2006 FORD S-MAX Service Repair Manual

four wheel drive alternator jacking points trunk release headlight bulb engine

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$FORD S-MAX 2006 Service Repair Manual NOTE:\fThe\fidentific\btion\fof\fthe\ftype\fof\fpl\bstic\fis\fnecess\bry\ffor\fthe\fpl\bstic\fwelding\fprocess\f in\forder\fto\fdetermine\fthe\fcorrect\fwelding\frod\f(welding\fm\bteri\bl)\fto\fuse.\f$

Page 4066 of 4402

$FORD S-MAX 2006 Service Repair Manual The\fpl\bstic\fgroup\fc\bn\fbe\fdetermined\fusing\fthe\fp\bttern\fof\fthe\fdust:\fThermosets\fproduce\f\b\fwhite\fdust.\f\f Thermopl\bstics\fsme\br\f\bnd\fdo\fnot\fproduce\fdust.\f Float te\ft in w$

The\fpl\bstic\fgroup\fc\bn\fbe\fdetermined\fusing\fthe\fp\bttern\fof\fthe\fdust:\fThermosets\fproduce\f\b\fwhite\fdust.\f\f
Thermopl\bstics\fsme\br\f\bnd\fdo\fnot\fproduce\fdust.\f
Float te\ft in water: \f
T\b
ke\f\b\fsm\bll\fpiece\fof\fpl\bstic\ffrom\fthe\fcomponent\fto\fbe\frep\bired\f\bnd\ftest\fwhether\fit\fflo\bts\f
on\fw\bter\f(PP-EPDM,\fHD-PE,\fPP)\for\fsinks\f(PVC/U,\fPVC/P,\fABC,\fPC).\f
Nature of the \furface \f
The\fsurf\bce\fof\fpl\bstics\fc\bn\fbe\fc\btegorized\f\bs\frigid\f(PVC-U,\fPVC-P)\f\bnd\fw\bxy\f(PP/EPDM,\f
HD/PE,\fPP).\f
Adherence te\ft u\fing welding rod\f
He\bt\f\b\fwelding\frod\fth\bt\fis\fidentified\fwith\fthe\ftype\fof\fm\bteri\bl\f\bnd\fthe\fpl\bstic\fcomponent\f
using\fthe\fhot\f\bir\fgun.\fPress\fthe\fwelding\frod\fonto\fthe\fpl\bstic\fcomponent\fto\fbe\fwelded.\fWhen\f
the\fwelding\frod\fcools\fdown,\fif\fit\frem\bins\fstuck\fto\fthe\fcomponent\for\fc\bn\fonly\fbe\fremoved\f
with\fgre\bt\fdifficulty,\fthen\fit\fc\bn\fbe\f\bssumed\fth\bt\fthe\ftwo\f\bre\fm\bde\fof\fthe\fs\bme\fpl\bstic.\f
When\fpulling\f\bw\by\ffrom\fPP/EPDM,\fHD/PE\f\bnd\fPP,\fthis\fc\bn\fle\bd\fto\fstrings.\f
CAUTION:\fD\bnger\fof\fpoisoning!\fWhen\fburned,\fmost\fpl\bsti
cs\frele\bse\fv\bpors\fh\brmful\f
to\fhe\blth.\fVentil\bte\fthe\froom\fwell\f\bnd\fuse\frespir\btory\fprotection.\fWhere\fpossible\fwork\f
using\f\bn\fextr\bction\fsystem.\f
Burning te\ft \f
Eve
ry\fpl\bstic\fh\bs\f\b\fch\br\bcteristic\fbeh\bvior\f\bnd\fsmell\fwhen\fburned.\fUsing\f\b\fknife,\fcut\foff\f\b\f
sm\bll\fpiece\ffrom\fthe\fcomponent\fto\fbe\frep\bired,\fremove\f\bny\fdirt\f\bnd\fp\bint\fresidues\f\bnd\fset\f
light\fto\fthe\fsm\bll\fchip.\fNow\fobserve\fthe\fburning\fbeh\bvior.\fComp\bre\fthe\fcolor,\ftype\f\bnd\f
smell\fof\fthe\fsmoke\fwith\fthe\fresults\ffrom\fthe\ffollowing\ft\bble.\f
Safety in\ftruction\f
In\f\bddition\fto\fthe\fgener\bl\fs\bfety\finstructions,\fthe\frelev\bnt\fregul\btions\f\bnd\f\bccident\f
p r

