Clearance Checks — General Information (Body and coating / Body repairs / Ford Focus 1 1998-2004)

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 modification of previously used elements.

The lock panel and crossbar are completely new in design. The wings are bolted to the body.

Pos.	Spare Part No	Name
1	-	Lock panel
2	-	Wing
3	-	Crossbar

Soldered joints made using hard soldering technology None of the Focus models have any soldered joints made using hard soldering technology.

High-strength steel elements

All Focus models use high-strength steel components.

NOTE: For all repairs, follow the work procedures outlined in the Body Repair Manual (501-25A).

NVH events

In the Focus, NVH elements designed to prevent noise penetration are located in the bonnet panel, the A and B pillars, and the D pillar on the wagon. The NVH elements are a carrier plate with compressed insulating material located at the edges. The body is heated to approximately 170°C during immersion priming. At this temperature, the insulating material expands, sealing the gaps between the carrier plate and the body.

NOTE: When performing repairs, NVH components should be reinstalled or replaced. Missing or damaged NVH components may result in engine and road noise entering the vehicle's cabin.

Measures to ensure NVH parameters

Pos.	Spare Part No	Name
1	-	Hood front panel
2	-	Stand "A"
3	-	Stand "B"
4	-	D-pillar

Restoring NVH characteristics

NVH elements without sealant are installed during repair to ensure that the NVH performance requirements are met again. Sealing is provided by 1K body sealant applied after repair is completed. The bearing plates are attached to the internal reinforcement or internal panels in the area of the pillars. If the bearing plate is not damaged, the NVH element can be reused, but if the bearing plate is damaged, a new NVH element must be installed.

Install a new NVH element.

1. Make the necessary separating cuts and separate the welded joints.

NOTE: If the insulating material is overheated, gases harmful to health may be released.

2. Using heat, separate the NVH element from the body panel and then remove the body panel.

3. Separate the NVH element using the appropriate tool and remove it.

4. Degrease the body panel in the NVH area and prime and paint if necessary.

Pos.	Spare Part No	Name
1	-	Carrier plate
2	-	Clamps
3	-	Fixing tabs for insulating material

5. Remove the insulating material from the new NVH element.

6. Fix the carrier plate in the required position.

7. Lift the outer panel and measure the gap between the carrier plate and the panel.

8. Apply 1K body sealant around the entire outer edge of the carrier plate according to the measured gap width.

9. Install the new spare part. Check the sealing quality of the NVH element. Cover any gaps found in the sealing bead using a paint brush, as small holes can allow external noise to pass through.

Reuse installed NVH components.

Pay particular attention not to damage factory installed NVH components when separating body panels using cutting or abrasive tools.
Before installing a new replacement part, apply body sealant to the existing NVH seal.