Ford Fiesta: Front End Sheet Metal Repairs / Front Side Member Section. Removal and Installation

Special Tool(s) / General Equipment

Removal

1.   WARNING: Before beginning any service procedure in this manual, 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 following items.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

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. NOTICE: Due to the positions of the inner reinforcement(s), it is very important that the dimension provided is accurately met.

   NOTE: The cut shown is the final cut for the inner part.

   Carefully measure and cut the side member front inner frame rail.
   Use the General Equipment: Air Body Saw

1. Drill out the spot welds and position aside the bracket.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTICE: Do not cut inner part or reinforcements of the side member.

   Separating cut through outer part of the front side member.
   Carefully measure and cut the side member front outer frame rail.
   Use the General Equipment: Air Body Saw

Installation

1. Install the front side member section to the rail frame. Carefully measure and cut to fit repair area.
   Use the General Equipment: Air Body Saw

1. Carefully measure and cut the sectioning piece from service part.
   Use the General Equipment: Air Body Saw

1. Install the front side member section, spot welds and seam weld.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Position the bracket and install the seam weld.
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Drill and install plug weld.
   Use the General Equipment: 8 mm Drill Bit
   Use the General Equipment: MIG/MAG Welding Equipment

1. Stitch weld as indicated.
   Use the General Equipment: MIG/MAG Welding Equipment

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

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

1. NOTE: Seam sealing must be restored to factory original condition.

   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 following items.
   Refer to: Fender (501-02 Front End Body Panels, 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. Install and align the hood.
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).