Ford Fusion: Side Panel Sheet Metal Repairs / A-Pillar Outer Panel Section and Reinforcement. Removal and Installation
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Hot Air Gun |
8 mm Drill Bit |
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Locking Pliers |
Materials
Name |
Specification |
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM |
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|
Flexible Foam Repair 3M™ 08463, LORD Fusor® 121 |
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|
Removal
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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: Health and Safety Precautions (100-00 General Information, Description and Operation).
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Reposition the carpeting and the wiring harness away from the repair area.
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Remove the A-pillar outer panel.
Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
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Refer to the following:
Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
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Drill out the A-pillar reinforcement spot welds.
Use the General Equipment: Spot Weld Drill Bit
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Break the adhesive bond and remove the A-pillar reinforcement.
Use the General Equipment: Hot Air Gun
Installation
-
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: Health and Safety Precautions (100-00 General Information, Description and Operation).
-
Drill plug weld holes in the new A-pillar reinforcement.
Use the General Equipment: 8 mm Drill Bit
-
Apply foam as indicated.
Material: Flexible Foam Repair
/ 3M™ 08463, LORD Fusor® 121
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Install, clamp and plug weld the new A-pillar reinforcement.
Use the General Equipment: MIG/MAG Welding Equipment
Use the General Equipment: Locking Pliers
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Clamp and spot weld the new A-pillar reinforcement.
Use the General Equipment: Resistance Spotwelding Equipment
Use the General Equipment: Locking Pliers
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Finish the repair area using typical metal finishing procedures.
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Sealing work: All ares must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
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Refinish using a Ford Motor Company approved paint system.
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Install the A-pillar outer panel.
Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
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Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
Special Tool(s) /
General Equipment
Grinder
Knife
MIG/MAG Welding Equipment
Materials
Name
Specification
Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
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Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Flexible Foam Repair3M™ 08463, LORD Fusor® 121
-
Removal
NOTE:
Left Hand (LH) side shown, Right..
Other information:
Special Tool(s) /
General Equipment
Forming Gas Pressure Gauge and Leak Detector
Materials
Name
Specification
Forming Gas
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Leak detection
All vehicles
NOTE:
Use a Rotunda-approved Tracer Gas A/C System Dealership Leak Detection Service Kit that meets SAE J2790.
Recover the refrigerant. Refer to the appropriate Recovery procedure in Group 412.
..
B0082:11, B0082:12, B0082:13 and B0082:1A
Refer to Wiring Diagrams Cell 46 for schematic and connector information.
Normal Operation and Fault Conditions
The RCM continuously monitors the passenger seatbelt load limiter circuits for the following faults:
Resistance out of range
Unexpected voltage
Short to ground
Faulted passenger seatbelt load limiter
If a faul..