Ford Fusion: Body Repairs - General Information / Welding Precautions. General Procedures
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WARNING:
Invisible ultraviolet and infrared rays emitted in welding
can injure unprotected eyes and skin. Always use protection such as a
welder's helmet with dark-colored filter lenses of the correct density.
Electric welding will produce intense radiation, therefore, filter plate
lenses of the deepest shade providing adequate visibility are
recommended. It is strongly recommended that persons working in the weld
area wear flash safety goggles. Also wear protective clothing. Failure
to follow these instructions may result in serious personal injury.
WARNING:
Always wear protective equipment including eye protection
with side shields, and a dust mask when sanding or grinding. Failure to
follow these instructions may result in serious personal injury.
NOTICE:
SRS components should always be depowered and disconnected before beginning any welding procedure.
NOTICE:
Electronic modules and related wiring can be damaged when
exposed to heat from welding procedures. Carefully disconnect and
remove, or position away from heat affected areas.
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A test weld should always be carried out on a test sample.
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The correct protective clothing should always be worn.
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Always work in a well ventilated area to avoid accumulation of noxious and oxygen displacing gases.
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Place protective covers around components and wiring harnesses to protect from welding spatter.
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Use grinding discs and wire brushes dedicated to the type of material being welded.
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Follow equipment manufacturer's prescribed procedures
and equipment settings for the type of weld being used. ER70S-3 or
ER70S-6 wire is typically used for MIG welding on steel.
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Disconnect and isolate battery ground cable.
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Components made of Boron, Martensitic, HSS
(high-strength steel) and UHSS (ultra high-strength) steel should not be
heated to straighten or repair. Severely bent or kinked components
should be replaced with new ones.
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Factory welds may be substituted with either STRW (squeeze-type resistance welding) spot welds or MIG plug welds.
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MIG plug welds must equal factory welds in both location and quantity.
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MIG plug weld holes should equal 8 mm (0.31 in) diameter.
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Resistance spot welds must equal factory welds in quantity and be placed adjacent to original weld location.
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Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
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Use of a weld-through primer is recommended where applicable.
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When welding, always place the ground clamp as close as possible to the weld area.
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Never connect the welder ground clamp to the vehicle subframe.
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Never weld a vehicle subframe, steering or suspension component. Service is through replacement only.
Other information:
Removal
Turn the ignition switch to the OFF position and apply the parking brake.
Remove the air cleaner.
Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
Remove the air cleaner outlet pipe.
Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distributio..
Note: Depending on your vehicle option
package, the controls may look different
from what you see here.
Directing Air to the Instrument Panel Air Vents
Press and release the button to
direct airflow to instrument
panel air vents.
Directing Air to the Footwell Air Vents
Press and release the button to
direct airflow to footwell air
vents.
Setting the Blower Motor Speed
Turn the control t..