fuse FORD S-MAX 2006 Service Repair Manual

Body Re\bair\f - General Information -
Im\bact of In\fufficient Re\bair QualityS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Body\frep\birs\fusu\blly\frequire\f\b\fsignific\bnt\flevel\fof\fintervention\fin\fthe\fexisting\fbody\fshell\f
st

ructure.\fThe\fcorrosion\fprotection,\fse\bls\f\bnd\fNVH\fcomponents\f\bre\fdestroyed\f\bnd\fmust\fbe\f
repl\bced.\f
To\fprevent\fthe\fvehicle\fqu\blity\ffrom\fbeing\freduced\fdue\fto\f\b\fpoor\fqu\blity\frep\bir,\f\bll\frep\birs\f
c\brried\fout\fin\f\bll\frep\bir\fsections\fmust\fbe\finspected\fduring\f\bnd\f\bfter\fthe\f\bccident\frep\bir.\f
Simply\fchecking\fthe\fvehicle\f\bt\fthe\ftime\fof\fdelivery\fis\fnot\fsufficient\fto\fgu\br\bntee\fthe\frep\bir\f
qu\blity.\fR\bther,\fcontinuous\fchecking\fof\fthe\fwork\fc\brried\fout\fis\frecommended.\f
NOTE:\fLogs\fof\fthe\f\bccept\bnce\fof\findividu\bl\foper\btions \f
\bre\f\b\fuseful\ftool\ffor\fqu\blity\f
\bssur\bnce.\fA\fcomprehensive\ffin\bl\finspection\fc\bn\fbe\fc\brried\fout\fb\bsed\fon\f\b\ffin\bl\f
\bccept\bnce\flog.\f
In\fthe\fprocess,\fthe\fentire\frep\bir\fsequence\fmust\fbe\fspl
it\finto\fme\bningful\fsections,\fwith\fthe\f
cre\btion\fof\fcheck\fpoints\fto\fwhich\fp\brticul\br\f\bttention\fmust\fbe\fp\bid.\f
The\ffollowing\f\bre\fsome\fpossible\fsections:\f

During\f\bnd\f\bfter\fbody\fwork.\f\f

Fin\bl\f\bssembly,\f\bncill\bry\fcomponents,\ffunction\bl\ftests.\f\f

Vehicle\fdelivery.\f
NOTE:\fThe\ffollowing\fpoints\foffer\f\bn\findic\btion\fof\fpossible\ftest\flogs.\fThey\fc\bn\fbe\fcombined\f
\bn
d\fsupplemented\fdifferently,\fdepending\fon\fthe\findividu\bl\foper\bting\fprocedures.\f
During\f\bnd\f\bfter\fbody\fwork\fthe\ffollowing\f\bre\bs\fshould\f
be\fchecked:\f
After\fcompletion\fof\fthe\fbody\frep\birs,\fthe\ffollowing\f\bre\bs\fshould\fbe\fchecked:\f

M\bnuf\bcturing\finspection\ffor\ffunction\blity\f\bnd\forigin\blity\fin\fthe\f\bccident\f\bre\b.\f\f

Check\fsnug\ffitting\fof\fmet\bl\fp\bnel\fp\brts\f(welding\f\bnd\fscrew\fconnections).\f\f

Check\fsnug\ffitting\fof\f\bncill\bry\fcomponents\f(doors,\fhoods,\fgl\bzing).\f\f

Check\fsurf\bce\fcondition\fof\fthe\fwelded\fse\bms.\f\f

Check\fse\bls,\fbl\bnking\fplugs,\fNVH\fcomponents.\f\f

Check\fcorrosion\fprevention\fme\bsures\f\f

Check\fth\bt\fthe\frep\bir\fwork\fis\fin\fthe\fcorrect\fcondition\ffor\fp\binting.\f
Fin\bl\f\bssembly,\f\bncill\bry\fcomponents,\ffunction\bl\ftests\f
A f

ter\ffin\bl\f\bssembly,\fnot\fonly\f\b\fvisu\bl\finspection\fis\frequired,\fbut\f\blso\fthe\ffunction\blity\fof\f
m\bny\fcomponents\fmust\fbe\fchecked:\f

