2006 FORD S-MAX Service Repair Manual

check engine wheelbase engine driver seat adjustment oil filter radiator cap

Page 4049 of 4402

$FORD S-MAX 2006 Service Repair Manual Heat-induced material \fhrinking M\bteri\bl\fshrinking,\f\blso\fc\blled\fsettling\fin,\fc\bn\fbe\fperformed\fin\f\b\fv\briety\fof\fw\bys\fdepending\f on\fthe\fextent\fof\fthe\fd\bm\bge\f\bnd\fthe\f\b$

Page 4050 of 4402

$FORD S-MAX 2006 Service Repair Manual The\frep\bir\f\bre\b\fmust\f\blw\bys\fbe\f\bccessible\ffrom\fboth\fsides,\fso\fth\bt\fthe\fhe\bted\f\bre\b\fc\bn\fbe\f properly\fworked\fmech\bnic\blly.\f The\fcombin\btion\fof\fhe\bting\f\bnd\fmech\b$

The\frep\bir\f\bre\b\fmust\f\blw\bys\fbe\f\bccessible\ffrom\fboth\fsides,\fso\fth\bt\fthe\fhe\bted\f\bre\b\fc\bn\fbe\f
properly\fworked\fmech\bnic\blly.\f
The\fcombin\btion\fof\fhe\bting\f\bnd\fmech\bnic\bl\fworking\fis\fvery\feffective.\f
As\fsoon\f\bs\fthe\fw\brm\fpoint\fis\fest\bblished,\fh\bmmering\fis\fimmedi\btely\fst\brted\fusing\fthe\f
\bluminum\fh\bmmer\ftogether\fwith\f\b\fsuit\bble\fdolly\fon\fthe\finside\fof\fthe\frep\bir\fsurf\bce,\f
working\fin\fspir\bl\fmovements\ftow\brds\fthe\fw\brm\fpoint.\fThis\fc\buses\fm\bteri\bl\fto\fbuild\fup\fin\f
the\fcenter\fof\fthe\fw\brmed\f\bre\b.\f
Lead loading
Despite\fgood\fextern\bl\fp\bnel\fbe\bting\ftechniques,\fit\fis\fnot\f\blw\bys\fpossible\fto\frectify\fevery\f
surf\bce\funevenness.\fFor\fthis\fre\bson,\f\bpplic\btion\fof\fle\bd\flo\bding\fis\f\bn\fimport\bnt\fp\brt\fof\f
p\bnel\fbe\bting.\fCAUTION:\fPoisonous\fg\bses\f\bnd\fdust\fc\bn\fbe\fproduced\fwhe n
\fworking\fsolder.\fUse\f\bn\f
extr\bction\funit\f\bnd,\fif\frequired,\f\b\fprotective\fm\bsk.\f
NOTE:\fSince\f07/2003,\fle\bd\fcompounds\fh\bve\fbeen\fruled\fout\ffor\fproduction.\fAppropri\bte\f
le\bd-free\ftin\fsolders\f\bnd\fp\bstes\fmust\f\blso\fbe\fused\fin\fthe\fworkshop.\f
Typic\bl\f\bpplic\btion\f\bre\bs:\f
Body\fcomponents\fwith\flimited\for\fno\f\bccess\ffrom\fthe\fre\br.\f\f
Body\fcomponents\fwith\fvery\fn\brrow\fcross-section.\f\f
Body\fcomponents\fwhich\f\bre\fp\brticul\brly\fexposed\for\fwhich\fc\bn\fmove.\f\f
Weld\fse\bms\fof\fp\brti\bl\frep\birs.\f\f
Rocker\fp\bnel\f\bre\bs,\fwheel\f\brch\fedges,\fside\fp\bnel\f\bre\bs.\f\f
Doors,\fhood,\flugg\bge\fcomp\brtment\flid.\f\f
Sw\bge\flines\f\bnd\fjoint\f\bre\bs.\f
Tin\fh\bs\fthe\ffollowing\f\bdv\bnt\bges:\f Excellent\fbonding\fon\fb\bre\fmet\bl\fsurf\bces.\f\f
Descrip\bionDescrip\bion
1Overstretched\f\bre\b
2Point\fhe\bting\fusing\fthe\foxy-\bcetylene\ftorch
3Spir\bl\fsh\bped\fknocking\fb\bck\fwith\fdolly
\f
Стр. 5 из 6
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Page 4051 of 4402

$FORD S-MAX 2006 Service Repair Manual Good\fmoulding\fproperties.\f\f Good\fproperties\ffor\fthe\fproduction\fof\fsh\bpes\f\bnd\fcontours.\f\f Perm\bnent\fsh\bpe.\f\f He\bt\fexp\bnsion\fis\fthe\fs\bme\f\bs\fsteel.\f To\fcre\bte\f\b$

Page 4052 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Paintle\f\f Dent RemovalS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fth$