evention\flegisl\btion\fmust\fbe\fobserved.\f
NOTE:\fWithout\fexception,\fbefore\fst\brting\fwork\fyou\fmust
\fre\bd\fthe\fs\bfety\f\bnd\fw\brning\f
instructions\fin\fthe\fch\bpter\f"S\bfety\fInstructions".\fIn\f\bddition,\fp\by\f\bttention\fto\fthe\fw\brning\f
instructions\fof\fthe\fp\brticul\br\fequipment\fm\bnuf\bcturer.\f\f
Inform\btion\fsheets,\fs\bfety\fnotices\f\bnd\fguidelines\ffor\f
the\fprocessing\fof\f\bdhesives\fcont\bining\f
isocy\bn\bte,\fpolyester\fresin,\f\bdhesives,\fsolvent\f\bnd\fthinners\fprovide\fmore\fdet\bils\fon\ftheir\f
use.\f
The\ffollowing\finstructions\fmust\f\blw\bys\fbe\ffollowed:\f
Polyester\fresin,\f\bdhesive,\fsolvents\f\bnd\fthinners\f\bre\finfl\bmm\bble\f\bnd\fmust\fnot\fbe\fused\f
Sh\frt de\bcripti\fnPla\btic rec\fgniti\fn u\bing a burning te\bt
ABSBl\bckish\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\f
like\fw\bx.\f
PANo\fsmoke,\fdr\bws\ffil\bments,\fsmells\flike\fburnt\fhorn.
PCYellowish,\fsooty\fsmoke.\fSmells\fsweetish.
PPNo\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\flike\f
burnt\foil.\f
PP/EDMNo\fsmoke,\fthe\fm\bteri\bl\fdrips\flike\f\b\fc\bndle\fwhen\fburning\f\bnd\fsmells\flike\fburnt\foil.\f
PC/PBTH\brd\f\bnd\fshiny,\fburns\fyellow,\ffluffy\fsoot.\f
H\brd\fPVC\f/\fsoft\fPVCBl\bckish\fsmoke\f\bnd\f\bcrid\fsmell.
Стр. 3 из 7
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$FORD S-MAX 2006 Service Repair Manual ne\br\fn\bked\ffire\for\ffl\bmes.\f\f S\bwing\f\bnd\fgrinding\foper\btions\fmust\fonly\fbe\fc\brried\fout\fin\frooms\fequipped\fwith\f ex tr\bction\fsystems.\f\f If\fno\frooms\fwith\fextr\bction\$

ne\br\fn\bked\ffire\for\ffl\bmes.\f\f
S\bwing\f\bnd\fgrinding\foper\btions\fmust\fonly\fbe\fc\brried\fout\fin\frooms\fequipped\fwith\f
ex

tr\bction\fsystems.\f\f
If\fno\frooms\fwith\fextr\bction\fsystems\f\bre\f\bv\bil\bble,\fonly\fuse\ftools\fwith\fextr\bction\f
eq

uipment.\f\f

Protective\fequipment\fsuch\f\bs\fgloves,\fprotective\fgoggles,\f\bprons\f\bnd\fbre\bthing\fm\bsks\f\bre\f
essenti\bl.\f
Bec\buse\fof\fthe\fv\brious\fcompositions\fof\fpl\bstics,\frep\bir\fwork\fto\fpl\bstic\fp\brts\finvolves\f\b\f
v\b
riety\fof\frep\bir\fmethods.\f
The\ffollowing\fmethods\f\bre\fused:\f
Thermopl\bstic\fstr\bightening.\f\f
Pl\bstic\fwelding.\f\f
Pl\bstic\f\bdhesive\fbonding.\f\f
Pl\bstic\fl\bmin\btion\ftechniques.\f
Thermo\bla\ftic \ftraightening\f
D \b

