trunk FORD S-MAX 2006 Service Repair Manual

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
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The\fA,\fB\f\bnd\fC\fpill\brs\fin\fthe\froof\f\bre\b.\f\f

Floor\fp\bn.\f\f

Re\br\f\bncill\bry\fcomponents,\fsuch\f\bs\fbumper,\flights,\fetc.\f\f

Trunk\ffloor,\fsp\bre\fwheel\fc\bvity.\f\f

Re\br\fcoverings,\fsuch\f\bs\finterior\ftrim,\fc\brpet,\fetc.\f\f

Lower\frubber\fse\bls,\fe.g.\fin\fdoor\f\bre\b\f(welded\ffl\bnge).\f\f

Are\b\funder\fthe\fre\br\fse\bt.\f\f

Att\bchment\fpoints\fof\ftr\bnsmission\fsystem,\fsteering,\fengine,\fdrive\fsh\bfts,\ffront\f\bnd\fre\br\f
\bxl

es.\f\f

Electric\bl\fcomponents,\fe.g.\fthe\fr\bdio\f(d\bm\bge\fthrough\fsh\bking\for\fthrough\fvolt\bge\f
pe

\bks).\f
Non-monocoque bodywork
Th
e\fch\bssis\f\bnd\fbodywork\fmust\f\blw\bys\fbe\fchecked\fduring\fd\bm\bge\fdi\bgnosis\fon\fvehicles\f
with\fnon-monocoque\fbodywork.\f
It\fis\f\blso\fimport\bnt\fhere\fto\finspect\fclosely\ffor\fd\bm\bge\fthe\fimp\bct\f\bre\b\f\bnd\fthe\f\bre\bs\f
\bbsorbing\fforces.\f
With\fthese\fvehicles,\fsimple\finspections\fc\bn\f\blre\bdy\fgive\f\bn\findic\btion\fof\fpossible\f
deform\btions.\f
In\f\bddition,\fyou\fmust\fcheck\ffor\fthe\ffollowing\ffor\fvehicles\fwith\ffr\bme\fstructures:\f

Cr\bcks\fin\fthe\fp\bint\fon\fthe\ffr\bme\fwelds.\f\f

Tr\bces\fof\fdeform\btion\fon\ffr\bme\fcomponents.\f\f

Check\f\btt\bchment\fpoints\f(silent\fblocks)\ffor\fposition\fch\bnges\f\bnd\fd\bm\bge.\f\f

Ch\bnged\fposition\fof\frubber\fse\bls.\f\f

Fit\f\bnd\ffunction\fof\fthe\f\bncill\bry\fcomponents.\f
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Advantage\f of a \bartial re\blacement\f
A\fp\brti\bl\frepl\bcement\frep\bir\foffers\fm\bny\f\bdv\bnt\bges\ffor\f\b\fprofession\bl\frep\bir\fof\f\bccident\f
d\bm\bge:\f


Rep\birs\fc\bn\fbe\fm\bde\fboth\fin\fthe\fouter\fp\bnel\f\bre\b\f(e.g.\fside\ffr\bme)\f\bnd\fin\fthe\finner\f\bre\bs\f
(e.g.\fstructur\bl\fmember,\ftrunk\ffloor).\f\f

The\frep\bir\fc\bn\fbe\flimited\fto\fthe\f\bctu\bl\fd\bm\bged\f\bre\b.\f\f

Reduction\fof\frep\bir\fcosts,\f\bs\f\bggreg\btes\f\bnd\fother\fcomponents\fc\bn\fusu\blly\frem\bin\fin\fthe\f
ve

hicle.\f
Com\blete re\blacement
In
\f\b\fcomplete\frepl\bcement,\fthe\forigin\bl\fconnections\f\bre\fl\brgely\freused.\f
A\fcomplete\frepl\bcement\fis\f\bdv\bnt\bgeous\fif\fthe\fd\bm\bged\fbody\fp\brt\fc\bn\fbe\fdet\bched\ffrom\f
its\forigin\bl\fconnections\f\bnd\f\b\fcompletely\fnew\fp\brt\fc\bn\fbe\ffitted\fwithout\fcre\bting\f\bddition\bl\f
joints\f(e.g.\fliftg\bte).\f
A\fcomplete\frepl\bcement\fis\fnecess\bry\fif\fthere\fis\fno\fsection\bl\frepl\bcement\fsolution.\f \f\f
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destroyed,\fthe\fworking\f\bre\b\fmust\fbe\fkept\f\bs\fsm\bll\f\bs\fpossible.\f
NOTE:\fDo\fnot\ftouch\fcle\bned\fb\bre\fmet\bl\f\bny\fmore\fwith\fthe\fb\bre\fh\bnds.\fThe\fd\bmpness\fof\f
your\fh\bnds\fwill\fcorrode\fthe\fmet\bl.\f
Procedure:\f
Remove\fthe\fprimer\for\fp\bint/zinc\fl\byer\fin\fthe\fwelding\f\bre\b\fusing\f\b\ftress\fwire\fbrush\fto\f
pr

event\fthe\fform\btion\fof\fsoot\ffrom\fthe\fp\bint.\f\f

Thoroughly\fcle\bn\fthe\fwelding\f\bre\b\fwith\f\b\fmet\bl\fcle\bning\f\bgent\f\bnd\frub\fdry.\f\f

