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Ford Focus RS (2011 year). Manual - part 106

Specification

Finis Code

Description

5 030 492

Underbody protection

WSK-M7C89-A

1 219 834

Anti-corrosion wax

5 030 081

Cavity wax

S-M3G4620-A

1 128 983

Profiled butyl seal

1 205 996

Weld primer

WSK-M4G245-B

1 136 479

Clinched flange protection

WSS-M4G364-A

1 205 817

Seam sealing compound

1 143 255

Body sealing compound

1 203 241

Metal adhesive kit

WSK-M4G329-A

1 613 838

Windshield sealant

1 219 837

Adhesive spoiler set

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SPECIFICATIONS

Description and Usage of Body Repair Literature

The purpose of this document is to give the vehicle
body specialist a general overview of possible
repair techniques for body repair on Ford vehicles.
Likewise, information about materials and tools to
be used is given.

No model-specific information is given. Such
information is saved in the respective Ford Etis
workshop manual. Supplementary or updated
information can be found in the Technical Service
Information.

Information on repair techniques, materials or tools,
which are not necessary for body repair on Ford
vehicles or which are not considered as
conventionally in use, are not listed in this
document.

Layout:

The general section is divided into the following
subject areas:

• How to use the document, with information on

the symbols used

• Health and safety information on using materials

and tools

• Information on bodywork construction and

materials used

• Workshop equipment and use of tools

• Damage Assessment and determining the

extent of the repair area

• Explanation of possible repair techniques for

body repair

• Possibilities of the repair or remedying leaks,

noises

Training:

The Ford Service Organization offers basic and
more in-depth training on much of the content of
this document. You can obtain an overview of the
entire training offering from the Ford Service
Organisation or on the Internet at
www.ford-training.de.

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DESCRIPTION AND OPERATION

Symbols

Warnings and hazard notices

Warnings and hazard notices are shown in this
literature by WARNING, CAUTION and NOTE
indicators. These notices are always shown before
a job step which can be associated with an
immediate personal or material danger.

WARNING: This notice is used when failure
to exactly follow the instructions given in
this literature or failure to follow them at
all may result in a hazard to persons and/or
in persons being injured.

CAUTION: This notice is used when failure
to exactly follow the instructions or test
procedures given in this literature or failure

to follow them at all may result in damage
to the vehicle or to components.

NOTE: This notice is used when the operator
should be made aware of special or extra
information.

Symbols used

Symbols are used to graphically represent
additional information about the operation, tool or
materials. This information will not be shown
separately again in the text.

The symbols used in this and other body repair
manuals may be used alone as well as in
combination in a diagram.

Description

Des

cript

ion

Measuring tape

Saw

Abrasive cutter

hot air blower

Temperature specification (170°C in this
example)

Drill with 6mm diameter

Drill through one panel thickness with a
5 mm dia. drill

Description

Des

cript

ion

Drill through two panel thicknesses with
a 5 mm dia. drill

Drill through one panel thickness

Drill through two panel thicknesses

Apply substance

Soldering iron

Metal-Inert Gas (MIG) weld

Resistance Spot Weld

Welded seam (full or intermittent seam)

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DESCRIPTION AND OPERATION

Color coding

Different colors or shading can be used to depict
special areas and components.

• Blue: Main component which will be removed

or installed. Only actual movements will be
shown in blue in the diagram.

• Magenta: Materials or fixings, e.g. spot welds

or adhesives.

In an assembly operation, the colors show the
sequence of removal steps.

• Green: First component or the first partial

replacement section.

• Blue: Second component or the second partial

replacement section.

• Brown: Third component or the third partial

replacement section.

Movement arrows

Necessary work such as clinching flanges or
moving lugs etc. will be represented by broken
arrows.

Magnified and detailed views

If a detail cannot be clearly seen in the illustration
because of its size or location, it is shown enlarged
in a separate window.

Position lines within a diagram

A position line is used to indicate a special position
or a component. A spot weld which must be drilled
out through two panel thicknesses is indicated
here, different to all the others.

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DESCRIPTION AND OPERATION

Health and Safety Precautions

General

Appropriate repair methods and their correct
implementation are very important for both vehicle
operating safety and personal safety.

WARNING: There is danger of injury
through:

• High voltage when electrical welding.

– Do not perform welding work in a damp

environment or on a wet substrate. Use
suitable insulation underneath.

• Flammable substances in the welding area.

– Remove flammable substances from the

danger area. Remove the fuel tank and,
where required, those components which
supply fuel.