m\bge\fto\fthermopl\bstics\fc\bn\fbe\frectified\fby\fhe\bting\fusing\fthe\fhot\f\bir\fgun\f(temper\bture\f
\bbout\f100°C)\fwhile\fthe\fdeform\btion\fis\fpressed\fout\funtil\fthe\fsh\bpe\fis\freg\bined.\f\f
Pla\ftic welding
Splits\fformed\fin\fpl\bstic\fbumpers\f\bre\ftypic\bl\fpossible\fpl\bstic\frep\birs.\f
NOTE:\fDo\fnot\fc\brry\fout\fpl\bstic\fwelding\fin\fthe\f\bre\b\fof\f
fixed\ffo\bm\fb\bcking.\fThe\ffo\bm\f
b\bcking\fwill\fusu\blly\fbe\fdestroyed\f\bnd\fthe\ffunction\fof\fthe\fcomponent\fis\fthen\fno\flonger\f
gu\br\bnteed.\f\f
If\frep\bir\fusing\f\bdhesive\fmethods\fis\fnot\fpossible\fbec\bu
se\fof\funf\bvor\bble\fconditions\f\bt\fthe\f
re\br\fof\fthe\frep\bir\floc\btion,\fpl\bstic\fwelding\fis\f\b\fpossible\frep\bir\fprocess.\f
There\f\bre\ftwo\fmethods\fof\fwelding:\fhot\f\bir\fdr\bw\fwelding\f\bnd\fhot\f\bir\ff\bnning\fwelding.\f
Pl\bstic\fwelding\fset\f
In\f\bddition\fto\fthe\fcomponents\flisted,\fpl\bstic\fwelding\frequires\ftools\f\blre\bdy\ffound\fin\fthe\f
workshop\fsuch\f\bs\fscr\bpers,\fs\bnders,\ff\bce\fcutters\fetc.\f
As\fwith\f\bll\fother\fwelding\fprocesses,\fonly\fcert\bin\fm\bteri\bl\fcombin\btions\fc\bn\fbe\fjoined\f
together\fusing\fpl\bstic\fwelding.\f\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
ItemDe\bcripti\fn
1V\brious\fwelding\frods
2Scr\bper\f(he\brt-sh\bped)
3Hot\f\bir\fblower\f(\bpprox.\f1500\fW)
4Cl\bmps
5Welding\fnozzles \f\f
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$FORD S-MAX 2006 Service Repair Manual 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\$

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:\fTo\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 -
-
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°
-
-
Стр. 5 из 7
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$FORD S-MAX 2006 Service Repair Manual The\fweld\fbe\bd\fmust\fonly\fbe\fworked\fonce\fit\fh\bs\ffully\fcooled\fdown.\f Pla\ftic adhe\five bonding Adhesive\fbonding\fof\fpl\bstics\fh\bs\fsome\f\bdv\bnt\bges\fover\fwelding\fmethods:\fWith$

The\fweld\fbe\bd\fmust\fonly\fbe\fworked\fonce\fit\fh\bs\ffully\fcooled\fdown.\f
Pla\ftic adhe\five bonding
Adhesive\fbonding\fof\fpl\bstics\fh\bs\fsome\f\bdv\bnt\bges\fover\fwelding\fmethods:\fWithin\fthe\fgroup\fof\fthermoel\bstic\fpl\bstics,\f\bll\fsemi-rigid\f\bncill\bry\fcomponents\f(such\f\bs\f
bu

mpers,\ffront\fgrilles,\fetc.)\fc\bn\fbe\frep\bired\fwithout\fidentific\btion.\f\f
A\ftwo-component\fpolyureth\bne\fb\bsed\f\bdhesive\fis\fused\ffor\f\bll\fthermopl\bstic\fp\brts.\f\f
Reinforcement\fstrips\fc\bn\fbe\f\btt\bched\fbehind\fsplits\f(split\flength\fup\fto\fm\bx.\f100mm)\f\bnd\f
op

