Ford Ecosport: Front End Sheet Metal Repairs / Removal and Installation - Cowl Panel

Special Tool(s) / General Equipment

Materials

Removal

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 (501-20B Supplemental Restraint System, General Procedures).
   

1. Remove the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the cowl panel grille and cowl panel.
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the windshield wiper motor and associated linkage.
   Refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Wiper Linkage Assembly (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 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

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

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

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. Drill plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

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 Identification Codes, Description and Operation).
   

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 Instrument Panel and Console, Removal and Installation).
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   

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

1. Install the cowl panel grille and the cowl panel.
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Cowl Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

1. Install the hood and align the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
   

1. Repower the SRS .
   Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).