service FORD S-MAX 2006 Service Manual PDF

The\frefriger\btion\fsystem\fis\ffilled\fwith\frefriger\bnt\fR134\b.\fThis\fc\bn\fc\buse\ffrostbite\fif\fit\f
cont\bcts\fthe\fskin.\fP\by\f\bttention\fto\fthe\fcorresponding\fw\brning\fnotices\f\bnd\finstructions\fin\f
the\fch\bpter\fAir\fConditioning\fSystems.\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
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\ff o
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,\fcle
\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
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
l\brge\fsurf\bces\fof\fthe\fw\bll\f\bnd\fceiling\fcl\bdding\fc\bn\fbe\fch\bnged\f\bnd\f\bre\fp\brticul\brly\fe\bsy\fto\f
rep\bir.\f
If\f\bccess\fto\fthe\fb\bck\fof\f\b\fbody\fp\bnel\fsection\fis\fneeded\fbec\buse\fof\fbody\fstr\bightening\fwork,\f
in\fsome\fcircumst\bnces\fit\fis\fche\bper\fto\fperform\f\b\fcut-out\frep\bir\finste\bd\fof\fremoving\f\bn\f
element.\f
The\frep\bir\fprocess\fis\ffully\fdescribed\fin\fthe\fStudent\fInform\btion\fbooklet\fRefriger\btion\f
System\fTechnology,\fTr\bnsit\f2000.5\fFreshline.\f
Стр. 4 из 4
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Body Re\bair\f - General Information -
Diagno\fi\f and Damage EvaluationS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Assessment\fof\fthe\fextent\fof\fthe\fd\bm\bge\fincludes\fvisu\bl\finspection\f\bnd\fdimension\bl\f
in

spection\fof\fthe\fvehicle.\fIn\forder\fto\fcorrectly\fdetermine\fthe\fextent\fof\fthe\fd\bm\bge\fc\bused\f
by\f\bn\f\bccident,\fin-depth\ftechnic\bl\fknowledge,\fpr\bctic\bl\fexperience\fwith\fthe\ftechnic\bl\f
equipment\f\bnd\fthe\ftesting\f\bnd\fme\bsuring\fdevices\fis\frequired.\f
Noticeable damage to the bodywork \ftructure
Positive\f\bccident\bl\fd\bm\bge\f\bssessment\fc\bn\fonly\fbe\f\bchieved\fif\fthe\fservice\ftechnici\bn\fis\f
\bble\fto\freconstruct\fthe\feffect\fof\f\bn\fimp\bct\fon\fthe\fbody\fstructure.\f
For\fex\bmple:\f
If\fthe\fimp\bct\foccurs\fon\fthe\ffront\fleft-h\bnd\fside\fmember,\fthe\fright-h\bnd\fside\fmember\fwill\f
usu\blly\f\blso\fh\bve\fbeen\fd\bm\bged.\fOften\fthe\flength\fof\fthis\fside\fmember\fwill\fnot\fh\bve\f
ch\bnged,\fbut\fbec\buse\fof\fthe\frigid\fbody\fdesign,\fit\fm\by\fh\bve\fbecome\fdeformed.\fThis\fd\bm\bge\f
c\bn\fbe\fdetected\fthrough\fthe\fsize\fof\fthe\fg\bp\fbetween\fthe\fdoor\f\bnd\ffender\for\fby\fme\bsuring\f
the\fvehicle.\f
In\fthe\fc\bse\fof\fmore\fsevere\fimp\bcts,\fin\fwhich\fthe\ffront\fp\brt\fof\fthe\fvehicle\fc\bnnot\f\bbsorb\f\bll\f
of\fthe\fimp\bct\fenergy,\fthe\fp\bssenger\fcell\fis\f\blso\fused\fto\f\bbsorb\fthe\fenergy.\fHere,\fthe\f
energy\fis\ftr\bnsferred\fvi\b\fthe\fA\fpill\br\f\bnd\fdistributed\fthere.\fThis\fresults\fin\fdeform\btions\fin\f
the\froof\f\bnd\fthe\fdoor\fsill.\f
NOTE:\fBec\buse\fof\fexisting\fd\bm\bge\fto\fthe\fbodywork\fstruc
ture,\fd\bm\bge\fdi\bgnosis\fon\f\b\f
vehicle\flift\fm\by\fgive\fextr\b\fincorrect\fdi\bgnosis\fresults.\f
NOTE:\fTr\bining\fcourses\f\bre\foffered\fon\fthis\fsubject.\fFor\f\bn\foverview,\fple\bse\frefer\fto\fthe\f
Ford\fService\fOrg\bnis\btion's\ftr\bining\fcourse\fbrochure.\f
If\ffor\finst\bnce\fthe\fFord\fFocus\fCoupé/C\bbriolet\fis\fr\bis
ed\fon\f\b\fvehicle\flift,\fthe\fde\bd\fweight\fof\f
the\fvehicle\fwill\fc\buse\fthe\ffront\fend\fto\fdrop\fby\f\bpprox.\f2\fto\f3\fmm.\f
The\f\bltered\fdoor\fposition\fis\fcle\brly\frecogniz\bble\fby\fstiffness\fof\fthe\flock;\fthe\fdoor\fmoves\f
upw\brds.\fThis\fc\buses\fthe\flock\fpin\fto\fcont\bct\fthe\fguide\felement\fof\fthe\fdoor\flock.\f
It\fis\fpossible\fto\fdr\bw\fconclusions\f\bbout\fthe\fextent\fof\fthe\fd\bm\bge\fthrough\f\b\fvisu\bl\f
inspection\fof\fthe\fextern\bl\fd\bm\bge.\fIn\fgener\bl,\fthe\ffollowing\f\bre\bs\f\bre\fto\fbe\fchecked\fduring\f
the\fvisu\bl\finspection:\f

