Ford Fiesta (2011 year). Manual — part 87

501-25-33

Corrosion protection measures during repair work. . . . . . . . . . . . . . .

501-25-37

Corrosion protection for the floor pan (example). . . . . . . . . . . . . . . .

501-25-38

Corrosion Damage/Corrosion Repair. . . . . . . . . . . . . . . . . . . . .

501-25-40

Sealer, Underbody Protection Material and Adhesives. . . . . . . . . . . . . ..

501-25-41

Cutting Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-41

Spot weld milling tool. . . . . . . . . . . . . . . . . . . . . . . . . . ..

501-25-42

Rod sander. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-42

Short stroke saw. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-42

Orbital saw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

501-25-43

Panel Beating Technique and Smart Repairs. . . . . . . . . . . . . . . . . .

501-25-43

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-43

Dent removal using special panel beating levers. . . . . . . . . . . . . . . ...

501-25-44

Dynamic puller with counter bearing . . . . . . . . . . . . . . . . . . . . .

501-25-44

Hollow leveling (removing dent without a dolly). . . . . . . . . . . . . . . . .

501-25-45

Dent removal using hammer and dolly. . . . . . . . . . . . . . . . . . . ...

501-25-45

Heat-induced material shrinking. . . . . . . . . . . . . . . . . . . . . . .

501-25-46

Lead loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-47

Paintless Dent Removal. . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-49

Plastic Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-49

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-51

Plastic welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-52

Plastic adhesive bonding. . . . . . . . . . . . . . . . . . . . . . . . .

501-25-53

GRP repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-55

Special Repair Techniques. . . . . . . . . . . . . . . . . . . . . . . . .

501-25-55

Cabriolet vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-55

Liquefied gas vehicles. . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-56

Refrigerated conversion vehicles. . . . . . . . . . . . . . . . . . . . . ...

501-25-57

Joining Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-57

Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-63

Soft soldering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

501-25-64

Rivets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

501-25-64

Bonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

501-25-65

Bonding and welding. . . . . . . . . . . . . . . . . . . . . . . . . . ..

501-25-65

Bonding and riveting. . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-66

Impact of Insufficient Repair Quality. . . . . . . . . . . . . . . . . . . . ...

501-25-68

Water Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-68

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-68

Test method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-69

Test with UV lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-69

Chalk/powder test. . . . . . . . . . . . . . . . . . . . . . . . . . . ...

501-25-70

Smoke test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

501-25-70

Stethoscope test. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-71

Ultrasonic detection. . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-71

Ultrasonic test device. . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-71

Workflow for tracing water entry. . . . . . . . . . . . . . . . . . . . . . .

501-25-72

Possible complaints and corrective actions. . . . . . . . . . . . . . . . . .

501-25-77

Wind Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-77

General information. . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-80

Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

501-25-82

Possible concerns with corrective measures. . . . . . . . . . . . . . . . . .

501-25-86

Noise, Vibration and Harshness. . . . . . . . . . . . . . . . . . . . . . .

501-25-

2

Body Repairs - General Information

501-25-

2

.

PAGE 2 OF 2

Specification

Finis Code

Description

-

5 030 492

Underbody protection

WSK-M7C89-A

1 219 834

Anti-corrosion wax

-

5 030 081

Cavity wax

S-M3G4620-A

1 128 983

Profiled butyl seal

-

1 205 996

Weld primer

WSK-M4G245-B

1 136 479

Clinched flange protection

WSS-M4G364-A

1 205 817

Seam sealing compound

-

1 143 255

Body sealing compound

-

1 203 241

Metal adhesive kit

WSK-M4G329-A

1 613 838

Windshield sealant

-

1 219 837

Adhesive spoiler set

G468061en

501-25-

3

Body Repairs - General Information

501-25-

3

SPECIFICATIONS

201

Description and Usage of Body Repair Literature

The purpose of this document is to give the vehicle
body specialist a general overview of possible
repair techniques for body repair on Ford vehicles.
Likewise, information about materials and tools to
be used is given.

No model-specific information is given. Such
information is saved in the respective Ford Etis
workshop manual. Supplementary or updated
information can be found in the Technical Service
Information.

Information on repair techniques, materials or tools,
which are not necessary for body repair on Ford
vehicles or which are not considered as
conventionally in use, are not listed in this
document.

Layout:

The general section is divided into the following
subject areas:

• How to use the document, with information on

the symbols used

• Health and safety information on using materials

and tools

• Information on bodywork construction and

materials used

• Workshop equipment and use of tools

• Damage Assessment and determining the

extent of the repair area

• Explanation of possible repair techniques for

body repair

• Possibilities of the repair or remedying leaks,

noises

Training:

The Ford Service Organization offers basic and
more in-depth training on much of the content of
this document. You can obtain an overview of the
entire training offering from the Ford Service
Organisation or on the Internet at
www.ford-training.de.

G468062en

501-25-

4

Body Repairs - General Information

501-25-

4

DESCRIPTION AND OPERATION

201

Symbols

Warnings and hazard notices

Warnings and hazard notices are shown in this
literature by WARNING, CAUTION and NOTE
indicators. These notices are always shown before
a job step which can be associated with an
immediate personal or material danger.

WARNING: This notice is used when failure
to exactly follow the instructions given in
this literature or failure to follow them at
all may result in a hazard to persons and/or
in persons being injured.

CAUTION: This notice is used when failure
to exactly follow the instructions or test
procedures given in this literature or failure

to follow them at all may result in damage
to the vehicle or to components.

NOTE: This notice is used when the operator
should be made aware of special or extra
information.

Symbols used

Symbols are used to graphically represent
additional information about the operation, tool or
materials. This information will not be shown
separately again in the text.

The symbols used in this and other body repair
manuals may be used alone as well as in
combination in a diagram.

Description

Des

cript

ion

Measuring tape

1

Saw

2

Abrasive cutter

3

hot air blower

4

Temperature specification (170°C in this
example)

5

Drill with 6mm diameter

6

Drill through one panel thickness with a
5 mm dia. drill

7

Description

Des

cript

ion

Drill through two panel thicknesses with
a 5 mm dia. drill

8

Drill through one panel thickness

9

Drill through two panel thicknesses

10

Apply substance

11

Soldering iron

12

Metal-Inert Gas (MIG) weld

13

Resistance Spot Weld

14

Welded seam (full or intermittent seam)

15

G468063en

501-25-

5

Body Repairs - General Information

501-25-

5

DESCRIPTION AND OPERATION

201