Ford Kuga

 Service Manual

Side Panel Sheet Metal Repairs
A-Pillar Outer Panel Section and Reinforcement

General Equipment

10 mm Drill Bit

6 mm Drill Bit

Air Body Saw

Hot Air Gun

Locking Pliers

Measurement and Alignment Angle System

General Equipment

Removal

General Equipment: Measurement and Alignment Angle System

• Front Door
• Refer to: Front Seat (501-10 Seating, Removal and Installation).

  Refer to: A-PillarTrim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

  Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

  Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).

  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.

3. General Equipment: Spot weld drill Bit

4. General Equipment: Air Body Saw

5. General Equipment: Spot weld drill Bit

6. General Equipment: Hot Air Gun

7. General Equipment: Spot weld drill Bit General Equipment: Air Body Saw 2008.50

8. General Equipment: Spot weld drill Bit

9. General Equipment: Hot Air Gun

Installation

1. NOTE: 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).

2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards.

Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation).

3. General Equipment: 6 mm Drill Bit

4. General Equipment: 10 mm Drill Bit

5. General Equipment: 10 mm Drill Bit

6. Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

7. General Equipment: 10 mm Drill Bit

8. General Equipment: Locking Pliers General Equipment: MIG/MAG Welding Equipment

9. Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Resistance Spotwelding Equipment

10. General Equipment: MIG/MAG Welding Equipment

11. General Equipment: Locking Pliers General Equipment: MIG/MAG Welding Equipment

12 Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Resistance Spotwelding Equipment

13, General Equipment: MIG/MAG Welding Equipment

14. Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

15.General Equipment: MIG/MAG Welding Equipment

16l Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Resistance Spotwelding Equipment

17. General Equipment: MIG/MAG Welding Equipment

18L General Equipment: Resistance Spotwelding Equipment

• Front Door
• Refer to: Front Seat (501-10 Seating, Removal and Installation).

  Refer to: A-PillarTrim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

  Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

  Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).

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

Rocker Panel

B-Pillar and Reinforcement

B-Pillar Outer Panel

Rocker Panel Inner Reinforcement

A-Pillar Outer Panel Section and Reinforcement