Outer\fp\bnel\fincluding\fse\bm\fse\bls\ffor\fcr\bcks\for\ffl\bkes\fin\fthe\fp\bint\fc\bused\fby\fthe\f\bccident.\f
\f

Size\fof\fthe\fg\bp\fon\fdoors\f\bnd\fhoods\ffor\fevenness.\f\f

Freedom\fof\fmovement\fof\fdoor\f\bnd\fhood/t\bilg\bte\flocks.\f\f

The\fvehicle\froof\ffor\ffolds\f(g\bp\fme\bsurement\fon\fvehicles\fwith\fsunroof)\f\f

Dotted\ffl\bnge\fin\fdoor\fsection\ffor\fdeform\btion\f\bnd\fcr\bcked\fweld\fspots.\f\f

The\fside\fmembers\f\bnd\fcr\bsh\fcomponents\ffor\fcrumpling\f\bnd\ffolding.\f\f

Trunk\ffloor\f\bnd\ffloor\fp\bn\ffrom\f\bbove\f\bnd\fbelow\ffor\fcrumpling.\f
No noticeable damage to the bodywork \ftructure
In
\f\bddition\fto\fextern\bl\findic\btors\fsuch\f\bs\ffl\bking\fp\bintwork\for\fcr\bcks\fin\fthe\funderbody\f
protection,\fit\fis\fvit\bl\fto\fcheck\ffor\fd\bm\bge\fto\fthe\fbody\fstructure\fth\bt\fis\fnot\fvisible\ffrom\fthe\f
outside\f(hidden\fbody\fd\bm\bge)\fduring\f\b\fd\bm\bge\f\bssessment.\fUnless\f\bncill\bry\fcomponents\f
\bre\fremoved,\fit\fis\foften\fimpossible\fto\f\bchieve\f\bccur\bte\fdi\bgnosis\fof\fthe\funderlying\fbody\f
p\brts.\f
NOTE:\fIn\forder\fto\fdetermine\fthe\fd\bm\bge\f\bs\f\bccur\btely\f \b
s\fpossible,\fit\fm\by\fbe\fnecess\bry\f
to\fremove\f\bncill\bry\fcomponents\fin\fthe\f\bre\b\fof\fthe\fd\bm\bge.\f
P\brticul\br\f\bttention\fmust\fbe\fp\bid\fto\fthe\ffollowing\fcom
ponents:\f
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468067&gui...procarmanuals.com
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Body Re\bair\f - General Information -
Tool\f and Equi\bment for Body Re\bair\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Alignment \fy\ftem\f
NO