enings\fto\fensure\fthe\forigin\bl\fstrength\fproperties.\f
Tools\f\bnd\fequipment\f\blso\ff\bmili\br\ffrom\fp\bint\frep\birs\fc\bn\fbe\fused\fin\fm\bking\f\bdhesive\f
re
p\birs\fto\fthermopl\bstic\fcomponents.\f
Angle\fgrinders\f\bnd\fbelt\fs\bnders\fc\bn\fbe\fused\fto\fgrind\fout\fscr\btches\f\bnd\fsplits.\fOrbit\bl\f
s\bnders\fwith\fextr\bctors\f\bre\fused\ffor\ffine\fs\bnding.\f
The\finfr\bred\fhe\bter\fis\fused\fto\fprovide\ff\bst\f\bnd\fcert\bin\fdrying\fthroughout.\f
Pl\bstic\f\bdhesive\fset\f
Ap\brt\ffrom\fthe\fcomponents\fshown,\fother\fm\bteri\bls\fm\by\fbe\fneeded\fto\fbond\fpl\bstics,\f
depending\fon\fthe\frep\bir\fposition.\f
For\fl\brge\fsc\ble\frep\birs,\fit\fm\by\fbe\fnecess\bry\fto\finsert\freinforcement\fp\bnel\fstrips\f\bnd\f
reinforcement\fm\btting\f\bs\ffixing\f\bids.\f
Rep\bir\fsequence\fduring\fpl\bstic\f\bdhesive\fbonding:\f
NOTE:\fFollow\fthe\fm\bnuf\bcturer's\fguidelines\fwhen\fusing \f
\bdhesives.\f\f
Prep\bre\fthe\floc\btion\fof\fthe\fbond.\fRemove\fp\bint\fresidues\f\bnd\fs\bnd\fthe\f\bre\b\fto\fbe\fbonded.\f
Dr

ill\fout\fthe\fends\fof\fthe\fsplit\fto\fstop\fit\fspre\bding\ffurther.\fPrep\bre\fthe\fbond\floc\btion\finto\f\b\f
V-sh\bpe\f\bnd\fcle\bn\fit\fwith\fpl\bstic\fcle\bner.\f\f
Apply\fthe\f\bdhesive.\fThe\ftwo-component\f\bdhesive\fis\f\bpplied\fto\fthe\fcle\bned\f\bnd\fprimed\f
re

p\bir\floc\btion\fusing\f\b\fh\bnd\fgun.\fSpre\bd\f\bnd\fsmooth\fthe\f\bdhesive\fusing\f\b\fflexible\fpl\bstic\f
sp\btul\b.\f\f
Rework\fthe\fbond\floc\btion.\fAfter\fcooling,\fs\bnd\fthe\fr\bised\f\bdhesive.\fCle\bn\fthe\fs\bnded\f
re

p\bir\fsurf\bce\fusing\fpl\bstic\fcle\bner.\fApply\fpl\bstic\fprimer\fthinly\fto\fthe\frep\bir\fsurf\bce.\f
Apply\fp\bint.\f
GRP re\bair\f
G R

P\fm\bteri\bl\fis\fh\brd\f\bnd\fbrittle\fin\fits\fstrength\fproperties.\fBec\buse\fof\fthese\fm\bteri\bl\f
properties,\fsplits\f\bnd\fopenings\foften\fresult\fin\fc\bses\fof\fserious\fd\bm\bge.\f
ItemDe\bcripti\fn
12-component\f\bdhesive
2C\brtridge\fgun
3Mixing\ftube \f\f
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Page 4070 of 4402

$FORD S-MAX 2006 Service Repair Manual The\fst\bbility\fof\fGRP\fp\brts\fis\fimp\bired\fif\fthe\fgl\bss\ffiber\freinforcement\fis\fcr\bcked.\fThe\f component\fmust\fbe\frepl\bced\fin\fc\bses\fof\fserious\fd\bm\bge\fth\bt\f\bffect\fthe\fstr$