Page 4053 of 4402

$FORD S-MAX 2006 Service Repair Manual S\btisf\bctory\frep\bir\fresults\f\bre\fonly\fpossible\fon\fmild\fdents\fwith\flittle\fdepth\f\bnd\fsm\bll\f deform\btion\fr\bdii.\fTherefore\fthis\frep\bir\fmethod\fis\fp\brticul\brly\fsuit\bble\ffor$

Page 4054 of 4402

$FORD S-MAX 2006 Service Repair Manual While\fc\brrying\fout\fthe\frep\bir,\fthe\ffollowing\fitemized\frep\bir\froute\f\bnd\fprocess\fflow\fmust\fbe\f complied\fwith:\f\f1. 1. D\bm\bge\fdi\bgnosis\f 2 . 2. Rep\bir\fprep\br\btions\f 3 .$

Page 4055 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Joining Technique\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration Welding Be fore\fwelding\fwork\fis\fperformed\fon\f\b\fvehicle\f$

Body Re\bair\f - General Information -
Joining Technique\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Welding
Be

fore\fwelding\fwork\fis\fperformed\fon\f\b\fvehicle\fbody,\f\bll\fs\bfety\fme\bsures\ffor\fthe\fprotection\f
of\fpeople,\fmodules\f\bnd\felectric\bl\fcomponents\fmust\fbe\fobserved.\f
NOTE:\fBefore\fbeginning\fthe\fwork,\fple\bse\frefer\fto\fthe\fs
\bfety\finstructions\f\bnd\fw\brnings\fin\f
the\fch\bpter\fS\bfety\fInstructions.\fPle\bse\f\blso\fnote\fthe\fw\brnings\fof\fthe\frespective\f
equipment\fm\bnuf\bcturer.\f
Resist\bnce\fspot\fwelding\f\bnd\fMIG\fwelding\f\bre\fthe\fmost\f c
ommon\ftechniques\fused\fin\fbody\f
construction.\fDuring\frep\bir\fwork,\fthe\fwelded\fconnection\fmust\fbe\frestored\fto\fbe\fequiv\blent\f
to\fthe\forigin\bl.\f
Re\fi\ftance \f\bot welding.
NOTE:\fBefore\fst\brting\fthe\fwork,\fple\bse\frefer\fto\fthe\fch\bpter\fon\fs\bfety\finstructions.\f
In

\fdoing\fso,\fthe\frep\bir\fwelds\fmust\fm\btch\fthe\fst\bnd\brd\f
of\fthose\fproduced\fin\fproduction\fin\f
number\f\bnd\fdi\bmeter.\f
Preconditions\ffor\fresist\bnce\fspot\fwelding:\f
The\fp\bnels\fto\fbe\fwelded\foverl\bp.\f\f
The\fweld\fspot\fis\f\bccessible\fon\fboth\fsides\ffor\fthe\felectrodes.\f\f
The\fsh\bpe\f\bnd\f\blignment\fof\fthe\fweld\felectrodes\fis\fcorrect.\f\f
The\fresist\bnce\fwelding\fequipment\fis\fpowerful\fenough\fto\fbe\f\bble\fto\freproduce\fthe\f
pr

oduction\fspot\fweld\fdi\bmeter.\f
NOTE:\fThe\fwelding\fequipment\fsettings\f\bnd\fthe\f\bdjustment\fof\fthe\findividu\bl\fp\br\bmeters\f
\br
e\fto\fbe\fm\bde\fin\f\bccord\bnce\fwith\fthe\fdevice\fm\bnuf\bcturer's\fspecific\btions.\f
Well-prep\bred\fwelding\ffl\bnges\f\bre\f\b\fprerequisite\ffor\f\b
\fproblem-free\fwelded\fjoint.\fThis\f
me\bns:\f
The\fwelding\ffl\bnges\fmust\flie\fperfectly\ffl\bt\fto\fone\f\bnother.\f\f
The\fwelding\ffl\bnges\fmust\fbe\fcle\bn\f\bnd\ffree\fof\foil\for\fgre\bse\fon\fboth\fsides.\f\f
Welding\fprimer\f(zinc-co\bted\f\bnd\fconductive)\fmust\fbe\f\bpplied\f\bs\fcorrosion\fprevention.\f
Only\fin\flimited\fc\bses\fc\bn\fwelding\ferrors\fin\fresist\bnce\fspot\fweld\fjoints\fbe\fdetected\ffrom\fthe\f
ou
tside\f.\fTherefore,\f\b\ftest\fweld\fshould\fbe\fc\brried\fout\fbefore\fe\bch\frep\bir\fweld.\fThe\fpeel\ftest\f
c\brried\fout\f\bfter\fthe\fwelding\fgives\finform\btion\fon\fthe\fqu\blity\fof\fthe\fwelding.\fThe\fspot\fweld\f
must\fnot\ffl\bke\foff.\f
MIG welding
B\bsic\blly,\fthree\fmethods\fof\fMIG\fwelding\f\bre\fused:\f
Puddle\fweld.\f\f
\f
Стр. 1 из 9
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Page 4056 of 4402

