2006 FORD S-MAX Service Repair Manual

diagnostic menu open hood parking sensors roof rack navigation update service

Page 4025 of 4402

$FORD S-MAX 2006 Service Repair Manual NOTE:\fIf\f\b\fsuit\bbly\fpowerful\fwelding\fm\bchine\fis\fnot\f\bv\bil\bble\f\bnd\fmulti-l\byer\fp\bnel\fjoints\f with\f\b\ftot\bl\fthickness\fof\fover\f3\fmm\fneed\fto\fbe\fm\bde,\fpuddle\fwelding\f$

NOTE:\fIf\f\b\fsuit\bbly\fpowerful\fwelding\fm\bchine\fis\fnot\f\bv\bil\bble\f\bnd\fmulti-l\byer\fp\bnel\fjoints\f
with\f\b\ftot\bl\fthickness\fof\fover\f3\fmm\fneed\fto\fbe\fm\bde,\fpuddle\fwelding\fmust\fbe\fused.\f
Although\fin\fprinciple,\fhigh\f\bnd\fsuper\fhigh-strength\fp\b
nels\f\bre\f\bdequ\btely\for\fwell\fsuited\fto\f
resist\bnce\fspot\fwelding,\fconsider\bble\fproblems\fm\by\f\brise\fbec\buse\fof\flow\fwelding\fpower,\f
especi\blly\fwhere\fthicker\fp\bnels\for\fthree\fl\byers\fof\fp\bnel\fmust\fbe\fwelded\ftogether\fin\fthe\f
workshop.\fIn\fp\brticul\br,\folder\fwelding\fequipment\fdoes\fnot\fh\bve\fthe\fl\btest\fwelding\f
technology\fnor\fwelding\fpower\f\bnd\ftherefore\fc\bnnot\freli\bbly\fjoin\fp\bnel\fthicknesses\fgre\bter\f
th\bn\f3\fmm.\f\f
Equipment\fwith\finverter\ftechnology\f\bllows\fbetter\fspot\fweld\fqu\blity\fbec\buse\fof\f\b\fconst\bnt\f
high\fwelding\fcurrent.\fIn\f\bddition\fthe\fhigh\fwelding\fcurrent\fm\bkes\fshorter\fwelding\ftimes\f
possible\f\bnd\fthe\felectrodes\ftherefore\fh\bve\f\b\flonger\fworking\flife.\fInverter\fwelding\fis\f\b\f
further\fdevelopment\fof\felectrode\fwelding.\f
Further\f\bdv\bnt\bges\fof\fthe\fnew\finverter\fwelding\fequipment\f\bre:\f
good\fwelding\fperform\bnce\fwith\fconst\bnt\fqu\blity,\feven\fwith\fhigh\fswitch-on\ftimes\f\f
recognition\fof\f\bnd\fcompens\btion\ffor\fdisruptive\ff\bctors:\fe.g.\fprimer,\f\bdhesive,\frust-
pr

evention\fp\bint\f\f
own\f\bnd\fpre-set\fwelding\fprogr\bms\fwhich\fc\bn\fbe\fs\bved\f\bnd\fc\blled\fup\f\f
qu\blity\fconfirm\btion\fthrough\flogging\fof\f\bll\fimport\bnt\fwelding\fd\bt\b\f\f
f\bst\fch\bnging\fof\fspot\fwelding\fcl\bmps\for\fspot\fwelding\fguns\f\bs\frequired\f
The\ffollowing\ffunctions\fc\bn\fbe\fcontrolled\f\bnd\fmonitored\fby\fprogr\bmming\fthe\fwelding\f
eq
uipment:\f
Control\fof\fthe\fst\brt\fconditions\fby\fresist\bnce\fme\bsurement\f(dirt,\fp\bint,\fbodywork\f
\bdh

esive,\fshunt\fcircuit\fthrough\fthe\fnext\fspot\fweld).\f\f
Ensuring\fthe\foptimum\fwelded\fconnection.\f\f
Checking\fthe\fenergy\fb\bl\bnce,\fresist\bnce\f\bnd\fqu\blity.\f
In\fthe\fc\bse\fof\fresist\bnce\fspot\fwelded\fconnections,\ff\bults\fin\fthe\fweld\f\bre\fdifficult\fto\fsee\f
fr
om\fthe\foutside.\fIt\fis\ftherefore\f\bbsolutely\fvit\bl\fto\fknow\fthe\fp\brticul\br\fproperties\fof\fthe\f
welding\fm\bchine\fbeing\fused.\fA\ftest\fweld\fwith\fsubsequent\fpeeling\ftest\fwill\fprovide\f
inform\btion\fon\fthe\fqu\blity\fof\fthe\fweld.\fThe\fspot\fweld\fitself\fmust\fnot\fsep\br\bte,\fit\fmust\fte\br\f
\bw\by\fle\bving\f\b\fhole.\f
In\fthe\fproduction\fof\fvehicle\fbodies,\fMIG\fwelding\fpl\bys\f\b\fminor\frole\f\bs\f\b\fjoining\ftechnique.\f
It\fis\fused\ffor\fcomponents\fsubject\fto\fhigh\fdem\bnds,\fsuch\f\bs\fthre\bded\fpl\btes\ffor\f\bxle\f
mountings,\for\f\bt\floc\btions\fwhich\fc\bnnot\fbe\fspot\fwelded\ffor\f\bccess\fre\bsons.\f\f
Descrip\bionDescrip\bion
1MIG\fwelding\fm\bchine
2Resist\bnce\fspot\fwelding\fm\bchine
\f
Стр. 5 из 5
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Page 4026 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - E\ftabli\fh Re\bair MethodS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration General Be fore\fst\brting\f\bccident\frep\bir\fwork,\fm\$