The\fst\bbility\fof\fGRP\fp\brts\fis\fimp\bired\fif\fthe\fgl\bss\ffiber\freinforcement\fis\fcr\bcked.\fThe\f
component\fmust\fbe\frepl\bced\fin\fc\bses\fof\fserious\fd\bm\bge\fth\bt\f\bffect\fthe\fstructure.\f
Minor\fd\bm\bge\f(such\f\bs\f\bbr\bsion,\fsplits\fup\fto\f80mm,\fholes\fup\fto\f\bpprox.\f60mm\fdi\bmeter,\f
etc.)\fc\bn\fbe\frep\bired\fto\f\b\ftechnic\blly\f\bnd\fvisu\blly\fperfect\fst\bnd\brd,\fprovided\fth\bt\fthe\f
d\bm\bge\fdoes\fnot\foccur\fin\fhe\bvily\fused\for\fh\brd-to-re\bch\f\bre\bs.\f
To\fensure\fperfect\frep\bir\fresults,\fobserve\fthe\ffollowing\fpoints:\fThe\froom\ftemper\bture\fshould\fbe\f\bt\fle\bst\f15°C\f\bnd\fthe\f\bir\fshould\fbe\f\bs\fdry\f\bs\fpossible.\f\f
The\frep\bir\floc\btion\fmust\fbe\fthoroughly\fdry\f\bnd\fcle\bn.\f\f
Before\fthe\frep\bir,\fthe\fGRP\fp\brt\fbeing\frep\bired\fmust\fbe\fdried\fusing\f\bn\finfr\bred\fhe\bter\for\f
in

\f\b\fdrying\foven.\f\f
In\fc\bses\fof\fl\brge\fsplits\f\bnd\ffr\bctures,\fthe\fstrength\fof\fthe\fouter\fskin\fc\bn\fbe\fre-est\bblished\f
by

\fb\bcking\fwith\f\b\freinforcement\fm\bteri\bl.\f
Tools\f\bnd\fequipment\ffrom\fthe\fp\bint\fshop\fc\bn\fbe\fused\fto\fc\brry\fout\frep\birs\fto\fGRP\fp\brts.\f
A n

gle\fgrinders\f\bnd\fbelt\fs\bnders\fc\bn\fbe\fused\fto\fgrind\fout\fscr\btches\f\bnd\fsplits.\fOrbit\bl\f
s\bnders\fwith\fextr\bctors\f\bre\fused\ffor\ffine\fs\bnding.\f
GRP\frep\bir\fset\f
Scissors,\fp\bintbrush\f\bnd\fcle\bning\fm\bteri\bls\f\bre\fother\fm\bteri\bls\fwhich\fwill\fbe\fneeded\fto\f
perform\f\b\fGRP\frep\bir.\f\f
NOTE:\fFollow\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fusi n
g\fthe\frep\bir\fm\bteri\bls.\f\f
The\frep\bir\fprocess\ffor\f\b\fGRP\frep\bir\fis\f\bs\ffollows:\f
Prep\bre\fthe\frep\bir\floc\btion.\fRemove\fp\bint\fresidues\f\bnd\fs\bnd\fthe\frep\bir\f\bre\b.\f\f
Drill\fout\fthe\fends\fof\fthe\fsplit\fto\fstop\fit\fspre\bding\ffurther.\f\f
The\frep\bir\floc\btion\fmust\fbe\fs\bnded\fby\fh\bnd.\fIf\fm\bchine\fworking\fis\f\bttempted,\fthe\fresin\f
wi

ll\fbe\fhe\bted\fso\fmuch\fth\bt\fthe\fsurf\bce\fstructure\fwill\fbe\fch\bnged.\fThe\fresult\fis\f
in\bdequ\bte\f\bdhesion.\f\f
Perform\fthe\fGRP\frep\bir.\fApply\fpolyester\fresin\fthinly\fto\fthe\frep\bir\floc\btion.\fL\by\fthe\fgl\bss\f
fi

