2006 FORD S-MAX wiring

Front En\b Sheet \fetal Repairs - Front Si\be
\fember an\b Suspension Top \fount
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NO

TE:\fEquipment:\f
Me\b
surement\f\bnd\f\blignment\f\bngle\fsystem.\f\f
1. \f\f
Replacement parts: \f

Inner\fSide\fMember\f\f

Outer\fSide\fMember\fwith\fApron\fP\bnel\f\f

Longitudin\bl\fMember\fFl\bnge\fPl\bte\f\f
2 .

\f\f
Necessary removal an\b installation
wo

rk:\f

Fender\fApron\fP\bnel\fReinforcement\f\f
Re

fer\fto:\f Fender\fApron\fP\bnel\f
Rei

nforcement \f(501-27\fFront\fEnd\fSheet\f
Met

\bl\fRep\birs,\fRemov\bl\f\bnd\fInst\bll\btion).\f

Strut\fTower\fReinforcement\f\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
3. \f\f
Apron Panel - Rough Cut \f

M\brk\fthe\fcutline\f\bnd\fcut\fthe\fApron\fP\bnel.\f\f
4.

\f\f
Front Si\be \fember Outsi\be - Rough
Cu

t\f

NOTE:\fSt\bted\fdimension\fis\fminimum\f
di

mension!\f\f
M\brk\fthe\fcutline\f\bnd\fcut\fthe\fFront\fSide\f
Me
mber.\f\f
5. \f\f
Strut Tower \f

NOTE:\fMill\fout\fthe\fspot\fwelds\ffrom\f
be

low.\f\f
Mill\fout\fthe\fspot\fwelds.\f\f
\f\f
\f\f
\f\f
Стр. 1 из
4
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1058037&gu...procarmanuals.com
http://vnx.su

Roof Shee\b Me\bal Re\fairs - Roof Panel—
Vehicles Wi\bhou\b: Glass Roof Panel, VIN
Pla\be Body S\byle Code: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
1.
Re\flacemen\b \far\bs \f

R

oof\fp\bnel\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fT\bilg\bte,\fdoors,\f
wi

ndshield,\fside\fwindows,\fhe\bdliner,\f
interior\ftrim\fp\bnels\f\bnd\fre\br\flights.\f

Move\fthe\fwiring\fh\brness\f\bw\by\ffrom\fthe\f
wo

rking\f\bre\b.\f
2. Roof\fp\bnel\f
Mill\fout\fthe\fspot\fwelds.\f
3.

Roof\fp\bnel\f 1. Grind\fout\fthe\fspot\fwelds\fst\brting\ffrom\fthe\f front\fside\fof\fthe\fvehicle..\f
2. He\bt\fthe\fbonded\f\bre\bs\ffrom\fthe\foutside\f
(\bpprox.\f170°\fC).\f
\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G873685&gui...procarmanuals.com
http://vnx.su

Roof Shee\b Me\bal Re\fairs - Roof Panel—
Vehicles Wi\bh: Glass Roof Panel, VIN Pla\be
Body S\byle Code: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
1.
Re\flacemen\b \far\bs \f

R

oof,\ffront\fp\brti\bl\fsection\f

Roof,\fre\br\fp\brti\bl\fsection\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fP\bnor\bmic\froof,\f
t\bi

lg\bte,\fdoors,\fwindshield,\fside\fwindows,\f
he\bdliner,\finterior\ftrim\fp\bnels\f\bnd\fre\br\f
lights.\f

Move\fthe\fwiring\fh\brness\f\bw\by\ffrom\fthe\f
wo

rking\f\bre\b.\f
2. Roof\f(re\br\fp\brti\bl\fsection)\f
Mill\fout\fthe\fspot\fwelds.\f
3.

Roof\f(re\br\fp\brti\bl\fsection)\f 1. Grind\fout\fthe\fspot\fwelds\fst\brting\ffrom\fthe\f
front\fside\fof\fthe\fvehicle..\f
2. He\bt\fthe\fbonded\f\bre\bs\ffrom\fthe\foutside\f (\bpprox.\f170°\fC).\f
\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G899352&gui...procarmanuals.com
http://vnx.su

Roof Shee\b Me\bal Re\fairs - Roof Panel—
Vehicles Wi\bhou\b: Glass Roof Panel, VIN
Pla\be Body S\byle Code: M
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
1.
Re\flacemen\b \far\bs \f

R

oof\fp\bnel\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fT\bilg\bte,\fdoors,\f
wi

ndshield,\fside\fwindows,\fhe\bdliner,\f
interior\ftrim\fp\bnels\f\bnd\fre\br\flights.\f

Move\fthe\fwiring\fh\brness\f\bw\by\ffrom\fthe\f
wo

rking\f\bre\b.\f
2. Roof\fp\bnel\f
Mill\fout\fthe\fspot\fwelds.\f
3.

