Ford Ecosport: Front End Sheet Metal Repairs / Removal and Installation - Front Side Member and Fender Apron Panel LH

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

NOTE: LH side shown, RH side similar.

1. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the following items:
   
   1. If Required:
      Remove the Radiator.
      Refer to: Radiator (303-03A Engine Cooling - 1.0L EcoBoost (92kW/125PS), Removal and Installation).
      Refer to: Radiator (303-03B Engine Cooling - 1.5L Duratec (90kW/120PS) – I3, Removal and Installation).
      Refer to: Radiator (303-03C Engine Cooling - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
      
   2. If Required:
      Remove the Engine.
      Refer to: Engine (303-01A Engine - 1.0L EcoBoost (92kW/125PS), Removal).
      Refer to: Engine - 5-Speed Manual Transmission – B5/IB5 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Removal).
      Refer to: Engine - 6-Speed Automatic Transmission – 6F15 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Removal).
      Refer to: Engine (303-01C Engine - 2.0L Duratec-HE (129kW/175PS), Removal).
      
   3. Remove the rocker panel moulding.
      Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
      
   4. Remove the brake booster.
      Refer to: Brake Booster - LHD (206-07 Power Brake Actuation, Removal and Installation).
      
   5. Remove the ABS module. Refer to: Anti-Lock Brake System (ABS) Module (206-09 Anti-Lock Brake System (ABS) and Stability Control, Removal and Installation).
      
   6. Remove the Front Impact Severity Sensor.
      Refer to: Front Impact Severity Sensor (501-20B Supplemental Restraint System, Removal and Installation).
      
   7. Remove the Front Seat.
      Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
      
   8. Remove the A-Pillar upper reinforcement.
      Refer to: A-Pillar Upper Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
      
   9. Remove the cowl side to front body pillar.
      Refer to: Fender Apron Panel Section (501-27 Front End Sheet Metal Repairs, Removal and Installation).
      

1. Reposition the carpet and wiring harness away from the working area.
   

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the floor side front member reinforcement.
   

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the dash penal reinforcement.
   

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds and remove the fender apron reinforcement panel.
   Use the General Equipment: Spot Weld Drill Bit

Installation

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards.

NOTE: LH side shown, RH side similar.

1. Assure correct placement of all components.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Drill plug welds holes in replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Drill plug welds holes in replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Install the front side member and properly position.
   Use the General Equipment: Locking Pliers

1. Install plug welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install plug welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install plug welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the dash penal reinforcement and properly position.
   Use the General Equipment: Locking Pliers

1. Install plug welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the floor side front member reinforcement and properly position.
   Use the General Equipment: Locking Pliers

1. Install plug welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Finish the repair area using typical metal finishing procedures.
   

1. Sealing work: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish using a Ford Motor Company approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Reposition the carpeting and the wiring harness to original location.
   

1. Install the following items:
   
   1. Install the cowl side to front body pillar.
      Refer to: Fender Apron Panel Section (501-27 Front End Sheet Metal Repairs, Removal and Installation).
      
   2. Install the rocker panel moulding.
      Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
      
   3. Install the Brake booster.
      Refer to: Brake Booster - LHD (206-07 Power Brake Actuation, Removal and Installation).
      
   4. Istall the ABS module.
      Refer to: Anti-Lock Brake System (ABS) Module (206-09 Anti-Lock Brake System (ABS) and Stability Control, Removal and Installation).
      
   5. If Required:
      Install the Engine.
      Refer to: Engine (303-01A Engine - 1.0L EcoBoost (92kW/125PS), Installation).
      Refer to: Engine - 5-Speed Manual Transmission – B5/IB5 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Installation).
      Refer to: Engine - 6-Speed Automatic Transmission – 6F15 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Installation).
      Refer to: Engine (303-01C Engine - 2.0L Duratec-HE (129kW/175PS), Installation).
      
   6. If Required:
      Install the Radiator.
      Refer to: Radiator (303-03A Engine Cooling - 1.0L EcoBoost (92kW/125PS), Removal and Installation).
      Refer to: Radiator (303-03B Engine Cooling - 1.5L Duratec (90kW/120PS) – I3, Removal and Installation).
      Refer to: Radiator (303-03C Engine Cooling - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
      
   7. Install the Front Impact Severity Sensor.
      Refer to: Front Impact Severity Sensor (501-20B Supplemental Restraint System, Removal and Installation).
      
   8. Install the Instrument Panel.
      Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
      
   9. Install the A-Pillar Trim Panel.
      Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      
   10. Install the Front Seat.
       Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
       

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).