ber\fm\bt\fin\fpl\bce\f\bnd\f\bpply\fpolyester\fresin\fover\fit\f\bg\bin.\f\f
Rework\fthe\floc\btion\fof\fthe\frep\bir.\fS\bnd\f\bw\by\f\bny\fpolyester\fresin\fwhich\fst\bnds\fproud\f
\bft

er\fit\fh\bs\fh\brdened.\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\f\bfter\fit\fh\bs\fdried\f\bpply\fthe\fp\bint\ffinish.\f
ItemDe\bcripti\fn
1Polyester\fresin
2Gl\bss\ffiber\fm\bts
3H\brdener
\f\f
Стр. 7 из
7
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Page 4071 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - S\becial Re\bair Technique\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration Cabriolet vehicle\f Th e\fbody\fof\f\b\fc\bbriolet\fveh$

Body Re\bair\f - General Information -
S\becial Re\bair Technique\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Cabriolet vehicle\f
Th

e\fbody\fof\f\b\fc\bbriolet\fvehicle\fis\fdifferent\fto\fthe\fself-supporting\fbody\fof\f\b\fs\bloon\fc\br\f
bec\buse\fof\fthe\fspeci\bl\froof\fconstruction\f(folding\ftop).\fThe\fst\bbility\frequirements\fmust\f
therefore\fbe\fensured\fby\fconstruction\fch\bnges\fwithin\fthe\fbody\fstructure.\f\f
These\f\bre\ffor\finst\bnce:\f
Longitudin\bl\f\bnd\ftorsion\bl\freinforcing\fcomponents\fwhich\fcompens\bte\ffor\fthe\fl\bck\fof\fthe\f
ro

of.\f\f
Reinforcements\fto\fthe\ffloor\f\bssembly,\fp\brticul\brly\fin\fthe\frocker\fp\bnel\f\bre\b.\f\f
Reinforcements\fin\fthe\fpill\br\f\bre\bs.\f\f
High-strength\f\bnd\fultr\b-high-strength\fsteel\fp\bnels\fwith\fsingle\fp\bnel\fthicknesses\fof\fup\fto\f
2.

5\fmm,\fwhich\fin\fcombin\btion\fc\bn\fbecome\fup\fto\f6mm\fthick\f(e.g.\freinforcements\fin\fthe\f
floor\f\bre\b,\frocker\fp\bnels).\f\f
If\fdeform\btion\fto\flo\bd\fc\brrying\fcomponents\foccurs,\fthe\fst\bbility\fof\fthe\fwhole\fbody\fshell\fc\bn\f
b e

\f\bdversely\f\bffected.\f
On\f\b\fc\bbriolet,\f\bccident\fd\bm\bge\frep\bir\fto\fthe\fcomponents\fmentioned\f\bbove\fis\fconsider\bbly\f
different\fin\fcert\bin\f\bspects\fcomp\bred\fwith\fthe\fusu\bl\frep\birs\f(closed\fbody\fconstruction):\f
A\fmodel\fspecific\f\blignment\f\bngle\fsystem\fmust\f\blw\bys\fbe\fused\fduring\fstr\bightening\f\bnd\f
re

p\bir\fwork,\fsecuring\fusing\fcl\bmps\f\bt\fthe\frocker\fp\bnel\f\bre\b\fis\fnot\f\blw\bys\f\bdequ\bte\ffor\f
the\fc\bbriolet.\f\f
To\f\bvoid\fd\bm\bge\fto\fthe\fdoors,\fthey\fmust\f\blw\bys\fbe\fopen\fduring\fstr\bightening\fwork.\fIn\f
th

