Ford Fusion: Front End Sheet Metal Repairs / Cowl Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTE: Roof removed for clarity.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .
   

1. Remove the hood and cowl panel grille.
   Refer to: Cowl Panel Grille (501-02) .
   

1. Remove the windshield wiper motor and associated linkage.
   Refer to: Windshield Washer Reservoir (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
   

1. Remove the windshield glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26) .
   

1. Remove the instrument panel and console.
   Refer to: Floor Console (501-12) .
   Refer to: Instrument Panel (501-12) .
   

1. Position the carpet, electrical modules and wiring harnesses away from the working area.
   

1. NOTE: Pay particular attention to the location of adhesives or sealers to aid in installation.

   Remove the welds and the cowl panel.
   Use the General Equipment: Spot Weld Drill Bit

Installation

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Roof removed for clarity.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Install, properly position, clamp and weld the replacement cowl panel.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Dress all welds as required using typical metal finishing techniques and materials.
   

1. Seam Sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Sand to remove old adhesive, paint, e-coat and clean.
   

1. Apply a Ford approved epoxy-based primer and allow to dry.
   

1. Mask the windshield channel.
   

1. Refinish the entire repair using a Ford approved paint system.
   

1. Remove the masking material from the windshield channel.
   

1. VIN Plate:
   Install a new VIN plate.
   Refer to: Identification Codes (100-01) .
   

1. Install the windshield glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Reposition the wiring harnesses, electrical modules and carpet in original location.
   

1. Install the instrument panel and console.
   Refer to: Instrument Panel (501-12) .
   Refer to: Floor Console (501-12) .
   

1. Install the windshield wiper components.
   Refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Washer Reservoir (501-16 Wipers and Washers, Removal and Installation).
   

1. Install the cowl panel grille and hood.
   Refer to: Cowl Panel Grille (501-02) .
   

1. Align the hood.
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
   

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .