Toyota
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 and Fender Apron Panel LH

  • 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).

Inner Panel - Fender Apron Panel Reinforcement

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

Inner Panel - Fender Apron Panel Reinforcement

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.

Front Side Member Inside

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 Inside

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

Front Side Member Inside

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

Front Side Member Inside

  • Front Side Member Outside
  • Continuous MIG weld seams.

Front Side Member Inside

  • Front Side Member Inside
  • Continuous MIG weld seams.

Front Side Member Inside

  • 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!

Strut Tower

Apron Panel

  • Resistance spot weld.

Apron Panel

Grill Opening Support

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

Grill Opening Support

Inner Panel - Fender Apron Panel Reinforcement

  • Continuous MIG weld seam.
  • Resistance spot weld.

Inner Panel - Fender Apron Panel Reinforcement

    More about «Front End Sheet Metal Repairs»:

    Fender Apron Panel Reinforcement

    Front Side Member Section

    Front Side Member and Fender Apron Panel LH

    Front Fender

    Fender Apron Panel Section

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