Repair of car body elements Ford Focus 1
Description and principle of operation
Introduction The body plays a significant role in the growing trend towards ever faster changes in model variants. Different customer groups are strongly influenced by...
Introduction The body plays a significant role in the growing trend towards ever faster changes in model variants. Different customer groups are strongly influenced by...
Protection of the body from corrosion
General information Care must be taken to maintain the corrosion protection material applied during the manufacture of the vehicles and/or to restore the protective...
General information Care must be taken to maintain the corrosion protection material applied during the manufacture of the vehicles and/or to restore the protective...
Repair of plastic parts
General information Due to differences in design, repair of plastic elements involves different repair methods: Thermoplastic straightening Welding of plastics (PC,...
General information Due to differences in design, repair of plastic elements involves different repair methods: Thermoplastic straightening Welding of plastics (PC,...
Water leaks
General information If water penetration occurs after body repair, the cause can be determined using the checks described below. A systematic and logical procedure is...
General information If water penetration occurs after body repair, the cause can be determined using the checks described below. A systematic and logical procedure is...
The sound of the wind
General information The noise of a car when driving cannot be avoided. The goal of all efforts of developers is to reduce wind noise. The quieter the noise produced by...
General information The noise of a car when driving cannot be avoided. The goal of all efforts of developers is to reduce wind noise. The quieter the noise produced by...
Removing unpainted dents
General information Minor dents can be repaired without damaging the paintwork. The dent is repaired from the inside using special straightening tools. Prerequisites...
General information Minor dents can be repaired without damaging the paintwork. The dent is repaired from the inside using special straightening tools. Prerequisites...
Noise, vibration and harshness
Introduction This chapter provides a brief overview of how noise, vibration and harshness (NVH) parameters manifest themselves in a vehicle and what corrective measures...
Introduction This chapter provides a brief overview of how noise, vibration and harshness (NVH) parameters manifest themselves in a vehicle and what corrective measures...
Clearance Checks — General Information
Design Features The Focus body is a completely new design. Not a single element of the body structure was borrowed from existing cars, and not a single element is a...
Design Features The Focus body is a completely new design. Not a single element of the body structure was borrowed from existing cars, and not a single element is a...
Checking underbody clearances
1. Frame dimensions - 3/5-door variants All dimensions have a tolerance of±3 mm. The detailed illustrations show the left side of the car. All dimensions are measured...
1. Frame dimensions - 3/5-door variants All dimensions have a tolerance of±3 mm. The detailed illustrations show the left side of the car. All dimensions are measured...
Checking frame and body clearances
1. Body dimensions - front - all models 2. All dimensions have a tolerance of±3 mm. All dimensions are measured from the center of the hole or edge of the panel using a...
1. Body dimensions - front - all models 2. All dimensions have a tolerance of±3 mm. All dimensions are measured from the center of the hole or edge of the panel using a...
Right hood hinge — removal and installation
Name Specification Hood hinge Removal 1. General notes: Before starting repairs, remove the front hood panel (left or right side). There is no need to remove the hood....
Name Specification Hood hinge Removal 1. General notes: Before starting repairs, remove the front hood panel (left or right side). There is no need to remove the hood....
Left Front Fender — Removal and Installation
Name Specification Wing Removal 1. General note. Remove the following components: headlight, bumper, windshield wiper/washer reservoir and wheel arch trim panel. 2. Wing...
Name Specification Wing Removal 1. General note. Remove the following components: headlight, bumper, windshield wiper/washer reservoir and wheel arch trim panel. 2. Wing...
Hood Latch Panel — Removal and Installation
Name Specification Hood Latch Panel Removal 1. General notes: The hood latch panel is a "hybrid" construction made of steel and plastic, which must be replaced if...
Name Specification Hood Latch Panel Removal 1. General notes: The hood latch panel is a "hybrid" construction made of steel and plastic, which must be replaced if...
Front cross member — removal and installation
Name Specification Crossbar Removal 1. General notes: Before starting repairs, remove the lock holder/grille panel, grille, headlights and bumper. Move electrical wiring...
Name Specification Crossbar Removal 1. General notes: Before starting repairs, remove the lock holder/grille panel, grille, headlights and bumper. Move electrical wiring...
Reinforcement of the wing apron panel — removal and installation
Name Specification Reinforcement of the apron panel Removal 1. General notes: Before starting repairs, remove the fender, hood and hood hinges. 2. Strengthening the...
Name Specification Reinforcement of the apron panel Removal 1. General notes: Before starting repairs, remove the fender, hood and hood hinges. 2. Strengthening the...
Inner reinforcement of the wing apron panel — removal and installation
Name Specification Apron panel Removal 1. General note. Before starting repairs, remove the apron panel reinforcement. 2. Strengthening the apron panel 1. Bend the tab...