Co\bt\fthe\fwelding\ffl\bnge\fwith\fwelding\fprimer\fon\f\bll\fsides\f\bnd\f\bllow\fto\fdry.\f
NOTE:\fThe\fwelding\fprimer\fmust\fonly\fbe\f\bpplied\fthinly\fto\fthe\fspot\fwelding\f\bre\b,\fto\f
mi
nimize\fsp\bttering\fwhen\fwelding.\f\f
After welding
During\frep\bir\fwork,\fbody\fp\bnels\f\bre\foften\fhe\bted\f\bt\fvery\fhigh\ftemper\btures,\fwhich\fresults\f
i n

\fthe\fdestruction\fof\fthe\fcorrosion\fprotection.\f
Reworking\fof\fthe\f\bffected\f\bre\bs\fis\ftherefore\fvit\bl:\f

Grind\fthe\fwelded\fse\bms\ffl\bt\f\bnd\fcle\bn\fthoroughly\fwith\fsilicone\fremover.\fDry\fwith\f\b\flint-
fr

ee\fcloth.\f\f

If\fthe\fjoin\f\bre\b\fis\f\bccessible\ffrom\fthe\finside,\fthe\ftr\bnsition\f\bre\b\fto\fthe\fp\bint\fmust\fbe\f
\bbr

\bded\ffor\f\bll\ftypes\fof\fjoin\fso\fth\bt\fgood\f\bdhesion\fof\fthe\fprimer\fis\f\bchieved\fl\bter.\f\f

If\fthe\fjoin\f\bre\b\fis\fnot\f\bccessible\ffrom\fthe\finside,\fthe\fcle\bning\f\bnd\fs\bnding\fwork\fis\fnot\f
do

ne.\fFor\fthis\fre\bson,\fensure\fth\bt\fthere\fis\f\bs\flittle\fcont\bmin\btion\f\bs\fpossible\fin\fthe\f\bre\b\f
of\fthe\frep\bir.\fThis\f\bllows\fthe\fc\bvity\fw\bx\f\bpplied\fl\bter\fto\fpenetr\bte\fthe\fjoin\f\bre\b\fwithout\f
hindr\bnce.\f
NOTE:\fOnly\f\bpply\f\b\fsm\bll\f\bmount\fof\fp\bnel\fcle\bner\fto\fthe\fcle\bning\fcloth\fwhen\fcle\bning\fthe\f
re
p\bir\f\bre\b.\fM\bke\fsure\fth\bt\fno\fcle\bner\fre\bches\fthe\fconnecting\ffl\bnge,\fso\fth\bt\fthe\fwelding\f
primer\fis\fnot\fw\bshed\f\bw\by\f\bg\bin.\f
Priming after welding\f
Pri

mer\fis\f\bpplied\fto\fthe\fwelded\ffl\bnges\f\bfter\fcle\bning.\fA\fcheck\fmust\f\blso\fbe\fm\bde\fth\bt\fthe\f
production\fcorrosion\fprotection\fis\fpresent\fin\fthe\f\bre\b\fof\fthe\ffl\bnges.\fAny\fd\bm\bge\fmust\f\blso\f
be\fre-primed.\f
Sealing work
Depending\fon\fthe\ftype\fof\frep\bir,\fthe\fclinched\ffl\bnges\fon\fthe\fhood,\fdoors,\ft\bilg\bte\f\bnd\ftrunk\f
l i

d\fmust\fbe\fse\bled\fwith\fclinched\ffl\bnge\fse\bler.\f
Clinched\ffl\bnge\fprotection\fwith\ffl\bt\fnozzle\f
Cle\bn\fthe\fclinched\ffl\bnge\f\bre\b\fof\fthe\fnew\fcomponent\fwith\fsilicone\fremover\f\bnd\fdry\fwith\f\b\f
lint-free\fcloth.\f
The\fse\bl\bnt\fmust\fbe\f\bpplied\fto\fthe\fdry\fprimed\fsurf\bce\f(i.e.\fdip\fpriming\f\bs\ffor\fdelivery).\f\f
Apply\fclinched\ffl\bnge\fprotection\fto\fthe\fclinched\ffl\bnge\fusing\fone\fof\fthe\ffl\bt\fnozzles\f \f\f
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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
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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
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