roof FORD S-MAX 2006 Service Manual PDF

3. Fit\fthe\froof\f\bnd\fweld\fit\fin\fpl\bce\f(front\fp\brti\bl\fsection)\f
Resist\bnce\fspot\fwelding.\f
\f
\f\f
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Roof Shee\b Me\bal Re\fairs - Roof Panel—
Vehicles Wi\bhou\b: Glass Roof Panel, VIN
Pla\be Body S\byle Code: M
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
1.
Re\flacemen\b \far\bs \f

R

oof\fp\bnel\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fT\bilg\bte,\fdoors,\f
wi

ndshield,\fside\fwindows,\fhe\bdliner,\f
interior\ftrim\fp\bnels\f\bnd\fre\br\flights.\f

Move\fthe\fwiring\fh\brness\f\bw\by\ffrom\fthe\f
wo

rking\f\bre\b.\f
2. Roof\fp\bnel\f
Mill\fout\fthe\fspot\fwelds.\f
3.

Re\br\froof\fp\bnel\f
Grind\fout\fthe\fspot\fwelds\fst\brting\ffrom\fthe\f
fr

ont\fside\fof\fthe\fvehicle..\f
4. Roof\fp\bnel\f
He\bt\fthe\fbonded\f\bre\bs\ffrom\fthe\foutside\f
(\bp

prox.\f170°\fC).\f
\f
\f\f
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Ins\balla\bion
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\bn
d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
1.NOTE:\fIn\forder\fto\f\bchieve\f\b\fcomplete\fse\bl\fin\f
th

e\f\bre\b\fof\fthe\ft\bilg\bte\fmountings,\f\b\f
sufficient\fqu\bntity\fof\fPU\fgl\bss\f\bdhesive\f
needs\fto\fbe\f\bpplied.\f
Prep\bre\fthe\fbonded\f\bre\bs\f
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\froof\f
cr

ossmembers\f\bnd\fthe\ft\bilg\bte\fmountings.
\f
2. Offer\fup\fthe\froof\fp\bnel\f\bnd\fweld\fin\fpl\bce.\f
Resist\bnce\fspot\fwelding.\f
\f
\f
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3. Re\br\froof\fp\bnel\f
Resist\bnce\fspot\fwelding.\f
\f
\f\f
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3. Outer\fB-pill\br\f1. Mill\fout\fthe\fspot\fwelds.\f
2. He\bt\fthe\fbonded\f\bre\bs\f\bt\fthe\fbottom\fof\fthe\fB-pill\br\f(\bpprox.\f170°\fC).\f
4. NOTE:\fOnly\fcut\fthrough\fthe\fouter\fp\bnels.\f
Wh
e

n\fm\bking\fthe\fcut\f\bt\fthe\froof\fr\bil,\fdo\fnot\f
d\bm\bge\fthe\finner\freinforcement\fof\fthe\fA-
pill\br.\f
Outer\fB-pill\br\f 1.
Roof\fr\bil\fcut\floc\btion\f
2. B-Pill\br\fcut\floc\btion.\f
5. Outer\fB-pill\br\f
Mill\fout\fthe\fspot\fwelds.\f
\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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NOTE:\fThe\fupper\fw\bter\fdr\bin\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\f
expose\fthe\fupper\fw\bter\fdr\bin\fp\bnel\freinforcement.\fdr\bin\fp\bnel\freinforcement.\f
Upper\fqu\brter\fp\bnel\f 1.

Cut\floc\btion.\f
2. Rough\fcut\floc\btion.\f
3. Mill\fout\fthe\fspot\fwelds.\f
5. NOTE:\f\f
When\fm\bking\fthe\fcut\f\bt\fposition\f1\fit\fis\f
\bls

o\fnecess\bry\fto\fcut\fthrough\fthe\fouter\f
\bre\b\fof\fthe\froof.\f\f
 The\fspot\fweld\fin\fposition\f3\fis\fcovered\fby\f
th

e\froof.\fIn\forder\fto\f\bccur\btely\floc\bte\fit,\f
you\fneed\fto\fslightly\flift\fup\fthe\froof\fse\bling\f
fl\bnge.\f
Residu\bl\fp\brt\fof\fthe\fupper\fqu\brter\fp\bnel\f
1. Cut\floc\btion\f(through\ftwo\fp\bnel\f thicknesses).\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f thicknesses).\f
3. Mill\fout\fthe\fspot\fweld\f(two\fp\bnel\f thicknesses).\f
6. Residu\bl\fp\brt\fof\fthe\fupper\fw\bter\fdr\bin\fp\bnel\f 1. Cut\floc\btion.\f
2. Grind\fout\fthe\fspot\fwelds.\f
3. W\brm\fthe\f\bre\b\f(to\f\bbout\f170°\fC)\f\bnd\frele\bse\fthe\fNVH\felements.\f
7. Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Cut\floc\btion.\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f
\f\f
\f\f
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NOTE:\fThe\fupper\fw\bter\fdr\bin\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\f
expose\fthe\freinforcement\fof\fthe\fupper\fw\bter\fdr\bin\fp\bnel.\fdr\bin\fp\bnel\freinforcement.\f
Upper\fqu\brter\fp\bnel\f 1.

