Ford Galaxy / Ford S-MAX. Manual — part 1002

Position lines within a diagram

A position line is used to indicate a special position or a component. A spot weld which must
be drilled out through two panel thicknesses is indicated here, different to all the others.

Body Repairs - General Information -
Health and Safety Precautions

S-MAX/Galaxy 2006.5 (02/2006-)

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Description and Operation

General

Appropriate repair methods and their correct implementation are very important for both
vehicle operating safety and personal safety.

WARNING: There is danger of injury through:

High voltage when electrical welding.

Do not perform welding work in a damp environment or on a wet substrate. Use

suitable insulation underneath.
Flammable substances in the welding area.

Remove flammable substances from the danger area. Remove the fuel tank and, where

required, those components which supply fuel.

Completely remove the battery before carrying out any welding in that area.

Welding fumes, which are harmful to health.

Always ventilate the workplace well and use an extraction system.

Welding spatter and UV radiation.

Wear protective clothing, gloves and welding mask or welding goggles.

Pyrotechnic components.

Disconnect the battery negative clamp and cover the battery terminal. Remove any

airbag components.

All the regulations governing Health and Safety at Work must be complied with during body
repairs.

Personal protection

Welding gases and grinding dusts can be harmful to the health. For this reason, make sure
that rooms are well ventilated and work using the welding fumes extraction system.
Sealants, underbody protection and paint residues must not be burnt down with an
unshielded flame, as this will produce gases which are damaging to health. A dedicated
extraction system must always be used when welding or brazing.

When working with substances containing solvents, good ventilation must be provided,
respiratory protection must be worn and an extraction system must be used.

Do not weld in damp areas, if necessary use an insulation mat. Welding and grinding work
near the battery presents the danger of explosion. For this reason, it must be removed
before the work is started.

Cutting, grinding and alignment work on metal panels can cause a noise level of 85 to 90
dB (A) or even more. For this reason, you must always wear ear defenders.

The various body areas are subject to very high forces during realignment work. Should
any component suddenly become detached during this process, there is a very great
danger of injury. For this reason, pulling chains and pulling shackles must be secured with
arrester cables.

NOTE: Work on airbag systems may only be performed by persons who have a relevant
certificate of competence.

Some special instructions must be followed when working on airbag systems:

Always stand to the side of it when removing or installing an airbag.
Always store an airbag or an airbag/steering wheel with the airbag side pointing upwards
and in a safe place.
Only install the airbag again when the vehicle is fully repaired and the complete electrical

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systems has been tested.
Take into account the location of air curtains and shoulder airbags.

Protection of the vehicle

Protect affected areas from weld spatter and dust during all welding and grinding work on
the vehicle. If metallic dust stays on the vehicle for some time, there is the likelihood of
film rust formation. Grinding or sanding work produce tiny spots of damage to the paint
surface, which may cause corrosion.

For this reason, make sure to:

Use carbon fibre blankets to protect the vehicle body.
Use covering film to protect the vehicle body from sanding dust and metal dust.
Take appropriate measures to protect the interior equipment of the vehicle during any
repair work.

In addition, take into account:

Remove fuel supply components as necessary.
Protect working areas which are in danger of catching fire with a fireproof blanket.
The welding must not cause components of the air conditioning system to become
heated.
Removal of any attached components in the space adjoining the repair area.
Use covering paper to protect the interior from grinding dust.
Create a definite barrier between the work area and the interior by using a carbon fibre
blanket.

Protective equipment

The following protective equipment must always be used:

Protective helmet or welding mask.
Ear defenders and breathing protection.
Protective gloves and safety boots.
Welding fume extraction.

Electronic components

Increased use of comfort and safety electronics in modern motor vehicles also requires the
greatest attention to be paid during body work. Overvoltages produced during welding and
in alignment work during bodyshell rectification may cause electronic systems to be
damaged. In particular, the safety instructions for performing welding work on vehicles with
airbag systems must be adhered to.

NOTE: After disconnecting the power supply and before performing further work, a wait
time of up to 15 minutes must be maintained, depending on the vehicle. Work on airbag
systems may only be performed by persons who have a relevant certificate of
competence.

Pay attention to the following points:

Disconnect the battery negative clamp and cover the battery terminal.
Disconnect the electrical connector at the airbag control module.
If welding is to be performed directly near a control module, it must be removed
beforehand.
Never connect the negative cable of the welder near an airbag or a control module.
Connect the negative cable of the welder close to the location of the weld.

For additional information, refer to: (501-20B Supplemental Restraint System)

Side Air Bag Module

(Removal and Installation),

Side Air Bag Module

(Removal and Installation),

Driver Air Bag Module - Vehicles Built From: 13-07-2009

(Removal and Installation),

Driver Lower Air Bag Module

(Removal and Installation),

Passenger Air Bag Module

(Removal and Installation),

Air Bag Supplemental Restraint System (SRS)

(Diagnosis and Testing).

Liquefied gas vehicles

Alternative fuel vehicles often require special handling in the workshop area. Above all,
assembly operations to some extent require particular knowledge when dealing with the
special technology and the safety regulations.

NOTE: Only fully trained personnel are permitted to work on alternative fuel vehicles.

These special requirements must be understood and taken into account in the body shop as
well.

CAUTION: Danger of fire and explosion. The safety instructions must always be

followed when performing service work on fuel/gas systems. Failure to observe this
instruction can lead to injury.

If the smell of liquefied petroleum gas (LPG) or compressed natural gas (CNG) is noticed in
the workshop, instruct everyone present as follows:

No smoking and extinguish all naked flames.
Shut off all electrical and air powered equipment.
Evacuate the area.
Ventilate the area.
Contact the fire control authorities.
Move the vehicle to a dedicated, well ventilated area.

Alternative fuels require special handling:

Handle them in a specially dedicated, well ventilated area, which is only accessible to
authorized persons.
Identify the designated area with new warning notices.
If possible close the main shut-off valve and run the vehicle on alternative fuel until it
switches automatically to petrol operation. Only then is it allowed to drive the vehicle into
the workshop or service area.
If possible do not allow any liquefied gas (LPG) to escape.
The ambient temperatures must not exceed 40°C. For this reason the LPG and CNG fuel
tanks must be removed on vehicles with LPG or CNG operation before using a drying
oven to dry the paint where the temperature exceeds 40°C.

Avoid situations in which fuel from an LPG or CNG fuel tank can escape. These situations
include:

Extremely hot ambient temperatures.
Parking near a heating device.
Raising the vehicle near a ceiling heater.

Refrigerated conversion vehicles

Apart from the special materials used in building the structure of the refrigerated
compartment, such vehicles have special energy and refrigeration systems which require
special handling during repair.

CAUTIONS:

Danger of injury. Work on the 230<SP>volt system of the refrigeration equipment

must only be carried out by trained specialist personnel.