Ford Tourneo Connect 2002, Owner'S Manual, Page: 2662 / 2797

Body:
Ensure that the flanges to be joined lie perfectly flat to one another.
Prepare a bare metal joint surface (inside and outside).
Notes on technique/method:
Carry out a test weld on a sample piece of the material coated in welding paste.
If any metal parts are located between the electrode arms then there will be a loss of
induction and therefore power (adjust current setting).
The power needs to be adjusted for high-strength low alloy steel.
Repeated welding on old welding points often leads to poor quality welds.
Keep the electrode tips as near as possible to an angle of 90° to the contact surface.
Keep the pressure on the electrodes for a short period after finishing the weld.
NOTE: Cool the electrodes in water after about 10 spot welds to ensure that the
welding results are consistent (not necessary on cooled electrodes).
The electrodes work best if their shape is convex. Clean the contact surface of the
electrodes regularly.
Resistance spot welding panels where the total thickness is 3 mm or more
For all repairs to modern Ford vehicles, spot-welding equipment should be suitable for
reliable welding of zinc-plated, high-strength and high-tensile steels in three or more
layers, up to 5 mm total thickness. If these requirements are not fulfilled, puddle welding
must be used for safety reasons. The electrical specifications (current, resistance, heat) of
the spot-welding equipment have different validity, depending upon the type of equipment.
Therefore, it is essential that the manufacturer's instructions are observed with regard to
the actual welding performance.
MIG / MAG welding
Setting up the equipment and co-ordinating the welding parameters
Any joins that are MIG/MAG welded in production must also be MIG/MAG welded during
repairs. Also during repairs, some resistance spot welds need to be replaced by puddle
welds.
If access is difficult, or if a suitably powerful spot welder (see above) for total panel
thicknesses of 3 mm or more is not available, resistance spot welding must be partially
replaced by puddle welding during repairs. In this case, the increased time needed and
the correspondingly more demanding corrosion protection requirements, must be taken
into account.
Welding repairs can only be carried out properly if the equipment is set up correctly and
all the welding parameters are co-ordinated.
Equipment:
Set up the equipment as directed by the manufacturer.
The hoses must be untwisted.
The core must be free of abraded rod particles.
The gas and current nozzles must be free of slag and scale residue.
Pay attention to the quality of the welding rod and the throughput of gas.
Body:
Ensure that the joint surface is perfect.
Prepare a bare metal joint surface.
Maintain the correct gaps (formation of roots).
Notes on technique/method:
NOTE: The increased application of heat during MIG welding destroys the welding
primer/zinc layer over a much larger area than during resistance spot welding, as a
result of which much more care needs to be taken when applying anti-corrosion
protection afterwards.
NOTE: A test weld should always be carried out to ensure that the welded joint is
not just a surface connection.
Attach the ground cable right next to the welding point (ensure that good contact is
made).
During puddle welding start welding on the lower panel to ensure adequate
penetration.
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