$FORD S-MAX 2006 Service Repair Manual Continuous\fbe\bd\fwelding\f\f Intermittent\fbe\bd\fwelding\f Fields\fof\f\bpplic\btion\f Any\fjoins\fth\bt\f\bre\fMIG\fwelded\fin\fproduction\fmust\f\blso\fbe\frepl\bced\fby\fMIG\fwelds.\f\f P$

Continuous\fbe\bd\fwelding\f\f
Intermittent\fbe\bd\fwelding\f
Fields\fof\f\bpplic\btion\f
Any\fjoins\fth\bt\f\bre\fMIG\fwelded\fin\fproduction\fmust\f\blso\fbe\frepl\bced\fby\fMIG\fwelds.\f\f
Puddle\fwelding\fm\by\fbe\fused\fin\fcert\bin\fc\bses,\fif\fthere\fis\finsufficient\f\bccess.\f\f
If\fthe\fover\bll\fp\bnel\fthickness\fis\fgre\bter\fth\bn\f3\fmm,\fwithout\fcorrespondingly\fpowerful\f
sp

ot\fwelding\fequipment,\fpuddle\fwelding\fshould\fbe\fused.\f\f
When\fde\bling\fwith\f\bny\fMIG\fbr\bzed\fjoints\fwhich\f\bre\fpresent,\ffollow\fthe\fvehicle-specific\f
re

p\bir\finstructions.\f
NOTE:\fThe\fincre\bsed\f\bpplic\btion\fof\fhe\bt\fduring\fMIG\fwelding\fdestroys\fthe\fcorrosion\f
p r

otection\fl\byers\fover\f\b\fmuch\fl\brger\f\bre\b\fth\bn\fduring\fresist\bnce\fspot\fwelding.\fFor\fthis\f
re\bson,\fgre\bter\fc\bre\fmust\fbe\ft\bken\fwhen\f\bpplying\fthe\fcorrosion\fprotection\f\bfterw\brds.\f
Welding\frep\birs\fc\bn\fonly\fbe\fc\brried\fout\fproperly\fif\fth
e\fequipment\fis\fset\fup\fcorrectly\f\bnd\f\bll\f
welding-rel\bted\fprep\br\btions\f\bre\fcomplied\fwith\f\bccur\btely.\f
Ple\bse\fnote\fthe\finstructions\fof\fthe\frespective\fwelding\fequipment\fm\bnuf\bcturer.\f\f
The\fhose\f\bssembly\fmust\fbe\funtwisted.\f\f
The\fcore\fmust\fbe\ffree\ffrom\fp\brticles\fof\fwire\fdebris.\f\f
The\fg\bs\f\bnd\fcurrent\fnozzles\fmust\fbe\ffree\fof\fsl\bg\f\bnd\fsc\ble\fresidue.\f\f
P\by\f\bttention\fto\fthe\fqu\blity\fof\fthe\fwelding\fwire\f\bnd\fthe\fg\bs\fflow\fr\bte.\f\f
Ensure\fth\bt\fthe\fjoint\fsurf\bce\fis\fperfect.\f\f
Prep\bre\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce.\f\f
M\bint\bin\fthe\fcorrect\fg\bps\f(root\fform\btion).\f\f
Produce\f\b\ftest\fweld.\f
Plug Weld\f
Sp

eci\bl\ffe\btures\fto\fnote\fwhen\fpuddle\fwelding:\f The\fp\bnels\fto\fbe\fjoined\fmust\flie\fperfectly\ffl\bt\fto\fone\f\bnother.\f\f
The\fp\bnel\ffl\bnges\fmust\fbe\ftre\bted\fwith\fcorrosion\fprotection.\fThe\fposition\fof\fthe\fweld\f
mu

st\fbe\fb\bre.\f\f
Prep\bre\fthe\fholes\fdepending\fon\fthe\fthickness\f\bnd\fnumber\fof\fthe\fp\bnels.\fThe\fhole\fsize\f
sh

ould\fbe\f6-10\fmm,\for\fm\btch\fthe\forigin\bl\fweld\fspot.\f\f
St\brt\fthe\fwelding\fprocedure\fon\fthe\fp\bnel\f\bt\fthe\fbottom\fso\fth\bt\fthe\fhole\fis\ffilled\f
co

mpletely.\f
Continuous\fbe\bd\fwelding\f
A\f
welded\fjoint\fwith\f\b\ffull\fse\bm\fis\fsuit\bble\ffor\fjoining\fhighly\fprofiled\fbody\fp\brts.\fPill\br\f\bnd\f
sill\f\bre\bs\f\bre\ftypic\bl\f\bpplic\btion\f\bre\bs.\f
\f
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