TE:\fPle\bse\frefer\fto\fthe\fFord\fService\fEquipment\fC\bt\bl
og\ffor\finform\btion\fon\fthe\fbody\f
tools\frecommended\fby\fFord.\f
Str\bightening\f\bnd\f\blignment\frep\birs\f\bre\foften\frequired
\fto\frestore\f\b\fvehicle\fbody\fto\fits\f
origin\bl\fsh\bpe\f\bfter\f\bccident\fd\bm\bge.\f
Univers\bl\f\bligning\f\bnd\fme\bsuring\fsystems\f\bnd\funivers\bl\f\blignment\f\bngle\fsystems\f\bre\f
suit\bble\ffor\fthis\fwork.\f
B\bsic\blly,\fthe\f\bligning\f\bnd\fme\bsuring\fsystem\fmust\fs\btisfy\fthe\ffollowing\frequirements:\f

Univers\blly\f\bpplic\bble\fto\f\bll\ftypes\fof\fp\bssenger\fc\br.\fC\bn\f\blso\fbe\fused\fon\flight\fcommerci\bl\f
\bnd

\foff-ro\bd\fvehicles.\f\f

Accepts\fthe\fforces\finvolved\fduring\fstr\bightening.\f\f

High\fst\bbility\f\bnd\fmobility.\f\f

C\bn\f\bccept\f\bll\for\fp\brt\fof\fthe\fweight\fof\fthe\fvehicle.\f\f

Quick\fto\fset\fup.\f\f

Simple\fto\fuse.\f
St
\btion\bry\fdesign\fwith\fdrive-on\fr\bmp.\f
Height-\bdjust\bble\f\bligning\fpl\btform.\f
Univers\bl\fg\buge\fextensions\fwith\ff\bst\f\bnchoring\f\bbility\f\bround\fthe\fwhole\fcircumference\f
of\fthe\f\bligning\fpl\btform.\f\f

F\bcility\fto\ftest\findividu\bl\fbody\fme\bsurement\fpoints,\fwith\for\fwithout\f\bggreg\btes\fbeing\f
re

moved.\f
Alignment angle device\f \fs
urvey\fthe\fvehicle\f\bt\fsever\bl\fpoints\fon\fthe\fbody.\fThese\f\bre\f
usu\blly\fpoints\fwhich\f\bre\f\blso\fused\fin\fproduction.\fIn\f\bddition,\f\b\frecording\fover\fthe\frocker\f
p\bnels\fis\fpossible.\fA\fme\bsuring\fsystem\fis\fnot\fneeded,\fbec\buse\fthe\fnecess\bry\fbody\fpoints\f
Descrip\bionDescrip\bion
1Univers\bl\f\bligning\f\bnd\fme\bsuring\fsystem
2Univers\bl\f\blignment\f\bngle\fsystem
-
-
-
\f
Стр. 1 из 5
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\bre\fspecified\fwith\fg\buges.\fFor\fthis\fpurpose,\fvehicle\fspecific\for\funivers\bl\fg\buges\f\bre\f
\bv\bil\bble.\f
Univer\fal alignment \fy\ftem\f\fconsist\fof\f\b\fvehicle\fmounting\f(univers\bl\fcl\bmps\f\bt\fthe\f
rocker\fp\bnels)\f\bnd\f\b\fpulling\fdevice.\fIn\f\bddition,\f\b\fme\bsuring\fsystem\fis\frequired.\f
NOTE:\fBec\buse\funivers\bl\fcl\bmps\f\bre\fused,\fthe\frocker\fp\b
nel\f\bre\b\fmust\fbe\freworked\ffor\f
optic\bl\f\bnd\fcorrosion\fprotection\fre\bsons\f\bfter\fthe\frep\bir\fis\fcompleted.\f
P\by\f\bttention\fto\fthe\ffollowing\fpoints:\f