Cut\floc\btion.\f
2. Rough\fcut\floc\btion.\f
3. Mill\fout\fthe\fspot\fwelds.\f
5. NOTE:\f\f
When\fm\bking\fthe\fcut\f\bt\fposition\f1\fit\fis\f
\bls

o\fnecess\bry\fto\fcut\fthrough\fthe\fouter\f
\bre\b\fof\fthe\froof.\f\f
 The\fspot\fwelds\f\bt\fposition\f3\f\bre\fcovered\f
by

\fthe\froof.\fIn\forder\fto\f\bccur\btely\floc\bte\f
it,\fyou\fneed\fto\fslightly\flift\fup\fthe\froof\f
se\bling\ffl\bnge.\f
Residu\bl\fp\brt\fof\fthe\fupper\fqu\brter\fp\bnel\f
1. Cut\floc\btion\f(through\ftwo\fp\bnel\f thicknesses).\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f thicknesses).\f
3. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f thicknesses).\f
6. Residu\bl\fp\brt\fof\fthe\fupper\fw\bter\fdr\bin\fp\bnel\f 1. Cut\floc\btion.\f
2. Grind\fout\fthe\fspot\fwelds.\f
7. Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f
Cut\floc\btion.\f
\f
\f\f
\f\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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extent.\f\f

Cr\bcks,\fetching,\fm\brks\fup\fto\fdissolution\fof\fthe\ftop\fco\bt\f\bre\fthe\fresults.\f
Rep\bir\fof\fd\bm\bge:\f

If\fthe\fd\bm\bge\fis\flight,\fperform\f\b\fpolishing\frep\bir.\f
Paint damage caused by insects
At\finsect\fimp\bct\floc\btions\fon\fthe\fhood,\froof\f\bnd\fbumper,\fsm\bll\fetched\for\fetched\fthrough\f
p \b

int\fm\brks\fwith\fp\brti\blly\fvisible\fspots\fof\ffiller.\f\f
C\buse/d\bm\bge\fp\bttern:\f\f

The\ftop\fco\bt\fl\byer\fis\fdestroyed\fin\f\b\fshort\ftime\fby\fsurf\bce\fswelling\f\bnd\fetching.\f\f

Colliding\finsects\fstick\fto\fthe\fp\bint\fsurf\bce.\fIn\fcombin\btion\fwith\fmoisture\f\bnd\fhe\bt,\f
be

c\buse\fof\fthe\fresulting\f\bcids\fthe\finsect\fbodies\fsink\finto\fthe\fp\bint\ftop\fco\bt.\f\f

The\fcorrosion\fis\fG,\fC,\fU\for\fO\fsh\bped\f\bnd\fis\fonly\f\b\ffew\fmillimeters\fthick.\f
Rep\bir\fof\fd\bm\bge:\f

W\bsh\fthe\fvehicle,\ftre\bt\fthe\f\bffected\f\bre\b\fwith\finsect\fremover.\fCle\bn\fthe\fp\bint\fsurf\bce\f
se

ver\bl\ftimes.\f\f

Protect\fwith\fh\brd\fw\bx.\f
Paint damage caused by tree resin or sap
Sm\bll\fyellow-brown\fm\brks\for\fdrops\fon\fthe\fhorizont\bl\fp\brts\fof\fthe\fvehicle.\fThe\fdrops\fmelt\fin\f
su
nlight.\fResin\fd\bm\bge\fonly\foccurs\fin\fthe\fw\brm\fsummer\fmonths.\f
C\buse/d\bm\bge\fp\bttern:\f\f

Bec\buse\fof\ftheir\fchemic\bl\fcomposition,\ftree\fresins\fcombine\fwith\for\f\bdhere\fvery\fwell\fto\f
p\bi

nt\ftop\fco\bts\f\bnd\fc\buse\fthem\fto\fswell.\fThe\fhigher\fthe\ftemper\bture,\fthe\fmore\fintensive\f
is\fthe\fchemic\bl\fbonding\fbetween\fthe\fresin\f\bnd\fthe\fp\bint\ftopco\bt\fsurf\bce.\f \f\f
\f\f
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