Ford Fiesta: Front End Sheet Metal Repairs / Fender Apron Panel Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Removal

1.   WARNING: Before beginning any service procedure in this section, refer to 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 hood.
   

1. Remove the fender.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

1. Remove the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the front door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Rough straighten to dimensionally restore the vehicle to a pre-accident condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Grind welds at rear flange of the apron reinforcement panel.
   Use the General Equipment: Grinder

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. Remove the welds and remove the fender apron panel reinforcement.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Grinder

Installation

1. NOTE: If the factory-installed MIG brazed joints are replaced by MIG plug welds, plug welds must be placed in a different position.

   NOTE: These MIG welds must not be carried out on or in the immediate vicinity of existing MIG brazed seams as even the smallest amount of brazing solder can result in a reduction in strength of the weld seam.

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

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. Install the fender apron panel reinforcement and install welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   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 spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Refinish using a Ford approved paint system and typical refinishing techniques.
   

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

1. Install the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Install the front door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Install the fender.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the following items.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   

1. Install and align the hood.
   

1. Install the following items.
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Front Fog Lamp (417-01 Exterior Lighting, Removal and Installation).