Ford Focus RS (2011 year). Instruction — part 127
4. Resistance spot weld.
E55359
3. Rocker panel
• Puddle weld.
E55360
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A-Pillar Outer Panel Section and Reinforcement
General Equipment
Measurement and alignment angle system
1. Replacement parts
• A-pillar outer panel
• A-pillar inner panel
• A-pillar reinforcement
• A-pillar/fender apron panel reinforcement
Removal
1. General notes
• The fender apron panel reinforcement is
already removed before commencing the
repair.
• Required removal operations: A-pillar trim
panel, rocker panel trim and driver or
passenger seat.
• Move the carpeting and the wiring away from
the working area.
2. A-pillar/fender apron panel reinforcement
• Mill out the spot welds.
E56215
NOTE: To gain access to the front area of the
B-pillar inner panel, the separating cut on the outer
rocker panel must be made according to the
specified dimensions (550 mm).
3. Outer A-pillar
1. Cut point.
2. Mill out the spot welds.
3. Mill out the spot welds (two panel
thicknesses).
E56216
550 mm
4. A-pillar reinforcement
1. Mill out the spot welds.
2. Heat the area (approx. 170°) and detach the
NVH element.
E56217
5. NOTE: To gain access to the original A-pillar
inner panel join, the B-pillar inner panel must
be cut at the front and removed. The part cut
away will be re-used for the installation.
B-pillar inner panel
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1. Cut point.
2. Mill out the spot welds.
6. Inner A-pillar
1. Cut point.
2. Mill out the spot welds.
3. Mill out the spot welds (two panel
thicknesses).
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. Inner A-pillar
1. Continuous MIG weld.
2. Resistance spot weld.
2. A-pillar reinforcement
• Drill holes for puddle welding (diameter: 10
mm).
3. NOTE: Only tack-weld A-pillar reinforcement.
The final weld joint is made with the outer
A-pillar installed. The puddle weld areas
(item 2) on the A-pillar reinforcement must
be ground down, otherwise the outer A-pillar
cannot be inserted correctly.
A-pillar reinforcement
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1. Apply PU glass adhesive to the NVH
element.
2. Puddle weld.
3. Resistance spot weld.
E56223
4. NOTE: The puddle weld areas on the B-pillar
inner panel must be ground down, otherwise
it cannot be installed using resistance spot
welding.
B-pillar inner panel
• Puddle weld.
E56222
5. B-pillar inner panel
1. Continuous MIG weld.
2. Puddle weld.
3. Resistance spot weld.
E56240
6. Outer A-pillar
• Drill holes for puddle welding (diameter: 10
mm).
E56224
7. Outer A-pillar
1. Continuous MIG weld.
2. Puddle weld.
3. Resistance spot weld.
E56225
8. NOTE: Only tack-weld A-pillar/fender apron
panel reinforcement. The final welded joint
is made with the fender panel reinforcement
installed.
A-pillar/fender apron panel reinforcement
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• Resistance spot weld.
E56226
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REMOVAL AND INSTALLATION
B-Pillar and Reinforcement — 3-Door
General Equipment
Measurement and alignment angle system
1. Replacement parts
• B-pillar inner panel
• B-pillar reinforcement
Removal
1. General notes
• Necessary removal work: Front door, B-pillar
trim panel, rocker panel trim, headliner, front
and rear seats.
• Fold back the carpets and move the wiring
harness out of the working area.
2. NOTE: If the B-pillar inner panel is also being
renewed, the cut on the upper B-pillar must
be made according to dimensions.
Depending on the damage, it is also possible
to carry out a partial replacement of the
B-pillar reinforcement.
B-pillar reinforcement
1. Cut point.
2. Mill out the spot welds.
3. Mill out the spot weld and drill out to 10 mm.
4. Cut location for partial replacement.
E56463
95 mm
3. Inner B-pillar
1. Cut locations.
2. Mill out the spot welds.
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REMOVAL AND INSTALLATION
3. Rough cut location.
E56464
155 mm
130 mm
4. NOTE: The spot welds at pos. 1 only join the
rear panel layers.
Inner B-pillar
1. Mill out the spot welds from the rear using
the spherical milling cutter.
2. Mill out the spot welds (three panel
thicknesses).
E56465
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. Inner B-pillar
• Drill holes for puddle welding (two panel
thicknesses).
E56466
2. NOTE: Only tack-weld the B-pillar inner panel
to the lower rocker panel. The final weld joint
is made with the B-pillar reinforcement and
quarter panel installed.
Inner B-pillar
1. Continuous MIG weld.
2. Puddle weld.
3. Resistance spot weld.
E56467
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REMOVAL AND INSTALLATION
3. NOTE: Only tack-weld the B-pillar
reinforcement in the areas of the door and
side window cut-out and the lower rocker
panel. The final welded joint is made with the
quarter panel installed.
B-pillar reinforcement
1. Continuous MIG weld.
2. Puddle weld.
3. Resistance spot weld.
E56468
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REMOVAL AND INSTALLATION
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