Body Re\bair\f - General Information -
E\ftabli\fh Re\bair MethodS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Be

fore\fst\brting\f\bccident\frep\bir\fwork,\fm\bke\fsure\fth\bt\fthe\fnecess\bry\fsp\bre\fp\brts\f\bnd\frep\bir\f
m\bteri\bl\f\bre\f\bv\bil\bble.\f\f
Planning
NOTE:\fThe\fbody\finterconnection\fis\fto\fbe\fm\bint\bined\fif\f
possible.\fRep\bir\fis\fpreferred\fto\f
renew\bl\fof\fbody\fcomponents.\fFurthermore,\fcheck\fif\fit\fis\fpossible\fto\fperform\f\b\fp\brti\bl\f
rep\bir.\f\f
During\fpl\bnning\fthe\ffollowing\fjob\fsteps\fmust\fbe\fobser v
ed\f\bnd\f\bdhered\fto:\f\f
Determine\fthe\frep\bir\fmethod\ft\bking\finto\f\bccount\fthe\finform\btion\fm\bde\f\bv\bil\bble\fin\fETIS.\f
\f
Work\fout\fwhich\frep\bir\fcomponents\fwill\fbe\fneeded\f\bnd\fobt\bin\fthem.\f\f
Est\bblish\fwh\bt\fdis\bssembly\fwork\fis\fneeded.\f\f
Check\ffor\fspecific\ffe\btures\fsuch\f\bs\f\birb\bgs,\froute\fof\fw\bter\fdr\bin\fhoses,\felectric\fc\bbles\f
\bnd

\fthe\floc\btion\fof\fNVH\felements.\f\f
Cut\fout\fthe\fold\fp\brts\f(only\fwhen\fthe\fnew\fp\brts\f\bre\fw\biting\fre\bdy).\f\f
Prep\bre\fthe\fjoint\floc\btions.\f\f
Att\bch\fthe\fnew\fp\brts.\f\f
Prep\bre\fthe\f\bre\b\fof\fthe\frep\bir\ffor\fp\binting\f(grinding\fwelded\fbe\bds).\f\f
Perform\f\bny\fsolder\fwork\fwhich\fis\frequired\f\bt\fthe\frep\bir\floc\btion.\f
Chronological \fequence of re\bair
NO
TE:\fRefer\fto\fe\bch\fvehicle\fspecific\fch\bpter\fin\fthe\fwo
rkshop\fliter\bture\ffor\fdet\bils\fon\fthe\f
individu\bl\fpoints.\f
The\f\bctu\bl\fsequence\fof\frep\bir\fc\bn\fbe\fdivided\finto\fthe\f
following\fsteps:\f
Job\fsteps\ffor\fthe\fco\bchbuilder:\f
Str\bightening\f\f
Est\bblish\fsep\br\bting\fcuts\f\bnd\fm\brk\fthem.\f
T\bk

e\finto\f\bccount\fthe\frequirements\fgiven\fin\fthe\frep\bir\finstructions.\f\f
Pl\bce\fthe\fnew\fp\brt\fre\bdy\ffor\fuse\f\bnd\finclude\fit\fin\fthe\frep\bir\fpl\bn.\f
Sep\br\bte\f\bnd\fremove\fthe\fold\fp\brt.\f
T\bk
e\finto\f\bccount\fthe\fspeci\bl\ffe\btures\fp\brticul\br\fto\fthe\fvehicle.\f
Prep\bre\fthe\fjoint\floc\btions.\f
-\f
S\bnd\f\bnd\f\blign\fthe\fweld\ffl\bnges.\f
Apply\fcorrosion\fprotection\fme\bsures.\f
Offer\fup\fthe\fnew\fp\brt.\f
Att\bch\fthe\fnew\fcomponent.\f\f
Rework\fthe\fwelded\fjoints\f(grind\fwelded\fse\bms).\f -
-
-
-
-
-
Стр. 1 из 1
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Page 4027 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Alignment CheckS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration Gener\bl\f If \fthere\fis\fconcern\fth\bt\fthe\fbody\fh\bs\fbeen\fdef$

Page 4028 of 4402

$FORD S-MAX 2006 Service Repair Manual Exam\ble of mea\furing the floor \ban\f \f Стр. 2 из 3 06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506657&gui...procarmanuals.com http://vnx.su$

Page 4029 of 4402

$FORD S-MAX 2006 Service Repair Manual \f Стр. 3 из 3 06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506657&gui...procarmanuals.com http://vnx.su$

Page 4030 of 4402

$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\$

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
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Page 4031 of 4402

$FORD S-MAX 2006 Service Repair Manual Str\bightening\fwith\fthe\f\bpplic\btion\fof\fhe\bt\f(welding\ftorch)\frequires\fmuch\fexperience\f\bnd\f \bcc ur\bte\fknowledge\fof\fthe\fbeh\bvior\fof\fsteel\fp\bnels\fwhen\fhe\bted.\f\f The\ftem$

Page 4032 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Com\blete Panel Re\blacement/Partial Re\blacement S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration NOTE:\fB\bsic\f\bnd\f\bdv\bnced\ft$

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
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