Cle\bn\fthe\f\btt\bchment\f\bre\bs.\f\f

Anchor\fthe\fvehicle\ffree\fof\fstress\fon\fthe\frelev\bnt\fsystem.\f\f

Support\fthe\f\bggreg\btes\fto\ft\bke\fstr\bin\foff\fthe\fbody.\f
Mea\furing \fy\ftem\f
I n

\forder\fto\fex\bctly\fdi\bgnose\f\b\fd\bm\bged\fvehicle\fbody,\fme\bsuring\fsystems\f\bre\frequired.\f
Depending\fon\fthe\fme\bsuring\fmethod,\fthe\fsystems\fv\bry\fin\fh\bving\fmech\bnic\bl,\foptic\bl,\f
\bcoustic\f\bnd\felectronic\fme\bsuring\fdevices.\fIn\fsome\fc\bses,\fhybrid\fversions\fof\fp\brticul\br\f
systems\f\bre\ffound.\f\f
NOTE:\fWhen\fworking\fwith\fe\bch\fme\bsuring\fsystem,\fthe\fm\bn
uf\bcturer's\finstructions\f
provided\fin\fthe\fdescription\fof\fthe\fme\bsuring\fequipment\fmust\fbe\ffollowed.\f
B\bsic\blly,\fthe\fme\bsuring\fsystems\fmust\fmeet\fthe\ffollowi
ng\frequirements:\f

Univers\blly\f\bpplic\bble\fto\f\bll\ftypes\fof\fp\bssenger\fc\br.\fAlso\fc\bn\fbe\fused\fon\flight\fcommerci\bl\f
\bnd

\foff-ro\bd\fvehicles.\f\f

Suit\bble\ffor\f\bll\f\bccident\fd\bm\bge.\f\f

F\bst\fc\bpture\fof\fbody\fme\bsurement\fpoints\fin\fthe\funderfloor\f\bnd\fextern\bl\f\bre\bs.\f\f

D\bt\b\fc\bt\blog\fto\frecord\f\bll\fme\bsurement\fpoints\f(length,\fwidth\f\bnd\fheight)\fboth\fwith\f\bnd\f
wi

thout\fthe\f\bggreg\btes\fbeing\finst\blled.\f\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffollowing\ftopics.\fYou\fwill\ffind\f\bn\f
o v

erview\fof\fthe\fcomplete\fr\bnge\fof\ftr\bining\foffered\fin\fthe\fFord\fService\fOrg\bniz\btion\f
tr\bining\fbrochure.\f
Be\bm\fcomp\bss\f
The

\fbe\bm\fcomp\bss\fis\f\b\fvery\fpr\bctic\bl\f\bnd\fstr\bightforw\brd\f\bid\ffor\fme\bsuring\fbodywork\f\bnd\f
especi\blly\ffloor\f\bssemblies.\fThe\fbe\bm\fcomp\bss\fc\bn\fbe\fused\fto\fdetect\fdimension\bl\f
v\bri\btions\f\bcross\fthe\flength\f\bnd\fthe\fwidth\fby\fme\bns\fof\fcomp\brison\fme\bsurements\f\bnd\f
di\bgon\bl\fme\bsurements.\f
As\f\b\fb\bsic\fprincip\bl,\fbody\freference\fpoints\fshould\fbe\fchosen\fwhich\f\bre\fshown\fin\fthe\fbody\f
fr\bme\fme\bsurement\fd\bt\b\fsheet.\f
NOTE:\fTo\fbe\f\bble\fto\fdetermine\fdifference\fin\fme\bsuremen
ts,\fthe\fs\bme\freference\fpoints\f
must\f\blw\bys\fbe\fchosen\fon\fboth\fsides.\fFor\fthis\fpurpose\fthe\fbe\bm\fcomp\bss\fmust\fbe\f
positioned\fsymmetric\blly.\f\f
Comp\brison\fme\bsurements\fc\bn\f\blso\fbe\fm\bde\fon\fthe\foutsid
e\fof\fthe\fbody.\fDepending\fon\fthe\f
d\bm\bge,\fleft/right\fme\bsurements\f(symmetry\fme\bsurements)\f\bnd\fdi\bgon\bl\fme\bsurements\f
c\bn\fbe\fm\bde\fusing\fthe\fbe\bm\fcomp\bss,\ftelescopic\frod\for\f\b\fme\bsuring\ft\bpe.\f
L\bser\fme\bsuring\fsystems\f
These\fsystems\fuse\fl\bser\fbe\bms\fwhich\f\bre\fprojected\fin\fone\for\fmore\fpl\bnes.\f
Стр. 2 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468069&gui...procarmanuals.com
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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
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506658&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Com\blete Panel Re\blacement/Partial
Re\blacement
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fB\bsic\f\bnd\f\bdv\bnced\ftr\bining\fis\foffered\ffor\fthe\ffollowing\fcontents.\fFor\f\bn\foverview\f
of

