Ford Workshop Service and Repair Manuals

New or modified and zinc-plated vehicle components

The body parts shown in the diagrams below are of a totally new design, or have been transferred from the Mondeo '97 and modified. A distinction is also made between zinc plated and unplated body parts.

Floor assembly

New or modified front end body parts - zinc plated on both sides

New or modified outer body parts - zinc plated

High-strength sheet metal parts

Certain body parts of the Cougar are manufactured from high-strength sheet metal. This optimises the response to impact and achieves a high level of passenger protection in the case of front, rear or side impacts.

NOTE:The repair methods outlined in the Body Manual (general section) must be observed for all repair work.

High-strength sheet metal parts

Corrosion prevention measures

All body parts that are liable to corrosion are zinc plated in production. Other corrosion prevention measures are carried out in addition.

Stone deflectors

Underbody protection

Cavity wax

Sheet metal parts for partial replacement

Precisely matched replacement body parts are available to the Service department for the partial replacement repairs listed in the repairs chapter.

Sheet metal parts for partial replacement

Adhesively bonded connections

The connection between the wheelhouse outer shell and the side panel is made in production by means of a clinched flange. This is strength bonding that must be created using two-component metal adhesive (Ford designation: WSK-M2G400A / B) in the case of repair. The bonding procedure may only be carried out on bare metal or on dip-primer applied in the factory. All bonding points shown in the diagrams below must be observed in repairs to the bodywork. If adhesively bonded connections are damaged, loosened or removed during repair work, then the bonded connection must be re-created as part of the repair work and must conform to production conditions.

Bonded connections, roof

These bonded connections must be re-created using clinched flange sealer (Ford designation: ESK-M4G245-A).

Bonded connections, sliding roof frame and roof

Bonded connections, side impact bar and door outer panel

Bonded connections, hood

Bonded connections, tailgate

Water hose and wiring harness layout

When working on the bodywork and making cut locations, the wiring harnesses and water hoses beneath the cut location must be re-routed away from the working area or removed.

Water hose and wiring harness layout

NOTE:When reassembling, insert the front drain hoses from below. Water is drained through the rear drain hoses in the area of the tailgate hinges.

Drain hoses, sliding roof

Sound insulation

Foam elements are installed in the body cavities and insulate the passenger compartment against engine and road noise. They must be re-installed as part of the repairs to be performed.

Foam elements, passenger compartment

Foam elements, front end