Ford Fiesta (2011 year). Manual — part 100

Description

Item

Polyester resin

1

Glass fiber mats

2

Hardener

3

Scissors, paintbrush and cleaning materials are
other materials which will be needed to perform a
GRP repair.

NOTE: Follow the manufacturer's instructions when
using the repair materials.

The repair process for a GRP repair is as follows:

• Prepare the repair location. Remove paint

residues and sand the repair area.

• Drill out the ends of the split to stop it spreading

further.

• The repair location must be sanded by hand. If

machine working is attempted, the resin will be
heated so much that the surface structure will
be changed. The result is inadequate adhesion.

• Perform the GRP repair. Apply polyester resin

thinly to the repair location. Lay the glass fiber
mat in place and apply polyester resin over it
again.

• Rework the location of the repair. Sand away

any polyester resin which stands proud after it
has hardened.

• Clean the sanded repair surface using plastic

cleaner. Apply plastic primer thinly to the repair
surface and after it has dried apply the paint
finish.

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Special Repair Techniques

Cabriolet vehicles

The body of a cabriolet vehicle is different to the
self-supporting body of a saloon car because of

the special roof construction (folding top). The
stability requirements must therefore be ensured
by construction changes within the body structure.

These are for instance:

• Longitudinal and torsional reinforcing

components which compensate for the lack of
the roof.

• Reinforcements to the floor assembly,

particularly in the rocker panel area.

• Reinforcements in the pillar areas.

• High-strength and ultra-high-strength steel

panels with single panel thicknesses of up to
2.5 mm, which in combination can become up
to 6mm thick (e.g. reinforcements in the floor
area, rocker panels).

If deformation to load carrying components occurs,
the stability of the whole body shell can be
adversely affected.

On a cabriolet, accident damage repair to the
components mentioned above is considerably
different in certain aspects compared with the usual
repairs (closed body construction):

• A model specific alignment angle system must

always be used during straightening and repair

work, securing using clamps at the rocker panel
area is not always adequate for the cabriolet.

• To avoid damage to the doors, they must always

be open during straightening work. In the case
of more severe damage, additional tension and
compression spindles must be used to stabilize
the door cut-outs (between the A- and B-pillars).

• In load bearing areas such as the rocker panels,

side members and floor pan, increased
straightening forces are necessary due to the
additional reinforcements.

• NOTE: Additional information on welding can

be found in the section Welding Equipment and
Joining Techniques.

High-power welding equipment for panel
thicknesses in overall combination of up to 6
mm total material thickness.

• The fitting accuracy and longitudinal rigidity of

the affected component is especially important
to ensure that the doors, door windows and the
roof fit and close correctly.

Liquefied gas vehicles

Alternative fuel vehicles often require special
handling in the workshop area. Above all, assembly
operations to some extent require particular

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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 follow these
instructions may result in personal injury.

NOTE: You will find further information about
working on liquefied gas vehicles in the section
Health and Safety Information.

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.

CAUTION: Danger of injury. Work on the
230<SP>volt system of the refrigeration
equipment must only be carried out by
trained specialist personnel.

NOTE: Work on the refrigerant circuit may only be
performed by persons who have a relevant
certificate of competence.

Vehicles with a refrigerated compartment are often
used to transport foodstuffs. For this reason,
additional hygiene regulations must be complied
with during repair work.

Aluminum and plastic are used to construct the
two different types of compartment found on
refrigerated vehicles.

The aluminum conversion is a very stable and
technically perfect variant. However, against this
the relatively high production costs and a lower
payload must be taken into account, because of
the weight of the aluminum conversion itself.

NOTE: Basic and in-depth training is offered on
the following topics. You will find an overview of
the complete range listed in the Training brochure
published by the Ford Service Organization.

The plastic conversion has developed into a light,
clean and economical alternative because of
constant further development of materials and
working techniques.

NOTE: The material combinations, the
workmanship and the working methods must
comply with the current food hygiene regulations.
For this reason, service and repair work on the
refrigerated conversion may only be performed by
authorized and specially trained technicians.

Refrigerated compartment constructions are often
made using both materials. The floor pan is made
of structured, slip-proof aluminum panels and the
wall and ceiling cladding is made of smooth
surfaced plastic elements.

CAUTION: PUR hard foam is flammable. If
PUR hard foam is overheated, it will burn
on its own with a brilliant yellowish flame.
It produces unpleasant choking and toxic
fumes. Special measures must be taken
when welding the vehicle body.

Polyurethane wall and ceiling elements are
manufactured using a sandwich principle. An
insulating polyurethane core is coated with food
grade ABS plastic on one side.

PUR hard foam does not decompose, is rot
resistant and is odorless. These properties make
it suitable for use as insulation.

Because of its closed cell structure, water uptake
by PUR hard foam is for the most part only a
problem at edges. Cut edges or other mechanically
worked surfaces must however be sealed with the
greatest care.

The conversion to a refrigerated vehicle is
performed as made-to-order production. The 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.

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Joining Techniques

Welding

Before welding work is performed on a vehicle
body, all safety measures for the protection of
people, modules and electrical components must
be observed.

NOTE: Before beginning the work, please refer to
the safety instructions and warnings in the chapter
Safety Instructions. Please also note the warnings
of the respective equipment manufacturer.

Resistance spot welding and MIG welding are the
most common techniques used in body
construction. During repair work, the welded
connection must be restored to be equivalent to
the original.

Resistance spot welding.

NOTE: Before starting the work, please refer to
the chapter on safety instructions.

In doing so, the repair welds must match the
standard of those produced in production in number
and diameter.

Preconditions for resistance spot welding:

• The panels to be welded overlap.

• The weld spot is accessible on both sides for

the electrodes.

• The shape and alignment of the weld electrodes

is correct.

• The resistance welding equipment is powerful

enough to be able to reproduce the production
spot weld diameter.

NOTE: The welding equipment settings and the
adjustment of the individual parameters are to be
made in accordance with the device manufacturer's
specifications.

Well-prepared welding flanges are a prerequisite
for a problem-free welded joint. This means:

• The welding flanges must lie perfectly flat to one

another.

• The welding flanges must be clean and free of

oil or grease on both sides.

• Welding primer (zinc-coated and conductive)

must be applied as corrosion prevention.

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