Ford Focus RS and ST Body Repair Manual

To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time of going to print. The right to change prices, specifications, and equipment and maintenance instructions at any time without notice is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers. No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic, mechanical, photocopy, recording, translation or by any other means without prior permission of Ford Motor Company. No liability can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and accurate as possible. FOREWORD

GROUP 5 SECTION TITLE PAGE Body and Paint Body System - General Information............................................................................... 501-00 Front End Body Panels.................................................................................................. 501-02 Body Closures................................................................................................................ 501-03 Interior Trim and Ornamentation.................................................................................... 501-05 Exterior Trim and Ornamentation................................................................................... 501-08 Rear View Mirrors.......................................................................................................... 501-09 Seating........................................................................................................................... 501-10 Glass, Frames and Mechanisms.................................................................................... 501-11 Instrument Panel and Console....................................................................................... 501-12 Handles, Locks, Latches and Entry Systems................................................................ 501-14 Wipers and Washers...................................................................................................... 501-16 Roof Opening Panel....................................................................................................... 501-17 Bumpers......................................................................................................................... 501-19 Safety Belt System......................................................................................................... 501-20A Supplemental Restraint System..................................................................................... 501-20B Body Repairs - General Information.............................................................................. 501-25 Body Repairs - Vehicle Specific Information and Tolerance Checks............................. 501-26 Front End Sheet Metal Repairs...................................................................................... 501-27 Roof Sheet Metal Repairs.............................................................................................. 501-28 Side Panel Sheet Metal Repairs.................................................................................... 501-29 Rear End Sheet Metal Repairs...................................................................................... 501-30 Paint - General Information............................................................................................ 501-36 Frame and Mounting Uni-Body, Subframe and Mounting System................................................................... 502-00 2011.00 Focus Body and Paint FORD FOCUS RS & ST FORD FOCUS RS & ST

SECTION 501-00 Body System - General Information PAGE CONTENTS DESCRIPTION AND OPERATION 501-00-2 Body (Overview)................................................................................................................. 501-00-2 General information............................................................................................................ 501-00- Body System - General Information 501-00-1 . VEHICLE APPLICATION: 2011.00 Focus

Body – Overview General information E112836 2 1 3 Description Item Ventilation slits 1 Finisher 2 Large trapezoidal air inlet 3 The completely newly designed front bumper features a generously dimensioned, grille-covered air inlet in a trapezoidal shape with a high-gloss piano-black paint finish. The trim strip at the front edge of the hood provides a striking contrast and is also finished in piano-black. Two ventilation slits have been incorporated in the hood. These provided the engine with additional cooling. The wheel arches of the front and rear fenders have been enlarged in order to afford enough space for the 19-inch wheels and to allow for the increased track width. Triangular air vents with the RS emblem are integrated behind the front wheel arches. 501-00-2 Body System - General Information 501-00-2 DESCRIPTION AND OPERATION 2011.00 Focus 8/2010

E112837 1 2 3 Description Item Split rear spoiler 1 High Mounted Stop Lamp Control 2 Diffuser plate 3 In order to increase downforce, a diffuser has been integrated in the lower part of the rear, along with a split rear spoiler above the rear window. The diffuser is framed by two chrome-plated end pipes. Small vent openings on both sides of the rear apron further emphasize the width of the vehicle. The high-mounted stoplamp and the rear window washer nozzle are integrated in the split rear spoiler. E112838 3 1 2 G1165408en 501-00-3 Body System - General Information 501-00-3 DESCRIPTION AND OPERATION 2011.00 Focus 8/2010

Description Item Rear window washer nozzle 1 High Mounted Stop Lamp Control 2 Description Item 3 Attachment bolts The high-mounted stoplamp uses LEDs rather than conventional bulbs. NOTE: The LEDs cannot be replaced individually. In event of failure the entire stoplamp needs to be replaced. The rear window washer nozzle is positioned next to the high-mounted stoplamp. The rear spoiler is attached to the tailgate with five bolts. G1165408en 501-00-4 Body System - General Information 501-00-4 DESCRIPTION AND OPERATION 2011.00 Focus 8/2010

SECTION 501-02 Front End Body Panels PAGE CONTENTS GENERAL PROCEDURES 501-02-2 (41 213 0) Hood Alignment.............................................................................................. REMOVAL AND INSTALLATION 501-02-4 Cowl Panel Grille................................................................................................................ 501-02-6 Fender ................................................................................................................................ 501-02-7 Air Deflector........................................................................................................................ 501-02- Front End Body Panels 501-02-1 . VEHICLE APPLICATION: 2011.00 Focus

Hood Alignment(41 213 0) Adjustment 1. NOTE: Adjust the hood without the hood latch. Remove the hood latch. For additional 501-14 [Handles, Locks, Latches and Entry Systems]. 2. NOTE: It is not possible to adjust the rear of the hood to the hight of the fender. Slacken the screws of the hood hinge approximately half a turn. DEE0002965 3. Adjust the hood in the longitudinal direction. 1. Adjust the hood so that the rear edges of the fender and the edge of the hood line up. 2. Check that the clearances with the left and right-hand fenders run parallel and correct them if necessary. DEE0002966 1 2 4. Adjust the clearances with the left and right-hand fenders. • The clearances with the fenders must be the same width on the left and right-hand sides. The clearances can be equalized by opening the hood on the hood support rod and correcting by pressing it to the left or right. DEE0002967 5. Tighten the screws. DEE0002968 10 Nm 6. NOTE: The hood must rest uniformly on both bump stop rubbers. Adjust the front of the hood to the height of the fenders. • Adjust the hood to the height of the fenders with the bump stop rubbers. DEE0002964 G18453en 501-02-2 Front End Body Panels 501-02-2 GENERAL PROCEDURES information, refer to Section 2011.00 Focus 8/2010

7. NOTE: The clearances and edge alignment must be correct before the hood latch is installed. Install the hood latch. • The hood latch must be installed so that the hood engages without stress and the clearances on the left and right-hand sides are not changed. G18453en 501-02-3 Front End Body Panels 501-02-3 GENERAL PROCEDURES 2011.00 Focus 8/2010

Cowl Panel Grille 1. Remove the brake fluid reservoir from the cowl panel. E39287 2. Remove the components in the order indicated in the following illustration(s) and table(s). CAUTION: Ensure that the wiper motor is in the park position. NOTE: Left-hand side shown. TIE45841 15 Nm 1 15 Nm 4 3 6 2 5 8 7 Description Item Windshield wiper arm bolts (passenger side) 1 Windshield wiper arm washer (passenger side) 2 Description Item Windshield wiper arm (passenger side) 3 Windshield wiper arm bolts (driver side) 4 Windshield wiper arm washer (driver side) 5 Windshield wiper arm (driver side) 6 G296767en 501-02-4 Front End Body Panels 501-02-4 REMOVAL AND INSTALLATION 2011.00 Focus 8/2010

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Ford Focus RS and ST Body Repair Manual

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