Ford Focus RS (2011 year). Manual — part 124
the edge of the steel panel using a
symmetrically adjusted measuring gauge.
• Measuring points 1, 2, 3, 4, 6, 7, 10 and 11
are measured in the curve and represent the
greatest distance to the measuring point
opposite.
• The detail views of measuring points 5, 8, 9
and 12 are shown looking from the vehicle
interior outwards.
Measuring points and dimensions
4 - 7 = 1136 mm
1 - 10 = 992 mm
5 - 8 = 711 mm
2 - 11 = 1281 mm
9 - 12 = 838 mm
3 - 6 = 1025 mm
G371030en
501-26-
57
and Tolerance Checks
501-26-
57
GENERAL PROCEDURES
E62631
1
3
2
10
11
12
7
6
9
8
5
4
5
6
7
9
8
10
2
1
3
4
11
12
12. Body dimensions, rear (wagon)
• All dimensions have a tolerance of ± 3 mm.
All dimensions were determined starting from
the center of the welded flange using a
symmetrically adjusted measuring gauge.
G371030en
501-26-
58
and Tolerance Checks
501-26-
58
GENERAL PROCEDURES
Measuring points and dimensions
3 - 6 = 1276 mm
1 - 4 = 1155 mm
2 - 5 = 906 mm
E62632
1
2
3
5
6
4
13. Body dimensions, interior (wagon)
• All dimensions have a tolerance of ± 3 mm.
All dimensions were determined starting from
G371030en
501-26-
59
and Tolerance Checks
501-26-
59
GENERAL PROCEDURES
the center of the welded flange using a
symmetrically adjusted measuring gauge.
Measuring points and dimensions
5 - 6 = 1441 mm
1 - 4 = 1458 mm
2 - 3 = 1442 mm
2
3
6
5
4
1
E62633
G371030en
501-26-
60
and Tolerance Checks
501-26-
60
GENERAL PROCEDURES
SECTION 501-27 Front End Sheet Metal Repairs
PAGE
CONTENTS
REMOVAL AND INSTALLATION
501-27-2
Fender Apron Panel Section. . . . . . . . . . . . . . . . . . . . . . . ..
501-27-4
(44 277 4)
Fender Apron Panel Reinforcement. . . . . . . . . . . . . . . ...
501-27-6
Front Side Member Section. . . . . . . . . . . . . . . . . . . . . . . .
501-27-8
Front Side Member and Fender Apron Panel LH. . . . . . . . . . . . . . . ...
501-27-
Front End Sheet Metal Repairs
501-27-
1
.
VEHICLE APPLICATION:
Fender Apron Panel Section
1. Replacement parts
• Apron panel section
• Front module bracket
• Inner apron panel reinforcement
Removal
1. General information
• The apron panel reinforcement is already
removed as a sectional replacement before
repair work starts.
• Necessary removal work: Bonnet, wing,
bumper, door, front module, headlamp and
wheelhouse liner.
2. Front module bracket
• Mill out the spot welds.
E62220
3. Apron panel and apron panel inner
reinforcement
1. Separating cut.
2. Mill out the spot welds.
E62221
4. Apron panel
• Mill out the spot welds.
E62222
Installation
NOTE: Before resistance spot welding of body
panels with a total panel thickness of 3 mm and
greater, the welding equipment instructions
contained in sub-section 501-25 must be followed.
1. Apron panel
• Resistance spot weld.
E62223
2. Apron panel and apron panel inner
reinforcement
1. Continuous MIG weld seam.
G531298en
501-27-
2
Front End Sheet Metal Repairs
501-27-
2
REMOVAL AND INSTALLATION
2. Resistance spot weld.
E62224
3. Front module bracket
• Resistance spot weld.
E62220
G531298en
501-27-
3
Front End Sheet Metal Repairs
501-27-
3
REMOVAL AND INSTALLATION
Fender Apron Panel Reinforcement(44 277 4)
1. Replacement Parts
• Fender panel reinforcement
Removal
NOTE: Where possible, a partial replacement of
the fender panel reinforcement is preferred to a
complete replacement, as this can save a
considerable amount of time on assembly work in
the inner area of the A-pillar. The partial
replacement options shown do not require the MIG
brazed joints on the A-pillar to be detached.
1. General notes
• Necessary removal work: Bonnet, wing,
bumper, door, front module, headlamp and
wheelhouse liner.
2. Fender panel reinforcement
• Cut locations for partial replacement.
E55225
3. Fender panel reinforcement
1. Mill out the spot welds.
2. Grind out the MIG brazed joints.
2
1
1
E55226
Installation
NOTE: Before resistance spot welding of body
panels with a total panel thickness of 3 mm and
greater, the welding equipment instructions
contained in sub-section 501-25 must be followed.
1. Prepare fender panel reinforcement
• Cut off the sheet metal tabs, leaving a
residual flange of approx. 5 mm.
E55239
2. NOTE:
• When carrying out a repair, the MIG brazed
joints made during vehicle production must be
replaced by MIG weld joints in a different
location
(see diagram E55241).
• These MIG welds must not be carried out on or
near existing MIG brazed seams as even the
smallest amount of brazing solder can result in
a reduction in the strength of the weld seam.
Fender panel reinforcement
• Continuous MIG seam weld.
E55241
3. NOTE: After carrying out the repair carefully
apply cavity seal. Also treat the areas of the
original MIG brazed joints.
G371039en
501-27-
4
Front End Sheet Metal Repairs
501-27-
4
REMOVAL AND INSTALLATION
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