– Completely remove the battery before

carrying out any welding in that area.

• Welding fumes, which are harmful to health.

– Always ventilate the workplace well and use

an extraction system.

• Welding spatter and UV radiation.

– Wear protective clothing, gloves and welding

mask or welding goggles.

• Pyrotechnic components.

– Disconnect the battery negative clamp and

cover the battery terminal. Remove any
airbag components.

All the regulations governing Health and Safety at
Work must be complied with during body repairs.

Personal protection

Welding gases and grinding dusts can be harmful
to the health. For this reason, make sure that
rooms are well ventilated and work using the
welding fumes extraction system. Sealants,
underbody protection and paint residues must not
be burnt down with an unshielded flame, as this
will produce gases which are damaging to health.
A dedicated extraction system must always be
used when welding or brazing.

When working with substances containing solvents,
good ventilation must be provided, respiratory
protection must be worn and an extraction system
must be used.

Do not weld in damp areas, if necessary use an
insulation mat. Welding and grinding work near the
battery presents the danger of explosion. For this
reason, it must be removed before the work is
started.

Cutting, grinding and alignment work on metal
panels can cause a noise level of 85 to 90 dB (A)
or even more. For this reason, you must always
wear ear defenders.

The various body areas are subject to very high
forces during realignment work. Should any
component suddenly become detached during this
process, there is a very great danger of injury. For
this reason, pulling chains and pulling shackles
must be secured with arrester cables.

NOTE: Work on airbag systems may only be
performed by persons who have a relevant
certificate of competence.

Some special instructions must be followed when
working on airbag systems:

• Always stand to the side of it when removing or

installing an airbag.

• Always store an airbag or an airbag/steering

wheel with the airbag side pointing upwards and
in a safe place.

• Only install the airbag again when the vehicle

is fully repaired and the complete electrical
systems has been tested.

• Take into account the location of air curtains

and shoulder airbags.

Protection of the vehicle

Protect affected areas from weld spatter and dust
during all welding and grinding work on the vehicle.
If metallic dust stays on the vehicle for some time,
there is the likelihood of film rust formation.
Grinding or sanding work produce tiny spots of
damage to the paint surface, which may cause
corrosion.

For this reason, make sure to:

• Use carbon fibre blankets to protect the vehicle

body.

• Use covering film to protect the vehicle body

from sanding dust and metal dust.

• Take appropriate measures to protect the

interior equipment of the vehicle during any
repair work.

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In addition, take into account:

• Remove fuel supply components as necessary.

• Protect working areas which are in danger of

catching fire with a fireproof blanket.

• The welding must not cause components of the

air conditioning system to become heated.

• Removal of any attached components in the

space adjoining the repair area.

• Use covering paper to protect the interior from

grinding dust.

• Create a definite barrier between the work area

and the interior by using a carbon fibre blanket.

Protective equipment

The following protective equipment must always
be used:

• Protective helmet or welding mask.

• Ear defenders and breathing protection.

• Protective gloves and safety boots.

• Welding fume extraction.

Electronic components

Increased use of comfort and safety electronics in
modern motor vehicles also requires the greatest
attention to be paid during body work. Overvoltages
produced during welding and in alignment work
during bodyshell rectification may cause electronic
systems to be damaged. In particular, the safety
instructions for performing welding work on vehicles
with airbag systems must be adhered to.

NOTE: After disconnecting the power supply and
before performing further work, a wait time of up
to 15 minutes must be maintained, depending on
the vehicle. Work on airbag systems may only be
performed by persons who have a relevant
certificate of competence.

Pay attention to the following points:

• Disconnect the battery negative clamp and

cover the battery terminal.

• Disconnect the electrical connector at the airbag

control module.

• If welding is to be performed directly near a

control module, it must be removed beforehand.

• Never connect the negative cable of the welder

near an airbag or a control module.

• Connect the negative cable of the welder close

to the location of the weld.

For additional information,

refer to:

Side Air Curtain Module

Vehicles Built From:

22-06-2007

(501-20 Supplemental Restraint

System, Removal and Installation),

Side Air Bag Module

(501-20 Supplemental

Restraint System, Removal and Installation),

Driver Air Bag Module

(501-20 Supplemental

Restraint System, Removal and Installation),

Passenger Air Bag Module - Vehicles Built

From: 04/2006

(501-20 Supplemental

Restraint System, Removal and Installation),

Air Bag and Safety Belt Pretensioner

Supplemental Restraint System (SRS)

(501-20

Supplemental Restraint System, Diagnosis
and Testing).

