Ford Galaxy / Ford S-MAX. Manual — part 1019

large surfaces of the wall and ceiling cladding can be changed and are particularly easy to
repair.

If access to the back of a body panel section is needed because of body straightening work,
in some circumstances it is cheaper to perform a cut-out repair instead of removing an
element.

The repair process is fully described in the Student Information booklet Refrigeration
System Technology, Transit 2000.5 Freshline.

NOTE: You will find further information about working on vehicles with a refrigerated
compartment in the section Health and Safety Information.

Body Repairs - General Information -
Impact of Insufficient Repair Quality

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

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Description and Operation

Body repairs usually require a significant level of intervention in the existing body shell
structure. The corrosion protection, seals and NVH components are destroyed and must be
replaced.

To prevent the vehicle quality from being reduced due to a poor quality repair, all repairs
carried out in all repair sections must be inspected during and after the accident repair.

Simply checking the vehicle at the time of delivery is not sufficient to guarantee the repair
quality. Rather, continuous checking of the work carried out is recommended.

NOTE: Logs of the acceptance of individual operations are a useful tool for quality
assurance. A comprehensive final inspection can be carried out based on a final
acceptance log.

In the process, the entire repair sequence must be split into meaningful sections, with the
creation of check points to which particular attention must be paid.

The following are some possible sections:

During and after body work.
Final assembly, ancillary components, functional tests.
Vehicle delivery.

NOTE: The following points offer an indication of possible test logs. They can be combined
and supplemented differently, depending on the individual operating procedures.

During and after body work the following areas should be checked:

After completion of the body repairs, the following areas should be checked:

Manufacturing inspection for functionality and originality in the accident area.
Check snug fitting of metal panel parts (welding and screw connections).
Check snug fitting of ancillary components (doors, hoods, glazing).
Check surface condition of the welded seams.
Check seals, blanking plugs, NVH components.
Check corrosion prevention measures
Check that the repair work is in the correct condition for painting.

Final assembly, ancillary components, functional tests

After final assembly, not only a visual inspection is required, but also the functionality of
many components must be checked:

Check repair area for originality.
Check ancillary components for correct installation.
Check precision fitting of all parts.
Check that the doors and flaps are working correctly.
Check that all mechanical parts, such as the window winder are working correctly.
Check for leaks in the repair area.

Vehicle delivery

Vehicle delivery again offers the opportunity of checking the repair quality. In the process,
the following points are to be checked again:

Corrosion protection, sound damping matting and rubber seals.
Check for traces of leftover paint.

Check the cleanliness of the vehicle.
Functional check of the mechanical and electrical components.
Road test the vehicle.
Check for noise, vibration and harshness (NVH).
Check for wind noises.

After repair work on the body and vehicle, not only the visual restoration of the damaged
vehicle, but also the functional restoration must be guaranteed.

Customers are making increasingly high demands of vehicles, particularly in terms of
driving comfort. Customers find noise, vibrations and harshness (NVH) as well as squeaking
and rattling annoying, particularly after repair work. It is therefore important that the
condition of the vehicle at the time of production be restored after an accident repair.

After body repairs, the entire repair area must be checked for any water leaks. It is crucial
that a leak test be carried out as part of the final inspection so that water leaks can be
detected and eliminated even before delivery of the vehicle to the customer.

The requirements of the vehicle manufacturer are to be taken into consideration during all
inspections. Only in this way can it be guaranteed that the vehicle quality is not reduced
through insufficient repair quality.

Body Repairs - General Information -
Water Leaks

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

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Description and Operation

Water leaks can occur after body repair work, but can also occur on new vehicles. The test
methods described below allow the various causes to be identified. In all cases, a
systematic and logical procedure is required to locate water leaks.

General

When searching for faults, it must be taken into account that water can enter the vehicle
passenger compartment in various ways and circumstances. Therefore, it is sometimes not
sufficient to perform a water test on a stationary vehicle.

Before beginning extensive checks, a thorough visual inspection must be carried out. The
following points are to be taken into account in the process:

Check the clearance and accurate fit of ancillary components such as the trunk lid and
doors.
Check for correct installation and possible damage to sealing elements such as blanking
plugs, seals and rubber door seals.
Check that the water runoff openings and pipes are free of obstructions

Test method

Water test

NOTE: Do not use a power washer. Use a normal garden hose with a spray nozzle or
sprinkler head. Make certain that all windows and doors are completely closed.

Water leaks into the vehicle passenger compartment cannot usually be located
immediately, as the water often spreads across a large area. For this reason, the passenger
compartment must be dried before the leak tests. Any ancillary components that block the
view must be removed. During the water test, the vehicle is sprayed or sprinkled with
water at the suspected location of the leak. At the same time, a second person checks the
passenger compartment for places where water enters the vehicle. Depending on the test
and the vehicle, it may take some time before there is any sign of water entering the
vehicle. We recommend laying blotting paper under the location being tested so that the
water entry can be localized.

Example: Water test with sprinkler head (rain test)