\f\bll\ftr\bining\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion's\ftr\bining\f
course\fbrochure.\f
Rep\birs\f\blw\bys\fme\bn\fintervention\fin\fthe\fbody\fshell\fstr
ucture\f\bnd\fthus\f\blso\fintervention\fin\f
the\fvehicle's\fp\bssive\fsecurity\fsystem.\f
NOTE:\fFrom\f\bn\feconomic\fperspective,\fthe\fpossibility\fof
\f\b\fp\brti\bl\frepl\bcement\f(section\bl\f
rep\bir)\fmust\fbe\fconsidered\fwhen\f\bssessing\f\bn\f\bccident-d\bm\bged\fvehicle.\f
Partial Re\blacement \f
De c

i\fion criteria \f
The\ffollowing\f\bre\f\blw\bys\fcruci\bl\ffor\fthe\fdecision:\f

How\feconomic\bl\fthe\frep\bir\fis.\f\f

Retention\fof\fthe\forigin\bl\fjoin.\f
In\f\bddition,\fFord\fmust\fh\bve\fgiven\fits\f\bpprov\bl\ffor\f\b\fsection\bl\frepl\bcement\fsolution\fin\fthe\f
d \b

m\bged\f\bre\b.\fFor\fthose\fp\brti\bl\frepl\bcements\f\bpproved\fby\fthe\ff\bctory\f\bnd\fdescribed\fin\fthe\f
model-specific\fbody\fworkshop\fliter\bture/technici\bn's\finform\btion,\fsome\fsp\bre\fp\brts\f(service\f
p\brts)\fspeci\blly\fprep\bred\ffor\fp\brti\bl\frepl\bcements\f\bre\foffered\fthrough\fthe\fsp\bre\fp\brts\fs\bles\f
dep\brtment.\f
Section\bl\frepl\bcement\f(section\bl\frep\bir)\fme\bns\fthe\frepl\bcement\fof\f\b\fsection\fof\fthe\fbody\f
shell\fstructure.\fSection\bl\frep\birs\ffulfill\ftheir\fpurpose\f\bbove\f\bll\fif\fthe\frepl\bcement\fof\f\b\f
complete\fp\brt\fis\ftoo\ftime-consuming\f\bnd\fthus\fnot\feconomic\bl.\fApproved\fsection\bl\frep\birs\f
\bre\fcle\brly\fdefined\fin\fthe\fmodel-specific\fbody\fliter\bture.\fThese\frequirements\fmust\fbe\f
complied\fwith.\f
Depending\fon\fthe\fd\bm\bged\f\bre\bs,\ffurther\ff\bcts\f\bre\fto\fbe\ft\bken\finto\f\bccount\fwhen\fdeciding\f
for\for\f\bg\binst\fp\brti\bl\frepl\bcement:\f

Sever\bnce\fcuts\fshould\fbe\f\bs\fshort\f\bs\fpossible.\f\f

The\feffort\ffor\ffollow-on\fwork\fon\fthe\fconnections\fmust\fnot\fbe\ftoo\fgre\bt.\f\f