Liquefied gas vehicles

Alternative fuel vehicles often require special
handling in the workshop area. Above all, assembly
operations to some extent require particular
knowledge when dealing with the special
technology and the safety regulations.

NOTE: Only fully trained personnel are permitted
to work on alternative fuel vehicles.

These special requirements must be understood
and taken into account in the body shop as well.

CAUTION: Danger of fire and explosion.
The safety instructions must always be
followed when performing service work on
fuel/gas systems. Failure to observe this
instruction can lead to injury.

If the smell of liquefied petroleum gas (LPG) or
compressed natural gas (CNG) is noticed in the
workshop, instruct everyone present as follows:

• No smoking and extinguish all naked flames.

• Shut off all electrical and air powered

equipment.

• Evacuate the area.

• Ventilate the area.

• Contact the fire control authorities.

• Move the vehicle to a dedicated, well ventilated

area.

Alternative fuels require special handling:

• Handle them in a specially dedicated, well

ventilated area, which is only accessible to
authorized persons.

• Identify the designated area with new warning

notices.

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• If possible close the main shut-off valve and run

the vehicle on alternative fuel until it switches
automatically to petrol operation. Only then is it
allowed to drive the vehicle into the workshop
or service area.

• If possible do not allow any liquefied gas (LPG)

to escape.

• The ambient temperatures must not exceed

40°C. For this reason the LPG and CNG fuel
tanks must be removed on vehicles with LPG
or CNG operation before using a drying oven
to dry the paint where the temperature exceeds
40°C.

Avoid situations in which fuel from an LPG or CNG
fuel tank can escape. These situations include:

• Extremely hot ambient temperatures.

• Parking near a heating device.

• Raising the vehicle near a ceiling heater.

Refrigerated conversion vehicles

Apart from the special materials used in building
the structure of the refrigerated compartment, such
vehicles have special energy and refrigeration
systems which require special handling during
repair.

CAUTIONS:

Danger of injury. Work on the 230<SP>volt
system of the refrigeration equipment must
only be carried out by trained specialist
personnel.

The refrigeration system is filled with
refrigerant R134a. This can cause frostbite
if it contacts the skin. Pay attention to the
corresponding warning notices and
instructions in the chapter Air Conditioning
Systems.

NOTE: Work on the refrigerant circuit may only be
performed by persons who have a relevant
certificate of competence.

Vehicles with a refrigerated compartment are often
used to transport foodstuffs. For this reason,
additional hygiene regulations must be complied
with during repair work.

Aluminum and plastic are used to construct the
two different types of compartment found on
refrigerated vehicles.

The aluminum conversion is a very stable and
technically perfect variant. However, against this
the relatively high production costs and a lower

payload must be taken into account, because of
the weight of the aluminum conversion itself.

NOTE: Basic and in-depth training is offered on
the following topics. You will find an overview of
the complete range listed in the Training brochure
published by the Ford Service Organization.

The plastic conversion has developed into a light,
clean and economical alternative because of
constant further development of materials and
working techniques.

NOTE: The material combinations, the
workmanship and the working methods must
comply with the current food hygiene regulations.
For this reason, service and repair work on the
refrigerated conversion may only be performed by
authorized and specially trained technicians.

Refrigerated compartment constructions are often
made using both materials. The floor pan is made
of structured, slip-proof aluminum panels and the
wall and ceiling cladding is made of smooth
surfaced plastic elements.

CAUTION: PUR hard foam is flammable. If
PUR hard foam is overheated, it will burn
on its own with a brilliant yellowish flame.
It produces unpleasant choking and toxic
fumes. Special measures must be taken
when welding the vehicle body.

Polyurethane wall and ceiling elements are
manufactured using a sandwich principle. An
insulating polyurethane core is coated with food
grade ABS plastic on one side.

PUR hard foam does not decompose, is rot
resistant and is odorless. These properties make
it suitable for use as insulation.

Because of its closed cell structure, water uptake
by PUR hard foam is for the most part only a
problem at edges. Cut edges or other mechanically
worked surfaces must however be sealed with the
greatest care.

The conversion to a refrigerated vehicle is
performed as made-to-order production. The large
surfaces of the wall and ceiling cladding can be
changed and are particularly easy to repair.

If access to the back of a body panel section is
needed because of body straightening work, in
some circumstances it is cheaper to perform a
cut-out repair instead of removing an element.

The repair process is fully described in the Student
Information booklet Refrigeration System
Technology, Transit 2000.5 Freshline.

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