Ford Focus RS (2011 year). Instruction — part 126
Lubricants, Sealers and Adhesives
Specification
Part number
WSK-M11 P57-A1
1 102 109
PU glass adhesive (150 ml)
G371067en
501-28-
2
Roof Sheet Metal Repairs
501-28-
2
SPECIFICATIONS
Roof Panel
1. Repair parts
• Roof panel
• Middle roof rail
Removal
1. General Notes
• Required removal operations: Windshield,
side windows, tailgate, headliner, interior trim
panels and rear lights.
2. NOTE:
• Release the screw fixings (4 off) at the sides on
the middle roof rail.
• Warm the bonded areas of the roof panel from
outside (front and rear roof crossmembers)
before removal. The middle roof rail will be
removed with the roof.
Roof
• Mill out the spot welds.
3. Rear roof panel
1. Mill out the spot welds.
2. Grind out the spot welds from the rear.
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. Roof panel rear
• Drill holes for puddle welding.
2. NOTE: Measure out the correct installation
position of the roof rail on the vehicle.
G371069en
501-28-
3
Roof Sheet Metal Repairs
501-28-
3
REMOVAL AND INSTALLATION
Install the middle roof rail
1. Apply PU glass adhesive.
2. Resistance spot weld.
3. Prepare the bonded areas
• Apply PU glass adhesive.
4. Offer up the roof panel and weld in place.
1. Resistance spot weld.
G371069en
501-28-
4
Roof Sheet Metal Repairs
501-28-
4
REMOVAL AND INSTALLATION
2. Puddle weld.
5. Weld the roof into place
1. Puddle weld.
2. Resistance spot weld.
G371069en
501-28-
5
Roof Sheet Metal Repairs
501-28-
5
REMOVAL AND INSTALLATION
SECTION 501-29 Side Panel Sheet Metal Repairs
PAGE
CONTENTS
SPECIFICATIONS
501-29-2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
REMOVAL AND INSTALLATION
501-29-3
Rocker Panel — 3-Door. . . . . . . . . . . . . . . . . . . . . . . . . .
501-29-4
Rocker Panel — 5-Door. . . . . . . . . . . . . . . . . . . . . . . . . .
501-29-6
A-Pillar Outer Panel Section and Reinforcement. . . . . . . . . . . . . . . ...
501-29-10
B-Pillar and Reinforcement — 3-Door. . . . . . . . . . . . . . . . . . . .
501-29-13
B-Pillar and Reinforcement — 4-Door/5-Door/Wagon. . . . . . . . . . . . . .
501-29-
Side Panel Sheet Metal Repairs
501-29-
1
.
VEHICLE APPLICATION:
Lubricants, Sealers and Adhesives
Specification
Part number
WSK-M11 P57-A1
1 102 109
PU glass adhesive (150 ml)
WSK-M4 G200 A/B
1 203 241
Metal adhesive kit - 2-component
G371071en
501-29-
2
Side Panel Sheet Metal Repairs
501-29-
2
SPECIFICATIONS
Rocker Panel — 3-Door
1. Replacement parts
• Rocker panel
Removal
1. General notes
• Necessary removal work: doors, front and
rear seats, rocker panel inner trim, A- and
B-pillar inner trim.
• Fold back the carpets and move the wiring
harness out of the working area.
2. NOTE: The cut locations may vary depending
on the extent of the damage. When cutting
the quarter panel (pos. 1) ensure there is a
sufficient gap (min. 10 mm) from the
horizontal edge of the panel so that a strip
can be left for welding.
Rocker panel
1. Cut locations.
2. Mill out the spot welds.
3. Grind down one panel thickness at the wheel
arch edge.
E56507
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. NOTE: Remove the damping matting which
is adhesive-bonded to the quarter panel.
Before inserting the rocker panel offer up a
panel strip to the quarter panel and insert.
The panel strip can be cut from the
remainder of the new part.
Panel strip
• Resistance spot weld (tack weld only).
E56508
2. Rocker panel
1. Apply two-component metal adhesive to the
clinched flange.
2. Continuous MIG weld.
3. MIG intermittent weld seam.
E56521
3. Rocker panel
1. Continuous MIG weld.
2. Resistance spot weld.
E56509
G450966en
501-29-
3
Side Panel Sheet Metal Repairs
501-29-
3
REMOVAL AND INSTALLATION
Rocker Panel — 5-Door
1. Replacement Parts
• Rocker panel
Removal
1. General notes
• Required removal operations: Doors, door
hinges, front and rear seats, door sill inner
trim, A- B- and C- pillar inner trim.
• Fold back the carpets and move the wiring
harness out of the working area.
NOTE: The cut location may vary depending upon
the extent of the damage. The repair shown
describes a partial rear repair.
2. Rocker panel
• Cut locations.
E55356
3. Rocker panel
1. Cut locations.
2. Grind out the spot welds.
3. Grind down one panel thickness at the wheel
arch edge.
E55357
4. Rocker panel
1. Mill out the spot welds.
2. Heat the area (approx. 170°) and detach the
NVH element.
E55363
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. Rocker panel
• Drill holes for puddle welding.
E55358
2. Rocker panel
1. Apply two-component metal adhesive to the
clinched flange.
2. Apply PU glass adhesive to the NVH
element.
3. Continuous MIG weld.
G371075en
501-29-
4
Side Panel Sheet Metal Repairs
501-29-
4
REMOVAL AND INSTALLATION
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