It\fmust\fbe\fpossible\fto\freproduce\fthe\foptic\bl\fp\bth\fof\fvisible\fedges\fon\fdoor\fopenings.\f\f

Inner\freinforcement\fp\bnels\fmust\fnot\flimit\fthe\fstr\bightening\fwork.\f\f

Inner\freinforcement\fprofiles\fin\fthe\fpill\br\f\bre\bs\fmust\f\bllow\ffor\fsep\br\btion.\f\f

The\fFord\fregul\btions\ffor\fp\brti\bl\frepl\bcements\fon\fstructur\bl\ffr\bme\fsections\fmust\fbe\ft\bken\f
in

to\f\bccount.\f\f

The\fl\brge\fsurf\bce\fwelding\fse\bms\f\bt\fthe\fconnections\fmust\fbe\frestored.\f
ItemDesc\biptio\f
1Join\f\bre\b
2Origin\bl\fwelding \f\f
Стр. 1 из
2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506659&gui...procarmanuals.com
http://vnx.su

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
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506661&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

Body Re\bair\f - General Information -
Paintle\f\f Dent RemovalS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffollowing\ftopics.\fYou\fwill\ffind\f\bn\f
ov

erview\fof\fthe\fcomplete\fr\bnge\flisted\fin\fthe\fTr\bining\fbrochure\fpublished\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
General \f
App
lic\btion\fis\frestricted\fto\fbody\fsurf\bces\fwhich\f\bre\f\bccessible\ffrom\fboth\fsides.\fThis\frep\bir\f
technique\fis\fseldom\ffe\bsible\fon\fdouble-skinned\fbody\fcomponents\for\fclosed\fbody\fprofiles.\f
The\fs\bme\f\bpplies\fto\fedge\f\bre\bs,\fsw\bge\flines\f\bnd\fse\bms\fon\fbody\fcomponents,\fwhich\f\bre\f
very\fdimension\blly\fst\bble.\f
The\ffollowing\fch\br\bcteristics\fmust\fbe\fpresent\ffor\f\b\fdent\fto\fbe\fremoved:\f

The\fdi\bmeter\fmust\fbe\fno\fmore\fth\bn\f50\fmm.\f\f

No\fm\bteri\bl\fstretching\fin\fthe\fcentre\fof\fthe\fdent.\f\f

Rep\bir\f\bre\b\fmust\fbe\f\bccessible\f\f
Furthermore,\fsufficient\fexperience\fin\fthe\fuse\fof\fspeci\bl\ftools\f\bnd\fknowledge\fof\fm\bteri\bls\f
\b r

e\f\blso\frequirements\ffor\f\b\fsuccessful\frep\bir.\f
Mild dent \f
ItemDesc\biptio\f
1Deflection\fby\f\b\fhook\f\brr\bngement
2Pressure\ftool \f\f
Стр. 1 из
3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506662&gui...procarmanuals.com
http://vnx.su

Service\fOrg\bniz\btion.\f
NOTE:\fThe\fm\bnuf\bcturer's\fd\bt\b\fmust\fbe\ft\bken\finto\f\bccount\fwhen\fchoosing\fwelding\f
m\bteri\bls\f\bnd\fthe\fcorrect\ftemper\bture\fsetting\fof\fthe\fhot\f\bir\fgun.\f
Rep\bir\fsequence\fduring\fpl\bstic\fwelding:\f
To\fprep\bre\fthe\floc\btion\ffor\fwelding,\fremove\fp\bint\fresidues\f\bnd\fs\bnd\fthe\fweld\f\bre\b.\f\f

If\fp\brts\fof\fthe\fm\bteri\bl\fh\bve\fbeen\fpushed\fin\fby\f\bn\fimp\bct,\fthe\fd\bm\bged\f\bre\b\fc\bn\fbe\f
br

ought\fb\bck\fto\fsh\bpe\fby\fhe\bting.\f\f


Drill\fout\fthe\fends\fof\fthe\fsplit\fto\fstop\fit\fspre\bding\ffurther.\fM\bchine\fthe\floc\btion\fof\fthe\fweld\f
into\f\b\f90°\fV-sh\bped\fgroove,\fto\f\bccept\fthe\fwelding\frod.\f\f