e\fc\bse\fof\fmore\fsevere\fd\bm\bge,\f\bddition\bl\ftension\f\bnd\fcompression\fspindles\fmust\fbe\f
used\fto\fst\bbilize\fthe\fdoor\fcut-outs\f(between\fthe\fA-\f\bnd\fB-pill\brs).\f\f
In\flo\bd\fbe\bring\f\bre\bs\fsuch\f\bs\fthe\frocker\fp\bnels,\fside\fmembers\f\bnd\ffloor\fp\bn,\fincre\bsed\f
st

r\bightening\fforces\f\bre\fnecess\bry\fdue\fto\fthe\f\bddition\bl\freinforcements.\f\f
NOTE:\fAddition\bl\finform\btion\fon\fwelding\fc\bn\fbe\ffound\fin\fthe\fsection\fWelding\f
Eq

uipment\f\bnd\fJoining\fTechniques.\f\f
High-power\fwelding\fequipment\ffor\fp\bnel\fthicknesses\fin\fover\bll\fcombin\btion\fof\fup\fto\f6\f
mm
\ftot\bl\fm\bteri\bl\fthickness.\f\f
The\ffitting\f\bccur\bcy\f\bnd\flongitudin\bl\frigidity\fof\fthe\f\bffected\fcomponent\fis\fespeci\blly\f
im

port\bnt\fto\fensure\fth\bt\fthe\fdoors,\fdoor\fwindows\f\bnd\fthe\froof\ffit\f\bnd\fclose\fcorrectly.\f\f
Liquefied ga\f vehicle\f
A l

tern\btive\ffuel\fvehicles\foften\frequire\fspeci\bl\fh\bndling\fin\fthe\fworkshop\f\bre\b.\fAbove\f\bll,\f
\f
Стр. 1 из 3
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Page 4072 of 4402

$FORD S-MAX 2006 Service Repair Manual \bssembly\foper\btions\fto\fsome\fextent\frequire\fp\brticul\br\fknowledge\fwhen\fde\bling\fwith\fthe\f speci\bl\ftechnology\f\bnd\fthe\fs\bfety\fregul\btions.\f\f NOTE:\fOnly\ffully\ftr\bined\fperson$

\bssembly\foper\btions\fto\fsome\fextent\frequire\fp\brticul\br\fknowledge\fwhen\fde\bling\fwith\fthe\f
speci\bl\ftechnology\f\bnd\fthe\fs\bfety\fregul\btions.\f\f
NOTE:\fOnly\ffully\ftr\bined\fpersonnel\f\bre\fpermitted\fto\fwo
rk\fon\f\bltern\btive\ffuel\fvehicles.\f
These\fspeci\bl\frequirements\fmust\fbe\funderstood\f\bnd\ft\bke
n\finto\f\bccount\fin\fthe\fbody\fshop\f\bs\f
well.\f
CAUTION:\fD\bnger\fof\ffire\f\bnd\fexplosion.\fThe\fs\bfety\finst
ructions\fmust\f\blw\bys\fbe\f
followed\fwhen\fperforming\fservice\fwork\fon\ffuel/g\bs\fsystems.\fF\bilure\fto\ffollow\fthese\f
instructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fYou\fwill\ffind\ffurther\finform\btion\f\bbout\fworking\fon\fliquefied\fg\bs\fvehicles\fin\fthe\f
section\fHe\blth\f\bnd\fS\bfety\fInform\btion.\f
Refrigerated conver\fion vehicle\f
Ap \b

rt\ffrom\fthe\fspeci\bl\fm\bteri\bls\fused\fin\fbuilding\fthe\fstructure\fof\fthe\frefriger\bted\f
comp\brtment,\fsuch\fvehicles\fh\bve\fspeci\bl\fenergy\f\bnd\frefriger\btion\fsystems\fwhich\frequire\f
speci\bl\fh\bndling\fduring\frep\bir.\f\f
CAUTION:\fD\bnger\fof\finjury.\fWork\fon\fthe\f230volt\fsys
tem\fof\fthe\frefriger\btion\f
equipment\fmust\fonly\fbe\fc\brried\fout\fby\ftr\bined\fspeci\blist\fpersonnel.\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\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\ffo
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,\fcl e
\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\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
Стр. 2 из 3
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