Ford Focus RS (2011 year). Manual — part 125
•
Fender panel reinforcement
• Resistance spot weld.
E55242
G371039en
501-27-
5
Front End Sheet Metal Repairs
501-27-
5
REMOVAL AND INSTALLATION
Front Side Member Section
General Equipment
Measurement or alignment angle system
1. Replacement Parts
• Outer side member
• Inner side member
• Crossmember retaining flange
Removal
1. General Notes
• Required removal operations: Bumper, hood,
fender, front module, headlamps and
crossmember with crash elements.
NOTE: The cuts in the side member must be offset
to one another.
2. Overview of cuts
1. Inside of member.
2. Outside of member.
1
2
1
2
E45788
3. NOTE: Cut through the complete cross
section of the side member using a large
jigsaw. This is the final cut on the outside of
the member.
Outer side member
• Cut location.
E45789
20 mm
4. Inner side member
1. Cut location.
2. Mill out the spot welds.
2
1
E45790
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 501-25A must be followed.
1. Inner side member
• Continuous MIG weld.
E45791
G287706en
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Front End Sheet Metal Repairs
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6
REMOVAL AND INSTALLATION
2. Outer side member
1. Continuous MIG weld.
2. Resistance spot weld.
E45792
1
2
2
3. Crossmember retaining flange
• Continuous MIG weld.
E45801
G287706en
501-27-
7
Front End Sheet Metal Repairs
501-27-
7
REMOVAL AND INSTALLATION
Front Side Member and Fender Apron Panel LH
General Equipment
Measurement and alignment angle system
1. Replacement parts
• Outer side member
• Inner side member
• Side member inner reinforcement
• Crossmember retaining flange
• Apron panel
• Inner apron panel reinforcement
• Front module bracket
Removal
1. General information
• The apron panel reinforcement is already
removed before commencing the repair.
• Necessary removal work: radiator, drive
aggregates, crossmember with crash
elements, crash padding and A-pillar trim.
• Move carpets and wiring out of the working
area.
2. NOTE: The cross member retaining flange
is already detached from the side member
during removal work.
Front module bracket
• Mill out the spot welds.
E45763
3. NOTE: After the rough separating cut both
panel layers of the side member connection
are accessible.
Inner apron panel reinforcement
1. Separating cut.
2. Mill out the spot welds (two panel
thicknesses).
E45764
1
2
4. Apron panel
• Mill out the spot welds.
E45765
5. Outer side member
1. Rough separating cut.
2. Mill out the spot welds.
3. Grind out the weld seam.
E45766
2
1
2
3
2
2
6. Outer side member (remainder)
1. Mill out the spot welds.
G509741en
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Front End Sheet Metal Repairs
501-27-
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REMOVAL AND INSTALLATION
2. Mill out the spot welds (two panel
thicknesses).
E45767
1
2
7. Side member inner reinforcement
• Mill out the spot welds.
E45768
8. NOTE: Cut dimensions measured from the
laser weld seam.
Inner side member
• Separating cut.
E45769
15 mm
Installation
NOTE:
• Fit the inner and outer side members as well as
the crossmember retaining flange using the
alignment angle and fix in place.
• 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. Inner side member
• Continuous MIG weld seam.
E59296
2. Side member inner reinforcement
• Offer up the new part and resistance spot
weld it.
E45768
NOTE: Determine the position of the holes for
puddle welding on the vehicle.
3. Outer side member
G509741en
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Front End Sheet Metal Repairs
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REMOVAL AND INSTALLATION
• Drill holes for puddle welding (diameter: 10
mm).
E45770
4. Outer side member
1. Resistance spot weld.
2. Puddle weld.
3. Continuous MIG weld seam.
E45771
1
2
2
3
1
1
5. Apron panel
• Drill holes for puddle welding.
E45772
6. Apron panel
• Puddle weld.
E45773
7. Inner apron panel reinforcement
1. Continuous MIG weld seam.
2. Resistance spot weld.
E45774
1
2
2
8. Front module bracket
• Resistance spot weld.
E45763
9. Crossmember retaining flange
G509741en
501-27-
10
Front End Sheet Metal Repairs
501-27-
10
REMOVAL AND INSTALLATION
• Continuous MIG weld seam.
E45801
G509741en
501-27-
11
Front End Sheet Metal Repairs
501-27-
11
REMOVAL AND INSTALLATION
SECTION 501-28 Roof Sheet Metal Repairs
PAGE
CONTENTS
SPECIFICATIONS
501-28-2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
REMOVAL AND INSTALLATION
501-28-3
Roof Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-28-
Roof Sheet Metal Repairs
501-28-
1
.
VEHICLE APPLICATION:
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