Ford Fiesta: Front End Sheet Metal Repairs / Front Side Member and Fender Apron Panel LH. 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. If required, dimensionally restore vehicle to pre-accident condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

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

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

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

1. Grind out the spot welds.
   Use the General Equipment: Grinder

1. Grind out the spot weld.
   Use the General Equipment: Grinder

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

1. Grind out from inside.
   Grind out the spot welds and remove the front side member section.
   Use the General Equipment: Grinder

Installation

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. Check for dimensional accuracy before welding.
   Install the LH fender apron panel and plug welds.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   Use the General Equipment: MIG/MAG Welding 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 plug welds.
   Use the General Equipment: MIG/MAG Welding Equipment

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

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

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