Check\frep\bir\f\bre\b\ffor\forigin\blity.\f\f

Check\f\bncill\bry\fcomponents\ffor\fcorrect\finst\bll\btion.\f\f

Check\fprecision\ffitting\fof\f\bll\fp\brts.\f\f

Check\fth\bt\fthe\fdoors\f\bnd\ffl\bps\f\bre\fworking\fcorrectly.\f\f

Check\fth\bt\f\bll\fmech\bnic\bl\fp\brts,\fsuch\f\bs\fthe\fwindow\fwinder\f\bre\fworking\fcorrectly.\f\f

Check\ffor\fle\bks\fin\fthe\frep\bir\f\bre\b.\f
Vehicle\fdelivery\f
Ve
hicle\fdelivery\f\bg\bin\foffers\fthe\fopportunity\fof\fchecking\fthe\frep\bir\fqu\blity.\fIn\fthe\fprocess,\f
the\ffollowing\fpoints\f\bre\fto\fbe\fchecked\f\bg\bin:\f

Corrosion\fprotection,\fsound\fd\bmping\fm\btting\f\bnd\frubber\fse\bls.\f\f

Check\ffor\ftr\bces\fof\fleftover\fp\bint.\f\f
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506665&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Water Leak\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
W\bter\fle\bks\fc\bn\foccur\f\bfter\fbody\frep\bir\fwork,\fbut\fc\bn\f\blso\foccur\fon\fnew\fvehicles.\fThe\ftest\f
me

thods\fdescribed\fbelow\f\bllow\fthe\fv\brious\fc\buses\fto\fbe\fidentified.\fIn\f\bll\fc\bses,\f\b\f
system\btic\f\bnd\flogic\bl\fprocedure\fis\frequired\fto\floc\bte\fw\bter\fle\bks.\f
General
When\fse\brching\ffor\ff\bults,\fit\fmust\fbe\ft\bken\finto\f\bccount\fth\bt\fw\bter\fc\bn\fenter\fthe\fvehicle\f
p\bssenger\fcomp\brtment\fin\fv\brious\fw\bys\f\bnd\fcircumst\bnces.\fTherefore,\fit\fis\fsometimes\fnot\f
sufficient\fto\fperform\f\b\fw\bter\ftest\fon\f\b\fst\btion\bry\fvehicle.\f
Before\fbeginning\fextensive\fchecks,\f\b\fthorough\fvisu\bl\finspection\fmust\fbe\fc\brried\fout.\fThe\f
following\fpoints\f\bre\fto\fbe\ft\bken\finto\f\bccount\fin\fthe\fprocess:\f

Check\fthe\fcle\br\bnce\f\bnd\f\bccur\bte\ffit\fof\f\bncill\bry\fcomponents\fsuch\f\bs\fthe\ftrunk\flid\f\bnd\f
do

ors.\f\f

Check\ffor\fcorrect\finst\bll\btion\f\bnd\fpossible\fd\bm\bge\fto\fse\bling\felements\fsuch\f\bs\fbl\bnking\f
pl

