Ford Focus Service Manual: Body Repairs - Description and Operation

WARNING: Collision
damage repair must conform to the instructions contained in this workshop manual. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.

Departure from the instructions provided in this manual, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.

The body consists of the following:

• Two-door coupe
• Four-door sedan
• Radiator support assembly made of high-strength steel
• Bolted, removable front fenders, hinged doors and hood
• Steel roof panel constructed of mild steel
• Steel hood constructed of dent-resistant steel
• Steel fenders constructed of dent-resistant steel
• Steel doors with outer door panels constructed of high-strength bake hardenable steel
• Steel luggage compartment lid constructed of dent-resistant steel
• Inner door shells contain a laser welded blank at the hinge area
• B-pillar inner reinforcement contains laser welded blank (4-door sedan only)
• Door panels on all models have sound deadener (mastic) applied
• Mastic and sound deadener material applied to floor pan interior and exterior
• High-strength welded-on front bumper beam
• High-strength bolt-on rear bumper beam
• Front and rear subframe assemblies housing suspension and steering components
• Front frame rail service kit available for all models
• Structural adhesive used in front structure, dash panel, rear floor and package tray
• Sound deadener mastic material used in roof panel, floor pan and door panels

For dimensional information refer to the following illustrations:

Body Margins

NOTE:

Four-door shown. Panel margins shown in this illustration apply to all body styles.

NOTE:

Dimensions apply to right and left side.

Item	Description	Specification	Flushness Specification
1	Hood to grille	5.0 mm (0.19 in) ± 2.0 mm (0.07 in)	2.0 mm (0.078 in) ± 2.0 mm (0.078 in)
2	Grille assembly to fascia	5.0 mm (0.19 in) ± 1.0 mm (0.03 in)	—
3	Lamp assembly to hood	5.0 mm (0.19 in) ± 2.0 mm (0.07 in)	2.0 mm (0.078 in) ± 2.0 mm (0.078 in)
4	Lamp to fender	2.5 mm (0.098 in) ± 2.0 mm (0.07 in)	1.5 mm (0.059 in) ± 2.5 mm (0.098 in)
5	Lamp assembly to fascia	5.0 mm (0.196 in) ± 2.0 mm (0.078 in)	—

Body Margins

Item	Description	Specification	Flushness Specification
6	Hood to fender	4.0 mm (0.15 in) ± 1.8 mm (0.07 in)	1.3 mm (0.051 in) ± 1.3 mm (0.051 in)
7	Front door to fender	4.0 mm (0.15 in) ± 1.5 mm (0.05 in)	1.0 mm (0.039 in) ± 1.0 mm (0.039 in)
8	Door(s) to roof	5.0 mm (0.19 in) ± 2.5 mm (0.098 in)	3.0 mm (0.118 in) ± 2.0 mm (0.078 in)
9	Front door to rear door	4.0 mm (0.15 in) ± 1.5 mm (0.05 in)	0.5 mm (0.019 in) ± 0.5 mm (0.019 in)
10	Door(s) to rocker panel	6.0 mm (0.23 in) ± 2.0 mm (0.07 in)	5.0 mm (0.196 in) ± 2.0 mm (0.078 in)
11	Rear door to quarter panel	4.0 mm (0.15 in) ± 1.5 mm (0.059 in)	0.0 mm ( in) ± 1.5 mm (0.059 in)
12	Luggage compartment lid to quarter panel	4.0 mm (0.15 in) ± 2.0 mm (0.07 in)	0.5 mm (0.019 in) ± 1.5 mm (0.059 in)
13	Lamp assembly to quarter panel	1.0 mm (0.03 in) ± 1.0 mm (0.03 in)	1.0 mm (0.039 in) ± 1.5 mm (0.059 in)
14	Lamp assembly to luggage compartment lid	4.5 mm (0.177 in) ± 3.0 mm (0.118 in)	0.0 mm ( in) ± 3.0 mm (0.118 in)
15	Luggage compartment lid to fascia	7.0 mm (0.27 in) ± 2.7 mm (0.10 in)	—

Underhood Dimensions

NOTE:

Measurements are obtained on center, unless otherwise indicated.

NOTE:

Underhood dimensions shown in this illustration apply to all body styles.

Body Side Closure Dimensions

2-Door Coupe

NOTE:

Measurements are obtained on center, unless otherwise indicated.

4-Door Sedan

NOTE:

Measurements are obtained on center, unless otherwise indicated.

Rear Opening Dimensions

2-Door Coupe

NOTICE: The service replacement luggage compartment lid ships without over-hem sealer applied. Sealer must be applied when replacement is carried out to avoid corrosion to the panel.

NOTE:

Measurements are obtained on center, unless otherwise indicated.

4-Door Sedan

NOTICE: The service replacement luggage compartment lid ships without over-hem sealer applied. Sealer must be applied when replacement is carried out to avoid corrosion to the panel.

NOTE:

Measurements are obtained on center, unless otherwise indicated.

Underbody Dimensions

Datum Height

Front Subframe Dimensions

NOTE:

If damage occurs to the subframe assembly, a new part should be installed.

Rear Subframe Dimensions

NOTE:

If damage occurs to the subframe assembly, a new part should be installed.

Underbody Dimensions — 2-Door Coupe

WARNING: Frame
rail crush zones absorb crash energy during a collision and must be replaced if damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone performance and may result in serious personal injury to vehicle occupants in a crash.

NOTE:

A structural frame rail sectioning kit is available for the front frame rail section. It is mandatory to maintain factory body dimensions when carrying out any repair procedure to the frame rails. Refer to Frame Members in this section.

NOTE:

Measurements are obtained on center, unless otherwise indicated.

Underbody Dimensions — 4-Door Sedan

WARNING: Frame
rail crush zones absorb crash energy during a collision and must be replaced if damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone performance and may result in serious personal injury to vehicle occupants in a crash.

NOTE:

A structural frame rail sectioning kit is available for the front frame rail section. It is mandatory to maintain factory body dimensions when carrying out any repair procedure to the frame rails. Refer to Frame Members in this section.

NOTE:

Measurements are obtained on center, unless otherwise indicated.