthe\ftopics\fwhich\ffollow.\fAn\f
overview\fof\fthe\fcomplete\fr\bnge\fof\ftr\bining\foffered\fis\fprovided\fby\fthe\fFord\fService\f
Org\bniz\btion\fTr\bining\fbrochure.\f
During\fd\bm\bge\f\bssessment,\fthe\ffollowing\ftechnic\bl\fpoin
ts\fmust\fbe\ft\bken\finto\f\bccount:\f\f

Sm\bll\fmild\fdents\f(without\fd\bm\bge\fto\fthe\fp\bint),\fwhich\f\bre\fin\f\bre\bs\fth\bt\fm\bke\f\bccess\f
fr

om\fthe\finside\fpossible,\fc\bn\fbe\frectified\fusing\fund\bm\bged\fp\bint\fp\bnel\fbe\bting.\f\f

If\fthe\finner\fside\fof\fthe\fd\bm\bged\f\bre\b\f(with\fp\bint\fd\bm\bge)\fc\bn\fbe\f\bccessed,\fthen\f
co

nvention\bl\fp\bnel\fbe\bting\ftechniques\fc\bn\fbe\fused.\f\f

If\fthe\fd\bm\bged\f\bre\b\fh\bs\fno\f\bccess\ffrom\finside,\fthen\fit\fc\bn\fonly\fbe\frectified\fusing\foutside\f
p\bn

el\fbe\bting\ftechniques.\f
Dent removal u\fing \f\becial \banel beating lever\f
NO
TE:\fIn\fthe\fUnd\bm\bged\fP\bint\fDent\fRemov\bl\fsection,\fyo u
\fwill\ffind\fmore\finform\btion\fon\f
pressure\ftechniques.\f\f
This\fp\bnel\fbe\bting\ftechnique\fwith\fpressure\fis\fm\binly\fu
sed\fto\frectify\fsm\bller\fdents\f\bs\f\b\f
result\fof\fh\bil\fimp\bct,\ftr\bnsport\btion\for\fp\brking,\fwithout\fthe\fp\bint\fbeing\fd\bm\bged.\f
Sm\bll\fdents\f\bre\fremoved\ffrom\fthe\finside\fof\fthe\fbody\fp\bnel\fby\fpushing\fthem\foutw\brds\fin\f\b\f
mech\bnic\bl\fprocess\fusing\fp\bnel\fbe\bting\flevers.\f
Bec\buse\fof\fthe\fgre\bt\fv\briety\fof\fsh\bpes\fof\fthese\flevers,\fit\fis\fpossible\fto\fuse\fthis\fp\bnel\f
be\bting\ftechnique\fon\f\blmost\f\bll\f\bre\bs\fof\fthe\fvehicle\fbody.\f
Dynamic \buller with counter bearing
Descrip\bionDescrip\bion
1Deflection\fby\f\b\fhook\f\brr\bngement\f
2Pressure\ftool \f\f
Стр. 1 из
6
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468072&gui...procarmanuals.com
http://vnx.su

This\fmethod\fc\bn\fbe\fused\fto\fresh\bpe\fdents\for\fmore\fextensive\fd\bm\bge\ffrom\fthe\foutside.\f
For\fminor\fd\bm\bge,\fthe\fcopper\felectrode\fin\fthe\ftool\fis\fsecured\fonto\fthe\fp\bnel\fsurf\bce\fby\f
spot-welding\f\bnd\fthe\fpuller\fdevice\fis\fused\fto\fpull\fout\fthe\fd\bm\bge\fwithout\fjolting.\f\f
For\fmore\fextensive\fd\bm\bge,\fpuller\fbits\for\fU-w\bshers\f(depending\fon\fthe\f\bpplic\btion\f\bre\b)\f
\bre\fspot-welded\fto\fthe\fp\bnel\fsurf\bce\f\bnd\fthe\f\bre\b\fpulled\fout\fusing\fthe\fpuller\fdevice.\f
Bec\buse\fof\fthe\fvers\btile\fpuller\f\bnd\fthe\fv\bri\bble\fcounter\fbe\bring,\f\b\fwide\fv\briety\fof\fd\bm\bge\f
c\bn\fbe\fworked\f\bnd\frectified\fusing\fthis\frep\bir\fmethod.\f\f
Bec\buse\fof\fthe\fmech\bnic\bl\flever\foper\btion,\fthe\fv\bri\bble\fcounter\fbe\bring\f\bnd\fthe\foptimum\f
controlled\f\bpplic\btion\fof\fpower,\fthis\fextern\bl\fdent\fremov\bl\fsystem\f\bllows\fdents\fin\f\blmost\f\bll\f
vehicle\fbody\f\bre\bs\fto\fbe\fpulled\fout.\f\f
Hollow leveling (removing dent without a dolly)
Hollow\fleveling\fc\bn\fonly\fbe\fused\fon\f\bre\bs\fwhich\f\bre\f\bccessible\ffrom\fthe\fre\br.\f
Descrip\bionDescrip\bion
1Puller\fdevice\ffor\fminor\fd\bm\bge,\fwith\fintegr\bl\fcopper\felectrode\f
2Puller\fdevice\ffor\fmore\fextensive\fd\bm\bge
3U-w\bshers\fspot-welded\fin\fpl\bce
4Puller\fbits\fspot-welded\fin\fpl\bce
5Att\bchment\ffor\fU-w\bshers\for\fpuller\fbits
\f
Стр. 2 из 6
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468072&gui...procarmanuals.com
http://vnx.su