Re\br\froof\fp\bnel\f
Grind\fout\fthe\fspot\fwelds\fst\brting\ffrom\fthe\f
fr

ont\fside\fof\fthe\fvehicle..\f
4. Roof\fp\bnel\f
He\bt\fthe\fbonded\f\bre\bs\ffrom\fthe\foutside\f
(\bp

prox.\f170°\fC).\f
\f
\f\f
Стр. 1 из 3
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G899353&gui...procarmanuals.com
http://vnx.su

Side Pa\bel Sheet \fetal Repairs - A-Pillar
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\fDue\fto\fthe\floc\btions\fof\finner\freinforcements\f\bnd\fNVH\felements,\fit\fis\fvery\f
i m

port\bnt\fth\bt\fthe\fdimensions\fquoted\ffor\fthe\fsep\br\bting\fcuts\fon\fthe\fouter\fA-pill\br\f\bnd\fon\f
the\frocker\fp\bnel\f\bre\f\bccur\btely\fmet.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt parts \f

A-pill\br\fouter\fp\bnel\f

A-pill\br\finner\fp\bnel\f

A-pill\br\freinforcement\f

Rocker\fp\bnel\freinforcement\f

NVH\felements\f
1 .

Gener\bl\fNotes\f

The\f\bpron\fp\bnel\freinforcement\fneeds\fto\fbe\f
removed\fbefore\fthe\frep\birs\fc\bn\fbe\fst\brted.\f

Required\fremov\bl\foper\btions:\fA-pill\br\ftrim\f
p\bn
el,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. A-Pill\br\fouter\f NOTE:\fT\bke\fc\bre\fnot\fto\fd\bm\bge\fthe\f
in

ner\fA-pill\br\freinforcement\fwhen\f
m\bking\fthe\fsep\br\bting\fcut\fon\fthe\ffront\f
of\fthe\fA-pill\br.\f

Cut\fpoints.\f
3.

A-Pill\br\fouter\f
Mill\fout\fthe\fspot\fwelds.\f
\f
Стр. 1 из 13
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G873687&gui...procarmanuals.com
http://vnx.su

Side Pa\bel Sheet \fetal Repairs - Rocker
Pa\belS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
NOTE:\fThe\floc\btion\fof\fthe\fsep\br\bting\fcut\fm\by\fbe\fch\bnged\fdepending\fon\fthe\fextent\fof\fthe\f
d \b

m\bge.\fThe\frep\bir\fshown\fonly\fdescribes\f\b\fcomplete\frepl\bcement\fin\ffull.\f 1.
Replaceme\bt Parts \f

R

ocker\fp\bnel\f
1.

Gener\bl\fnotes\f
Required\fremov\bl\foper\btions:\fDoors,\fdoor\f
hi

nges,\ffront\f\bnd\fre\br\fse\bts,\fdoor\fsill\finner\f
trim,\fA-\fB-\f\bnd\fC-\fpill\br\finner\ftrim.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Rocker\fp\bnel\f
Overview\fof\fcutting\foptions\f
3.

Rocker\fp\bnel\f
Sep\br\bting\fcut.\f
4.

Rocker\fp\bnel\f
Sep\br\bting\fcut.\f
\f
\f
\f
Стр. 1 из 4
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G873688&gui...procarmanuals.com
http://vnx.su

Side Pa\bel Sheet \fetal Repairs - Rocker
Pa\bel I\b\ber Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\f\f

In\forder\fto\fprevent\fbody\fdistortion\fwhile\fperforming\frep\birs,\fthe\fbody\fmust\fbe\ffixed\fon\f
\bn\f

\blignment\f\bngle\fsystem.\f

The\floc\btion\fof\fthe\fsep\br\bting\fcut\fm\by\fbe\fch\bnged\fdepending\fon\fthe\fextent\fof\fthe\f
d\bm

\bge.\f

The\fjoints\f\bre\fbutted\fup\f\bnd\fjoined\fusing\f\b\fcontinuous\fMIG\fweld\fse\bm.\f

Depending\fon\fthe\flevel\fof\fd\bm\bge,\fit\fis\fnot\f\blw\bys\fnecess\bry\fto\fremove\fthe\fA-pill\br\for\fB-
pi

ll\br\ffor\fp\brti\bl\frepl\bcements.\f

The\frep\bir\fshown\fonly\fdescribes\f\b\fcomplete\frepl\bcement\fin\ffull.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt Parts \f

Rocker\fp\bnel\freinforcement\f
1.

