Ford Kuga

 Service Manual

Front End Sheet Metal Repairs
Front Side Member and Fender Apron Panel LH

Removal

NOTE: Equipment:

Measurement and alignment angle system.

Replacement Parts:

• Inner Side Member
• Outer Side Member
• Apron Panel
• Strut Tower
• Grill Opening Support
• Longitudinal Member Flange Plate

Necessary Removal and Installation Work:

• Fender Apron Panel Reinforcement

Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).

• Reposition the carpeting and the wiring harness away from the working area.

Inner Panel - Fender Apron Panel Reinforcement

• Mark the outline and cut.

• Front Side Member Outside
• Mark the outline and cut.

1) Mill out the spot welds (0 10 mm).

2) Mill out the spot welds - Two panel thickness (0 10 mm).

• Strut Tower
• Grind out the spot welds from inside.

Front Side Member Inside

• Mark the outline and cut.

1) Mill out the spot welds.

2) Mill out the spot welds with a spherical cutter.

Installation

NOTE: Preparation of the replacement parts:

• The required replacement parts needs to be cut out from outer and inner side member replacement part.
• Fit the outer side member, the inner side member and the longitudinal member flange plate and secure them with the alignment angle.

NOTE: Welding

• Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed.

Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation).

• Preparation of the Strut Tower
• Drill holes for puddle welding (0 10 mm).

• Front Side Member Outside
• Resistance spot weld - Panel thickness 3 mm and greater!
• Continuous MIG weld seams.

• Front Side Member Outside
• Drill out by one panel thickness for puddle welding - puddle weld 3 panel layers.

• Front Side Member Outside
• Continuous MIG weld seams.

• Front Side Member Inside
• Continuous MIG weld seams.

• Strut Tower
• 1) Puddle weld.
• 2) Resistance spot weld - Panel thickness 3 mm and greater!

Strut Tower

1) Puddle weld.

2) Resistance spot weld - Panel thickness 3 mm and greater!

Apron Panel

• Resistance spot weld.

Grill Opening Support

• Resistance spot weld - Panel thickness 3 mm and greater!

Inner Panel - Fender Apron Panel Reinforcement

• Continuous MIG weld seam.
• Resistance spot weld.

Fender Apron Panel Reinforcement

Front Side Member Section

Front Side Member and Fender Apron Panel LH

Front Fender

Fender Apron Panel Section