Name Specification Apron panel Removal 1. General note. Before starting repairs, remove the apron panel reinforcement. 2. Strengthening the apron panel 1. Bend the tab...
Deformable element of the side member — removal and installation
Special tool Device for installing left deformable box profile 501065 Device for installing the right deformable box profile 501066 Name Specification Deformable element...
Special tool Device for installing left deformable box profile 501065 Device for installing the right deformable box profile 501066 Name Specification Deformable element...
Front side member section — removal and installation
General equipment: Measuring and straightening. Name Specification Spar section Section of the side member closing panel. Removal 1. General notes: Before starting...
General equipment: Measuring and straightening. Name Specification Spar section Section of the side member closing panel. Removal 1. General notes: Before starting...
Right front spar and left wing apron panel
General equipment: Measuring and straightening. Name Specification Reinforcement of the apron panel Spar with apron panel Removal 1. General notes: Before starting...
General equipment: Measuring and straightening. Name Specification Reinforcement of the apron panel Spar with apron panel Removal 1. General notes: Before starting...
Roof Panel (4-Door) — Removal and Installation
Name Specification Roof assembly Removal 1. CAUTION: Rout to a depth equal to twice the panel thickness in the area of the center roof cross member. Roof Remove the...
Name Specification Roof assembly Removal 1. CAUTION: Rout to a depth equal to twice the panel thickness in the area of the center roof cross member. Roof Remove the...
Roof panel (5-door) — removal and installation
Name Specification Roof assembly Removal 1. CAUTION: Rout to a depth equal to twice the panel thickness in the area of the center roof cross member. Roof Remove the...
Name Specification Roof assembly Removal 1. CAUTION: Rout to a depth equal to twice the panel thickness in the area of the center roof cross member. Roof Remove the...
Roof panel (station wagon) — removal and installation
Name Specification Roof assembly Removal 1. CAUTION: Rout to a depth equal to twice the panel thickness in the area of the center roof cross member. Roof Remove the...
Name Specification Roof assembly Removal 1. CAUTION: Rout to a depth equal to twice the panel thickness in the area of the center roof cross member. Roof Remove the...
Section and reinforcement of the outer panel of the 'A' pillar
Name Specification External panel of the pillar "A" Seal mounting panel Reinforcement panel of the pillar "A" Inner panel of the "A" pillar Reinforcement of the apron...
Name Specification External panel of the pillar "A" Seal mounting panel Reinforcement panel of the pillar "A" Inner panel of the "A" pillar Reinforcement of the apron...
Half door hinge — removal and installation
Name Specification Door hinge Removal 1. General note. To remove a door hinge section from the body, the door must be removed from the hinges. 2. Door Release the bolt....
Name Specification Door hinge Removal 1. General note. To remove a door hinge section from the body, the door must be removed from the hinges. 2. Door Release the bolt....
Lower trim panel (3-door)
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the doors, door seal, lower trim panel, lower door hinge, fender and...
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the doors, door seal, lower trim panel, lower door hinge, fender and...
Lower trim panel (5-door)
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the doors, door seal, lower trim panel trim, lower door hinges, fender...
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the doors, door seal, lower trim panel trim, lower door hinges, fender...
Lower Trim Panel Section (5-Door)
Name Specification Bottom trim panel Removal 1. General notes: Remove the door before starting repairs. Remove the following items: door seal and lower trim panel. Move...
Name Specification Bottom trim panel Removal 1. General notes: Remove the door before starting repairs. Remove the following items: door seal and lower trim panel. Move...
Front section of lower trim panel (3-door)
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the door, door seal, lower trim panel, lower door hinge, fender and inner...
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the door, door seal, lower trim panel, lower door hinge, fender and inner...
Front section of lower trim panel (5-door)
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the door, door seal, lower trim panel, lower door hinge, fender and inner...
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the door, door seal, lower trim panel, lower door hinge, fender and inner...
Rear section of the lower trim panel (5-door)
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the doors, weatherstrip, lower trim panel, lower door hinges and inner...
Name Specification Bottom trim panel Removal 1. General notes: Before beginning repairs, remove the doors, weatherstrip, lower trim panel, lower door hinges and inner...
B-Pillar and Reinforcement (3-Door)
Name Specification Stand "B" Seat belt mounting reinforcement panel Inner rear side panel Removal 1. General notes: Before starting repairs, remove the rear side panel...
Name Specification Stand "B" Seat belt mounting reinforcement panel Inner rear side panel Removal 1. General notes: Before starting repairs, remove the rear side panel...
B-Pillar and Reinforcement (5-Door)
Name Specification External panel of the B-pillar Reinforcement panel of the "B" pillar Inner panel of the B-pillar Removal 1. General notes: Remove the following items:...