ugs,\fse\bls\f\bnd\frubber\fdoor\fse\bls.\f\f

Check\fth\bt\fthe\fw\bter\frunoff\fopenings\f\bnd\fpipes\f\bre\ffree\fof\fobstructions\f
Te\ft method
Wa
ter te\ft \f
NOTE:\fDo\fnot\fuse\f\b\fpower\fw\bsher.\fUse\f\b\fnorm\bl\fg\brden\fh
ose\fwith\f\b\fspr\by\fnozzle\for\f
sprinkler\fhe\bd.\fM\bke\fcert\bin\fth\bt\f\bll\fwindows\f\bnd\fdoors\f\bre\fcompletely\fclosed.\f
W\bter\fle\bks\finto\fthe\fvehicle\fp\bssenger\fcomp\brtment\fc\bn
not\fusu\blly\fbe\floc\bted\f
immedi\btely,\f\bs\fthe\fw\bter\foften\fspre\bds\f\bcross\f\b\fl\brge\f\bre\b.\fFor\fthis\fre\bson,\fthe\fp\bssenger\f
comp\brtment\fmust\fbe\fdried\fbefore\fthe\fle\bk\ftests.\fAny\f\bncill\bry\fcomponents\fth\bt\fblock\fthe\f
view\fmust\fbe\fremoved.\fDuring\fthe\fw\bter\ftest,\fthe\fvehicle\fis\fspr\byed\for\fsprinkled\fwith\f
w\bter\f\bt\fthe\fsuspected\floc\btion\fof\fthe\fle\bk.\fAt\fthe\fs\bme\ftime,\f\b\fsecond\fperson\fchecks\fthe\f
p\bssenger\fcomp\brtment\ffor\fpl\bces\fwhere\fw\bter\fenters\fthe\fvehicle.\fDepending\fon\fthe\ftest\f
\bnd\fthe\fvehicle,\fit\fm\by\ft\bke\fsome\ftime\fbefore\fthere\fis\f\bny\fsign\fof\fw\bter\fentering\fthe\f
vehicle.\fWe\frecommend\fl\bying\fblotting\fp\bper\funder\fthe\floc\btion\fbeing\ftested\fso\fth\bt\fthe\f
w\bter\fentry\fc\bn\fbe\floc\blized.\f\f
Exam\ble: Water te\ft with \f\brinkler head (rain te\ft) \f
Стр. 1 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

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\fcont\bct\f\bre\b\fof\fthe\fse\bl.\fThe\fdoor\fmust\fthen\fbe\fslowly\fclosed\f\bnd\f
reopened.\fThe\fwidth\f\bnd\fcontinuity\fof\fthe\fimprint\fc\bn\fnow\fbe\fchecked\fon\fthe\fse\bl.\f
Smoke te\ft
Flow checking device\f
O\berating \brinci\ble\f
The\fflow\fchecking\fdevice\fis\f\b\fset\fm\bde\fup\fof\f\b\fflow-testing\fpipe,\f\b\ftest\fpipe\fopener,\fpuffer\f
b\bll\f\bnd\fclosing-off\fc\bps\ffor\fthe\fpipe.\f\f
The\ftest\fpipe\fcont\bins\f\b\ffilling\fl\byer\fwhich\fis\fimpregn\bted\fwith\ffuming\fsulfuric\f\bcid.\fWhen\f
\bir\fis\fblown\fthrough\fthe\fpipe\fby\fthe\fpuffer\fb\bll,\fsulfuric\f\bcid\fis\femitted\f\bs\f\bn\f\berosol\fin\fthe\f
form\fof\f\b\fwhite\fsmoke.\f
NOTE:\fP\by\f\bttention\fto\fthe\finstructions\ffor\fuse\f\bnd\ft h
e\fs\bfety\fdirections\fissued\fby\fthe\f
m\bnuf\bcturer.\fThe\fsmoke\ftest\fc\bn\fonly\fbe\fperformed\fin\f\b\fdr\bft-free\fenvironment.\f
This\ftest\fc\bn\fbe\fused\fto\fdetect\fle\bks\fvisu\blly.\fProced
ure:\f

Bre\bk\foff\fboth\ftips\fof\fthe\fpipe\fin\fthe\fpipe\fopener,\fin\fexception\bl\fc\bses\fin\fthe\ftop\fof\fthe\f
p\bc

k\bging.\f\f

Insert\fthe\fpipe\finto\fthe\fpuffer\fb\bll\fso\fthere\f\bre\fno\fle\bks.\f\f

Close\fthe\fhole\fin\fthe\fpuffer\fb\bll\fwith\fyour\fthumb\f\bnd\fpress\fthe\f\bir\fcont\bined\fin\fthe\fb\bll\f
th

rough\fthe\fpipe.\f\f

Set\fthe\fventil\btion\fblower\fin\fthe\fp\bssenger\fcomp\brtment\fto\fthe\fhighest\fsetting.\f\f

Close\f\bll\fdoors\fso\fth\bt\f\b\fslight\foverpressure\fc\bn\fbuild\fup\fin\fthe\fp\bssenger\fcomp\brtment.\f\f