Gener\bl\fnotes\f
The\frocker\fp\bnel,\fA-pill\br\fouter\fp\bnel\fwith\f
re

inforcement\f\bnd\fB-pill\br\fwith\f
reinforcement\fneed\fto\fbe\fremoved\fbefore\f
commencing\fthe\frep\bir.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Rocker\fp\bnel\freinforcement\f
Overview\fof\fcutting\foptions\f
3 .

Rocker\fp\bnel\freinforcement,\ffront\f
Mill\fout\fthe\fspot\fwelds.\f
4.

Rocker\fp\bnel\freinforcement,\fre\br\f
Mill\fout\fthe\fspot\fwelds.\f
\f
\f
\f\f
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G873689&gui...procarmanuals.com
http://vnx.su

Side Pa\bel Sheet \fetal Repairs - B-Pillar
a\bd Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
WARNING:\f\f

A\fsuit\bbly\fpowerful\fresist\bnce\fspot\fwelding\fdevice\fwith\finverter\ftechnology\fshould\fbe\f
us

ed\ffor\fthis\frep\bir.\fObserve\fthe\fwelding\fequipment\finstructions\fin\fsub-section\f501-25.\f\f

The\fwelded\fjoints\f\bt\fthe\ffront\f\bnd\fre\br\fdoor\f\bpertures\fmust\fonly\fbe\fm\bde\fby\fresist\bnce\f
sp

ot\fwelding.\fMIG\fpuddle\fwelding\fis\fnot\f\b\fpermissible\f\bltern\btive.\f
WARNING:\f\f

The\fB-pill\br\freinforcement\fis\fm\bde\fof\fhigh-strength\fsteel\fpl\bte\f(Usibor\f1500).\f\f

A\fp\brti\bl\frepl\bcement\fin\fthe\f\bre\b\fof\fthe\fB-pill\br\freinforcement\fis\fnot\fpermissible.\fThe\f
re

quired\fcontinuous\fMIG\fweld\fse\bm\fin\fthe\f\bre\b\fof\fthe\fcut\fc\buses\fstructur\bl\fch\bnges\f
which\fresult\fin\fsignific\bnt\floss\fof\fstrength\fin\fthe\fB-pill\br\freinforcement.\f\f

Due\fto\fits\fstrength,\fthe\fB-pill\br\freinforcement\fc\bnnot\f\blw\bys\fbe\fworked\fon\fwith\f
co

nvention\bl\fbody\ftools.\f\f

Addition\bl\fprep\br\btions\f\bre\frequired\ffor\fMIG\fpuddle\fwelding.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt Parts \f

B-pill\br\fouter\fp\bnel\f

B-pill\br\finner\fp\bnel\f

B-Pill\br\freinforcement\f

NVH\felement\f
1. Gener\bl\fnotes\f

Necess\bry\fremov\bl\fwork:\fDoors,\fB-pill\br\f
tr

im\fp\bnel,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. NOTE:\fDue\fto\fthe\finner\freinforcements\f\bnd\f
NV
H\felements,\fthe\fspecified\fdimensions\ffor\f
the\fcuts\fto\fbe\fm\bde\fin\fthe\frocker\fp\bnel\f\bre\b\f
must\fbe\fcomplied\fwith.\f
Outer\fB-pill\br\f NOTE:\fOnly\fcut\fthrough\fthe\fouter\f
p\b

nels\fof\fthe\fB-pill\br\f-\fdo\fnot\fd\bm\bge\f
the\finner\freinforcement\fof\fthe\frocker\f
p\bnel.\f
1. Rocker\fp\bnel\fcut\floc\btions\f
2.
B-Pill\br\fcut\floc\btion.\f
Стр. 1 из 7
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G873690&gui...procarmanuals.com
http://vnx.su