Name Specification External panel of the B-pillar Reinforcement panel of the "B" pillar Inner panel of the B-pillar Removal 1. General notes: Remove the following items:...
Subframe and mounting system specifications
Tightening torque specifications Name Nm pound-foot pound-inch Bolt securing the power steering line clamp to the steering gear 23 17 - Steering gear heat shield...
Tightening torque specifications Name Nm pound-foot pound-inch Bolt securing the power steering line clamp to the steering gear 23 17 - Steering gear heat shield...
Cross member — removal and installation
Special tool Subframe alignment pins 205-316 (15-097A) Ball joint puller 211-020 (13-006) General equipment: Gearbox jack Allen key 5mm Removal All cars 1. NOTE: Make...
Special tool Subframe alignment pins 205-316 (15-097A) Ball joint puller 211-020 (13-006) General equipment: Gearbox jack Allen key 5mm Removal All cars 1. NOTE: Make...
Checking for body misalignment
1. CAUTION: Never expose the bumper surface to excessive heat. This may cause the bumper to warp. When collecting exhaust gases in the repair area, never connect a metal...
1. CAUTION: Never expose the bumper surface to excessive heat. This may cause the bumper to warp. When collecting exhaust gases in the repair area, never connect a metal...
Checking for misalignment of the lower part of the body (bottom)
1. NOTE: Underbody inspection and service procedures are specified. Measurements can be made using the SHARK electronic measuring system, laser measuring system, or...
1. NOTE: Underbody inspection and service procedures are specified. Measurements can be made using the SHARK electronic measuring system, laser measuring system, or...
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See other similar sections for Ford cars:
• General information: Repair on the road Ford Mondeo 1 and 2 (1993-2000)
• Body: Repair and maintenance Ford Taurus 1 and 2 (1986-1994)
• Power unit: Engine overhaul Ford Transit 2 (1986-2000, diesel)
• General information: Repair on the road Ford Mondeo 1 and 2 (1993-2000)
• Body: Repair and maintenance Ford Taurus 1 and 2 (1986-1994)
• Power unit: Engine overhaul Ford Transit 2 (1986-2000, diesel)
Focus 2
Focus Turnier 1
Focus 1
- General information
- Vehicle device
- Owner's manual
- Faults en route
- Maintenance
- First maintenance
- Second maintenance
- Applications
- Consumables and spare parts
- Auto mechanic tips
- Power unit
- Engine repair
- Engine seal parts
- Cooling system
- Exhaust system
- Supply system
- Clutch
- Car gearbox
- Front wheel drives
- Chassis
- Front suspension
- Rear suspension
- Steering
- Brake system
- Wheels and tires
- Body and coating
- Body elements
- Side doors
- Tailgate
- Salon elements
- Safety system
- Windshield wipers and washers
- Body Care
- Electrical equipment
- Instruments and motors
- Battery and alternator
- Egnition lock
- Engine management
- Headlights and lighting
- Switches and sensors
- Schematic diagrams
Focus Turnier 1
- General information
- Introduction to guide
- Car care
- Power unit
- Engine repair
- Lubrication system
- Cooling system
- Fuel injection (gasoline)
- Fuel injection (diesel)
- Ignition system
- Power and exhaust system
- Transmission
- Clutch and drive shafts
- Mechanical gearbox
- Automatic gearbox
- Chassis
- Car suspension
- Steering
- Wheels and tires
- Brake system
- Body
- Exterior
- Interior
- Heating and ventilation
- Electrical equipment
- Equipment and devices
- Lighting and signaling
- Power devices
- Electrical circuits
Focus 1
- General information
- Using the manual
- Identification codes
- Power unit
- Engine
- Engine 1.4/1.6 Zetec-SE
- Engine 1.6/1.8/2.0 Zetec-E
- Engine Duratec ST 2.0 l
- Engine Duratec 8V 1.6 l
- Diesel engine 1.8 l
- Engine cooling
- Fuel supply
- Accessory drive
- Launch system
- Ignition system
- Air and vapor
- Engine management
- Exhaust toxicity
- Exhaust system
- Automatic gearbox
- Clutch
- Mechanical gearbox iB5
- Mechanical gearbox MTX-75
- Mechanical gearbox MT285
- Chassis
- Front suspension
- Rear suspension
- Wheels and tires
- Front axle axles
- Brake system
- Hydraulic brake
- Anti-lock braking system
- Steering
- Body and coating
- Body panels
- Body elements
- Salon elements
- Glass, frames and mechanisms
- Windshield wipers and washers
- Car sunroof
- Seat belts
- Body repairs
- Back elements
- Electrical equipment
- Climate control
- Heating and ventilation
- Instruments and control lamps
- Battery and alternator
- Audio system
- Headlights and lighting
- Power distribution
- Electronic Function Group