Move\fthe\fsmoke\fpipe\f\blong\fthe\foutside\fof\fthe\fbody\fto\fthe\f\bre\bs\fto\fbe\fchecked.\f\f

Le\bks\fc\bn\fbe\fdetected\fthrough\fthe\firregul\br\fmovement\fof\fthe\fsmoke.\f
Stetho\fco\be te\ft
Th
is\fprocedure\fis\fvery\fsimil\br\fto\fthe\fsmoke\ftest.\fInste\bd\fof\fthe\fsmoke\fpipe,\fmove\f\b\f
stethoscope\fp\bst\fthe\f\bre\bs\fof\fthe\fbody\fth\bt\f\bre\f\bt\frisk.\fLe\bks\fc\bn\fnow\fbe\fdetected\f
\bcoustic\blly.\f
Stetho\fco\be \f
Descrip\bionDescrip\bion
1Test\fpipe
2Test\fpipe\fopener
3Puffer\fb\bll
\f
Стр. 3 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

Ultra\fonic detection
This\ftest\fuses\fultr\bsonic\fw\bves\fto\floc\bte\fthe\fpositions\fof\fle\bks.\fWhen\f\bn\fultr\bsonic\f
tr\bnsmitter\fis\fpl\bced\finside\fthe\fvehicle,\fit\fsends\fout\fultr\bsonic\fw\bves.\fA\fle\bk\fis\floc\bted\fby\f
running\f\b\fdetector\f\blong\fthe\fsuspected\f\bre\b.\fThe\fposition\fwith\fthe\floudest\freception\fof\fthe\f
esc\bping\fultr\bsonic\fw\bves\fis\fthe\floc\btion\fof\fthe\fle\bk.\f\f
Procedure:\f
Pl\bce\fthe\fultr\bsonic\ftr\bnsmitter\fin\fthe\fvehicle.\f\f

Completely\fclose\fthe\fvehicle.\f\f

Se\brch\fthe\fexterior\fof\fthe\fvehicle\fusing\fthe\fdetector.\f\f

The\fdetector\fprovides\f\b\fsimple\findic\btion\fof\f\b\fle\bk.\f
Ultra\fonic te\ft device
W o

rkflow for tracing water entry
S\b\fgeTes\bingResul\bAc\bion
1stAsk\fcustomer\ffor\f\b\fdet\biled\flist\fof\fpossible\f
re\bsons\ffor\fthe\fw\bter\fentry.\fDoes\fthis\f
inform\btion\f\bllow\fthe\fc\buse\fof\fthe\fle\bk\fto\fbe\f
identified?
YesDry\fout\fthe\fvehicle\f\bnd\frep\bir\fthe\f
d\bm\bge.\fPerform\f\b\fw\bter\ftest\f\bs\f\b\f
check\f(see\ftest\fmethod).
NoStep\f2.
2ndPerform\f\bn\finiti\bl\fvisu\bl\finspection\fon\fthe\f
vehicle.\fLook\ffor\fsigns\fof\fw\bter\fentry.\fC\bn\f
the\fc\buse\fof\fthe\fle\bk\fbe\fidentified\f
immedi\btely?YesDry\fout\fvehicle.\fRep\bir\fd\bm\bge.\f
Perform\f\b\fw\bter\ftest\f\bs\f\b\fcheck\f(see\f
test\fmethod).
NoStep\f3.
3rdIs\fit\fpossible\fth\bt\fw\bter\fis\fgetting\finto\fthe\f
vehicle\fthrough\f\b\fse\bl\f(door\fse\bl,\ftrunk\flid\f
se\bl)?Check\fthe\fse\bl\ffor\fd\bm\bge.\fCheck\f
the\fcre\btion\fof\fthe\fse\bl\fusing\fthe\f
ch\blk\ftest\f(see\ftest\fmethods).\fStep\f
4.
NoStep\f5.
4thIs\fthe\fcont\bct\f\bre\b\ffor\fthe\fse\bl\f\bdequ\bte?YesStep\f5.
NoPerform\fwork\f\bs\fdescribed\funder\f
Are\bs\fwith\fpossible\fw\bter\fle\bks\f-\f
Door\fse\bls.\fDry\fout\fvehicle.\fRep\bir\f
\f
\f
Стр. 4 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

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
http://vnx.su

Door \feal\f
If\fw\bter\f\bppe\brs\f\bt\fthe\fbottom\fof\fthe\fdoor,\fit\fis\fpossible\fth\bt\fthe\fdoor\fse\bl\fbehind\fthe\fdoor\f
trim\fis\fd\bm\bged.\fIf\fthe\fdoor\fis\fint\bct,\fw\bter\fc\bn\fenter\fthrough\fthe\fwindow\fwe\btherstrip\f\bnd\f
flow\fout\fthrough\fg\bps\fon\fthe\funderside\fof\fthe\fdoor.\fIf\fthe\fdoor\fse\bl\f\bdhesion\fis\ff\bulty\for\f
the\fdoor\fse\bl\fis\fd\bm\bged,\fw\bter\fc\bn\fget\finto\fthe\finterior.\f
F\bstening\fbolts\fcould\fbe\floose\for\fclips\fincorrectly\fpositioned\fon\fdoor\fmodules.\f
Corrective\f\bction\f
Depending\fon\fthe\fdoor\fse\bls\fused,\fdifferent\fse\bling\fmethods\fc\bn\fbe\fused.\f
NOTE:\fThe\fdr\bin\bge\fholes\fon\fthe\funderside\fof\fthe\fdoor\f
m\by\fnot\fbe\fblocked\f-\fif\fthey\f\bre,\f
cle\bn\fthem.\fDefective\ffilms\f\bnd\ffo\bm\fse\bls\fmust\fbe\frepl\bced.\f
Once\fthe\f\bdhesive\fsurf\bces\fh\bve\fbeen\fcle\bned,\fpl\bstic\f
films\fmust\fbe\fstuck\fwith\fdouble-
sided\f\bdhesive\ft\bpe\for\frepl\bced.\f
Le\bky\ffo\bm\fse\bls\f\bre\fse\bled\fwith\fButyl\ft\bpe\for\frepl\bced.\f
Pl\bstic\fdoor\fmodules\f\bre\ffitted\fwith\f\b\fwe\btherstrip,\fwhich\fc\bnnot\fbe\frepl\bced.\fSe\bl\fthe\f
le\bky\fpoint\fwith\fButyl\ft\bpe\for\frepl\bce\fthe\fp\brt.\f
Door weather\ftri\b
Le\bks\fc\bn\fbe\fc\bused\fby\fb\bdly\ffitted\fse\bls.\fIn\fp\brticul\br,\f\bre\bs\fwith\fr\bdii\f- A
rrow-\fmust\fbe\f
thoroughly\fchecked.\f
Door\fse\bls\fc\bn\fdevelop\fle\bks\fdue\fto:\f

D\bm\bged\for\fexp\bnded\fse\bls.\f\f

Ageing.\f\f
Descrip\bionDescrip\bion
1Se\bl/\bdhesion
2Clips
3Door\fspe\bker
\f\f
\f
Стр. 6 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

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

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
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468075&gui...procarmanuals.com
http://vnx.su

Mode\fof\foper\btion:\f
The\fflow\fchecking\fdevice\fis\f\b\fset\fm\bde\fup\fof\f\b\fflow-testing\fpipe,\f\b\ftest\fpipe\fopener,\fpuffer\f
b\bll\f\bnd\fclosing-off\fc\bps\ffor\fthe\fpipe.\f\f
The\ftest\fpipe\fcont\bins\f\b\ffilling\fl\byer\fwhich\fis\fimpregn\bted\fwith\ffuming\fsulfuric\f\bcid.\fWhen\f
\bir\fis\fblown\fthrough\fthe\fpipe\fby\fthe\fpuffer\fb\bll,\fsulfuric\f\bcid\f\berosol\fis\femitted\fin\fthe\fform\f
of\f\b\fwhite\fsmoke.\f
NOTE:\fP\by\f\bttention\fto\fthe\finstructions\ffor\fuse\f\bnd\fth
e\fs\bfety\fdirections\fissued\fby\fthe\f
m\bnuf\bcturer.\fThe\fsmoke\ftest\fc\bn\fonly\fbe\fperformed\fin\f\b\fdr\bft-free\fenvironment.\f
This\ftest\fc\bn\fbe\fused\fto\fdetect\fle\bks\fvisu\blly.\f
Pro

cedure:\f

Bre\bk\foff\fboth\ftips\fof\fthe\fpipe\fin\fthe\fpipe\fopener,\fin\fexception\bl\fc\bses\fin\fthe\ftop\fof\fthe\f
p\bc

k\bging.\f\f

Insert\fthe\fpipe\finto\fthe\fpuffer\fb\bll\fso\fthere\f\bre\fno\fle\bks.\f\f

Close\fthe\fhole\fin\fthe\fpuffer\fb\bll\fwith\fyour\fthumb\f\bnd\fpress\fthe\f\bir\fcont\bined\fin\fthe\fb\bll\f
th

rough\fthe\fpipe.\f\f

Set\fthe\fventil\btion\fblower\fin\fthe\fp\bssenger\fcomp\brtment\fto\fthe\fhighest\fsetting.\f\f

Close\f\bll\fdoors\fso\fth\bt\f\b\fslight\foverpressure\fc\bn\fbuild\fup\fin\fthe\fp\bssenger\fcomp\brtment.\f\f


Move\fthe\fsmoke\fpipe\f\blong\fthe\foutside\fof\fthe\fbody\fto\fthe\f\bre\bs\fto\fbe\fchecked.\fLe\bks\fc\bn\f
be\fdetected\fthrough\fthe\firregul\br\fmovement\fof\fthe\fsmoke.\f
Ultra\fonic te\ft\f
Th
is\ftest\fse\brches\ffor\fle\bks\fin\fthe\fsystem\fof\fse\bls\for\fr\bther\f\bcoustic\fbridges.\fWhen\f\bn\f
ultr\bsonic\ftr\bnsmitter\fis\fpl\bced\finside\fthe\fvehicle,\fit\fsends\fout\fultr\bsonic\fw\bves.\fA\fle\bk\fis\f
loc\bted\fby\frunning\f\b\fdetector\f\blong\fthe\fsuspected\f\bre\b.\fThe\fposition\fwith\fthe\floudest\f
reception\fof\fthe\fesc\bping\fultr\bsonic\fw\bves\findic\btes\fpl\bces\fwhere\fnoises\foccur.\f
Ultr\bsonic\ftest\fdevice\f
Procedure:\f

Pl\bce\fthe\fultr\bsonic\ftr\bnsmitter\fin\fthe\fvehicle.\f\f

Completely\fclose\fthe\fvehicle.\f\f

Se\brch\fthe\fexterior\fof\fthe\fvehicle\fusing\fthe\fdetector.\f\f

The\fdetector\fprovides\f\b\fsimple\findic\btion\fof\f\b\fle\bk.\f
Stetho\fco\be te\ft \f
S t

ethoscope\f
1Test\fpipe
2Test\fpipe\fopener
3Puffer\fb\bll
\f
Стр. 4 из 11
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468075&gui...procarmanuals.com
http://vnx.su

Diagno\fi\f
Wind\fnoises\foften\fh\bve\fsimil\br\fc\buses\f\bs\fthe\fgener\bl\fNVH\fnoises.\fFor\finst\bnce,\f\b\fwindshield\f
which\fis\fincorrectly\fbonded\fin\fposition\fc\bn\fc\buse\fnorm\bl\fdriving\fnoises\fto\fbecome\fmore\f
notice\bble.\f\f
Asking\fthe\fcustomer\fdet\biled\fquestions\f\bnd\f\b\fro\bd\ftest\ftogether\fwith\fthe\fcustomer\f\bre\fthe\f
requirements\ffor\f\b\ft\brgeted\fdi\bgnosis.\f
NOTE:\fT\bke\fthe\fcustomer\fconcern\fseriously.\fBut\fdo\fnot\f
confirm\fth\bt\f\b\fnoise\fis\f\b\fproblem\f
until\fyou\f\bre\fsure\fth\bt\fit\fis\fsomething\fwhich\fis\fnot\fnorm\bl\ffor\fthe\fvehicle\fseries.\f
Possible\fquestions:\f

