Note the fitted position of the special washer. It will be based on the CD platform, which will also form the basis for future models. Two independent vehicle variants are initially available on this CD platform - the Galaxy with its internal designation LMV (Luxury Multipurpose Vehicle) and the S-MAX with its internal designation SAV (Sport Activity Vehicle).
The main differences between the body of the S-MAX and the body of the Galaxy lie in the roof section and in the rear end of the vehicle. The roof of the S-MAX is flatter overall, while the rear is shorter and more sloped. Consequently, there are differences in the shape and size of all of the glass surfaces of the S-MAX and Galaxy.
Crash element
At the front of the vehicle there is a steel plate crash element connected to the side member by threaded connections. This crash element can absorb light impacts of up to about 15 km/hr. Because of the threaded connections, the crash element can be changed very quickly. The front crash element is identical on both vehicle variants.
NOTE:Deformed crash elements must not be straightened or repaired.
Heavier impacts which can no longer be absorbed by the crash element must be absorbed by the side members or the floor pan structure. Depending on the extent of the damage, the side members can be replaced in whole or in part (see subsection 501-27).
A steel cross member is also installed at the rear of the vehicle using threaded connections. This forms a connection between the ends of the two side members and therefore contributes to an increase in passive safety in the event of rear end impact. This bolted-on crossmember absorbs the impact energy of minor impacts and thus prevents deformation of the side members and therefore the body structure. More severe impacts at the rear are absorbed by the rear panel, the reinforcement of the rear panel, the side members and the luggage compartment floor panel. It is possible to perform partial replacements of the side members and the luggage compartment floor panel (see subsection 501-30).
The crash element can be changed very quickly because of the threaded connections. The rear crash element is identical on both vehicle variants.
The mounting for the towing eye is integrated in the front and rear crash element.
Crash element
Arrows
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Mountings for the towing eyes
Laser weld seams on the side members
Laser weld seams are located on the front and rear side members. These laser weld seams are use to join body components of different material quality and different material thickness to each other.
Cut locations exactly on the laser weld seams are not permitted, as at present no joining techniques are approved for use in repair procedures that would re-create joins of the same quality.
NOTE:In the event of damage or repair work in these areas, the corresponding requirements is subsection 501-27 and 501-30 must be taken into account.
Location of the laser weld seams at the front end (S-MAX and Galaxy)
1
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Quarter panel / rear lamp mounting panel
2
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Rear side member / wheelhouse reinforcement
3
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Apron panel reinforcement / A-pillar
These MIG brazed joints must be replaced by MIG welds at another place if a repair is performed.
- These MIG welds must not be carried out on or near existing MIG brazed seams as even the smallest amount of brazing material can result in a reduction in the strength of the weld seams.
- When performing repairs in these areas of the body, the relevant requirements is subsection 501-27, 501-29 and 501-30 must be observed.
High strength and super high strength steel panels
High strength and, in some cases, super high strength steel panels are used on both vehicle variants (S-MAX and Galaxy).
NOTE:The instructions for working on high strength steel panels given in subsection 501-25 must be followed during body repair work.
The A and B-pillar reinforcements are made of super high strength Usibor steel (1500). These components must only be replaced as a complete part during repairs. Replacement of partial sections is not permitted, as the required MIG continuous seam in the cut area would lead to structural changes in the steel which would cause a significant loss of strength.
Due to their strength, it is not always possible to process these components with conventional body repair tools. Additional preparations are required for MIG puddle welding.
NOTE:The corresponding requirements in section 501-29 must be followed when performing repairs in these areas of the body.
Super high strength steel panels (S-MAX and Galaxy, Galaxy shown)
Galvanised body panels
On S-MAX and Galaxy vehicles, all external and corrosion prone steel body panels are galvanised on both sides.
The roof and some internal reinforcement panels on the floor pan and on the A-, B- and C-pillars are not zinc plated.
NOTE:The instructions for working on zinc plated steel panels given in subsection 501-25 must be followed during body repair work.
Further corrosion protection measures
Clinched flange sealer is not applied to the hood, tailgate and the doors until after the dip priming stage.
When applying clinched flange sealer as part of body repair work, an overlap of the clinched outer panel of at least 2 mm must be taken into account in addition to the width of the seam.
NOTE:When body repairs are performed or if these components are renewed, this procedure must be observed.
Clinched flange sealing