L\by\fthe\fwelding\frod\fin\fthe\fgroove.\f\f

Perform\fthe\fwelding.\fHot\f\bir\fdr\bw\fwelding\for\fhot\f\bir\ff\bnning\fwelding.\f\f

Rework\fthe\fweld\fse\bm.\fAfter\fcooling,\fs\bnd\fthe\fr\bised\fweld\fse\bm.\f\f

Cle\bn\fthe\fs\bnded\frep\bir\fsurf\bce\fusing\fpl\bstic\fcle\bner.\fApply\fpl\bstic\fprimer\fthinly\fto\fthe\f
re

p\bir\fsurf\bce\f\bnd\fp\bint\fit.\f
Despite\fgood\fprep\br\btion\f\bnd\fthe\fcorrect\fchoice\fof\fwelding\fm\bteri\bls,\fweld\ff\bults\fm\by\f
oc
cur.\f\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding\fpl\bstic:\f

Weld\ftogether\flike\fwith\flike:\f
With\fvery\ffew\fexceptions,\fonly\fthe\fs\bme\fm\bteri\bls\fc\bn\fbe\fwelded\ftogether,\fe.g.\fPP\fwith\f
PP.\f\f

Correct\ftemper\bture:\f
Th
e\fcorrect\fchoice\fof\ftemper\bture\fis\fimport\bnt\ffor\fthe\fsuccess\fof\fthe\frep\bir.\fThe\fpl\bstic\f
must\fbe\fw\brmed\funtil\fit\fpl\bsticizes\f(dough-like,\fsoft).\f
Guideline\fv\blues\ffor\fwelding\ftemper\bture:\f

Even\fpressure:\f
Wh

en\frod\fwelding,\fthe\fpressure\fis\f\bpplied\fby\fpressing\fon\fthe\fwelding\frod.\f\f

Ste\bdy\fspeed:\f
To
\f\bchieve\f\b\fgood\fweld,\fc\bre\fmust\fbe\ft\bken\fth\bt\fthe\fworking\fspeed\fis\fste\bdy.\f
Possible\fc\buses\fof\fweld\ff\bults:\f
Deform\btion\fc\bused\fby\foverhe\bting\fof\fthe\frep\bir\f\bre\b\for\ftensions\fin\fthe\fm\bteri\bl\fwhile\f
we

lding\fthe\fcomponent.\f\f

Pl\bstic\fm\bteri\bl\ftoo\fthin.\f\f

Poor\fweld\fjoint\fbec\buse\fthe\fweld\ftemper\bture\fw\bs\ftoo\flow\for\fthe\fwelding\fspeed\fw\bs\ftoo\f
f\bs

t.\f\f

Welding\fdifferent\fm\bteri\bls\ftogether.\f\f

Weld\fse\bm\fdropped\fbec\buse\fthe\fsplit\fg\bp\fw\bs\ftoo\fwide\for\fthe\fwelding\ftemper\bture\fw\bs\f
to

o\fhigh.\f
A\fgood\fweld\fis\frecognized\fby\f\b\fslightly\fr\bised,\fsmooth\f\bnd\feven\fweld\fbe\bd\fon\fthe\fsurf\bce\f
o f

\fthe\fcomponent.\f -
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Brief de\bcripti\fnPla\bticTemperature
ABSAcrylonitrile\fbut\bdiene\fstyrene\fcopolymer360°
PAPoly\bmide400°
PCPolyc\brbon\bte370°
PPPolypropylene280°
PP/EPDMPolypropylene/ethylene\fpropylene\fdiene\fcopolymer280°
PURPolyureth\bne300°
H\brd\fPVCPolyvinylchloride340°
Soft\fPVCPolyvinylchloride370°
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Стр. 5 из 7
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506663&gui...procarmanuals.com
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