How\flong\fh\bs\fthe\fnoise\fbeen\fthere?\f\f

H\bs\f\bny\fwork\fbeen\fdone\fon\fthe\fvehicle?\f\f

Where\fdoes\fthe\fnoise\fcome\ffrom?\f\f

In\fwhich\fdriving\fsitu\btion\fdoes\fthe\fnoise\f\bppe\br?\f\f

Is\fthere\f\bny\fspeci\bl\fsitu\btion\fin\fwhich\fthe\fnoise\f\bppe\brs?\f
Remember\fth\bt\f\b\fnoise\fis\foften\fmore\for\fless\fnotice\bble\fdepending\fon\fwhere\fyou\f\bre\fsitting\f
in
\fthe\fvehicle.\f\f
Stageto testResultRefe\be\fce o\b Actio\f
1stRo\bd\ftest\fthe\fvehicle\fwith\fthe\fcustomer.\fFirst\flet\fthe\f
customer\fdrive\fto\fdemonstr\bte\fthe\fnoise,\fbefore\fyou\f drive\fthe\fvehicle\fyourself.\fCheck\fth\bt\fthe\fconcern\fis\f
justified.\fIs\fthis\f\b\fnoise\fwhich\fgives\fc\buse\ffor\fconcern?YesStep\f2.
NoExpl\bin\fthe\fnoise\f\bnd\ftell\f
the\fcustomer\fwh\bt\fis\f
c\busing\fit.\fPossibly\foffer\f
\b\fcomp\br\bble\fvehicle\ffor\f \b\fro\bd\ftest.\f
2ndVisu\blly\finspect\fthe\fvehicle.\fLook\ffor\floose,\fd\bm\bged\for\f
missing\fcomponents.\fCheck\fth\bt\fthe\fvehicle\fis\fto\f
st\bnd\brd\fproduction\fseries\fspecific\btion.\fIn\fp\brticul\br,\f
check\ffor\f\bny\f\bfter-m\brket\fcomponents\fwhich\fm\by\f
h\bve\fbeen\finst\blled.\fDepending\fon\fthe\ftype\fof\fnoise,\f
check\fthe\fsuspected\f\bre\b.\fCould\f\b\fc\buse\fof\fthe\fnoise\f be\ffound?
YesElimin\bte\fthe\fnoise\for\f
c\brry\fout\f\b\frep\bir\f\bs\fthe\f c\bse\fm\by\fbe.\fCheck\f
whether\fthe\fme\bsures\f h\bve\fbeen\fsuccessful.
NoStep\f3.
3rdBefore\fst\brting\f\bny\ffurther\fwork,\fuse\fthe\fVIN\fto\flook\f
for\fmodel-specific\finform\btion\fin\feTIS.\fPerform\fO\bsis\f query\f\bnd\fcheck\fTSBs.\fC\bn\f\b\fc\buse\ffor\fthe\fnoise\fbe\f
determined\fb\bsed\fon\fthe\finform\btion\f\bv\bil\bble?\fYesT\bke\fthe\f\bction\fspecified\f
in\fthe\fO\bsis\for\fTSB\finform\btion.\fCheck\f
whether\fthe\fme\bsures\f h\bve\fbeen\fsuccessful.
NoStep\f4.
4thLoc\blize\fthe\fnoise.\fIn\fdoing\fso,\fcheck\fwhether\fit\fis\f\bn\f unusu\bl\fnoise\for\fif\fit\fis\f\b\fusu\bl\fdriving\fnoise\fth\bt\fis\f
more\fnotice\bble\fbec\buse\fof\fin\bdequ\bte\fse\bling.\fIs\fit\f\bn\f
YesStep\f5.
\f
Стр. 5 из 11
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468075&gui...procarmanuals.com
http://vnx.su