Ford Tourneo Connect 2002, Owner'S Manual

Page: 2661 / 2797

Small, sharp dents that face outwards can be worked on with a copper electrode.
Flattening using a flame and body files
NOTE: When applied correctly, this method can be used with all the attached
parts still in place (roof headlining, wiring harnesses etc.).
Small, soft dents (only slight stretching): Working at the edges of the dent in an inward
spiral pattern, the dent is heated with an oxyacetylene torch (torch size 1 - 2 mm, excess
gas flame) to approx. 250° C.
Working rapidly with a body file extracts heat from the edge area until the dent is
flattened. Preferably alternate between two files. This increases the amount of heat that
can be extracted.
Lead loading of panels
Lead loading is the best repair method for smoothing joins on sectional repair joins or for
rectifying small uneven areas on a panel surface.
Advantages:
Excellent bonding on bare metal surfaces.
Very good moulding properties.
Good properties for re-shaping.
Permanent shape.
Heat expansion is the same as steel.
NOTE: Tin alloy: PB 25% / 75%. Use an extraction unit. Breathing equipment.
Process: Hammer the applied lead loading before finishing it to remove air bubbles.
Welding and soldering repairs
Safety measures
NOTE: Refer to the notes in the chapter "Protective Equipment/Safety at Work".
Disconnect the battery negative terminal and cap the terminals in order to protect the
electronic modules in the vehicle (ABS, airbag etc.).
Do not allow electronic units or lines to come into contact with the ground connection or
the welding electrode.
Remove the battery before carrying out welding work in its vicinity.
Utmost care must be taken when welding near the fuel tank or other components that
contain fuel. If the tank filler neck or a fuel line must be detached to allow access for
welding work, then the fuel tank must be drained and removed.
Never weld, braze or solder on components of a filled air conditioning system. The same
applies if there is a risk of the air conditioning system heating up.
Connect the ground connection of the electrical welder directly to the part that is to be
welded. Ensure that there are no electrically insulating parts between the ground
connection and the welding point.
Adjacent vehicle parts and adjacent vehicles must be shielded against flying sparks and
heat.
Resistance spot welding
90% of welding in production is done by resistance spot welding. As a rule, the joining
technique used in production should also be used for repairs. The number and diameter of
repair spot welds must be the same as in production. Alternative joining techniques must
only be used in exceptional cases.
Setting up the equipment and co-ordinating the welding parameters
Equipment:
Follow the equipment manufacturer's instructions for the equipment settings.
Select the correct electrode arms (as short as possible).
Align the electrode arms and tips exactly.
Electrode tips should be convex (rough shaping with a file, fine shaping with a sanding
block).
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