Ford Fiesta: Side Panel Sheet Metal Repairs / A-Pillar Outer Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information, Description and Operation).
   

1. Remove the following items:
   Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Front Seat (501-10 Seating, Removal and Installation).
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Front Fog Lamp (417-01 Exterior Lighting, Removal and Installation).
   

1. Remove the fender apron panel reinforcement.
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

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

1. Remove the door hinges and door opening weatherstrip.
   

1. NOTICE: Use caution to cut the outer panel only.

   Carefully cut the A-pillar outer panel section.
   Use the General Equipment: Air Body Saw

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. Break the adhesive bond and remove the A-pillar outer panel.
   Use the General Equipment: Hot Air Gun

Installation

1. Carefully cut the replacement panel to fit repair area.
   

1. Drill plug weld holes in the replacement A-pillar outer panel.
   Use the General Equipment: 8 mm Drill Bit

1. Apply adhesive and install the replacement A-pillar outer panel as indicated.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Spot weld the door opening portion and the windshield flange area of the A-pillar panel.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Spot weld the lower portion of the A-pillar panel.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Seam and spot weld the A-pillar panel.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment

1. 1. Fill the cavity approximately 127 mm (5 in) with NVH foam.
      
   2. Immediately insert the baffle in to the NVH material before it has cured.
      Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Metal finish the repair area using typical metal finishing techniques.
   

1. Sand and prime repair area using a Ford approved paint system.
   

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 approved paint system.
   

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

1. Install the door hinges and door opening weatherstrip.
   

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

1. Install the apron panel reinforcement.
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

1. Install the following items:
   Refer to: Front Seat (501-10 Seating, Removal and Installation).
   Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Front Fog Lamp (417-01 Exterior Lighting, Removal and Installation).
   

1. Align the front door.
   Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
   

1. Install and align the hood.
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).