| Description and Operation Introduction The bodywork of Fiesta 2002 is a completely new development and comprises the following model variants: - 3-door version (anticipated for the second half of 2002 onwards)
- 5-door version
The model variants of Fiesta 2002 are identical in the front area up to the A-pillar, but differ in technical construction in the centre and rear areas. Construction features The front and rear side members, windshield frames, doors and D-pillar inner reinforcement are made of thick walled body panels. Because of the shape of the individual components and the built-in reinforcements, the bodywork is very resistant to torsion. For the first time, body panels reformed from tailored blanks are integrated into the crash and strength relevant areas. Because of this, the deformation performance of the chassis and the occupant protection are distinctly improved. Overall, the bodywork of the Fiesta proves to be very easy to repair. The overall body structure is made and assembled in such a way that individual body panels can be replaced without problem. Body components which are prone to deformation (e.g. front side member, A-pillar inner panel etc.) are made of several individual parts which are joined together. The majority of the welded joints which may need to be repaired can be re-created using resistance spot welding. Other changes relate to the increase in wheel base, overall length and vehicle height, deformation areas on the front and rear side members and the front and rear crash elements. Front crash element The front crash element consists of a steel crossmember with two deformation elements welded onto it. The energy of an impact is absorbed by the crossmember and is dissipated through the deformation elements for an impact below 15 Km/h. It is attached to the bodywork by threaded connections. Crash element 2 - Pre-determined folding points 3 - Threaded bore for the towing eye Hood lock panel The hood lock panel is made of plastic and is reinforced with high-resistance foam in the areas of most load. Attachment to the crossmember and to the upper side members is achieved by threaded connections. The hood lock panel supports a variety of other components (e.g. the radiator, radiator fan and hood lock). Minor damage can be repaired using the applicable plastic repair process. NOTE:If there are penetrating cracks, partial breaking away of material or part of it is missing, a new hood lock panel must be installed. Front module 3 - High-resistance foam reinforcement In the case of repairs, the front module, consisting of the crash element and the hood lock panel, can be detached as a unit together with the components which are bolted to it. Front side member In contrast to the previous model, the side member is made of several parts, and the inner sides are made of tailored blanks. If the frontal damage extends past the crash element (impact above 15 Km/h), the impact energy is absorbed by the side members and dissipated in the area of the intentional yield points (deformation area). A deformation area has no inner reinforcement. Sectional replacement is possible if the damage does not extend past the deformation area (intentional yield points). If there is deformation inside the engine compartment, the front section can be replaced individually. Front side member 1 - Side member (multiple part) 2 - Pre-determined folding points 4 - Resistance spot weld joint Rear crossmember The rear crossmember is secured to the side members by threaded connections. Because the crossmember is curved, impact energy is more easily converted into deformation energy. For light impacts this prevents deformation of the side members and therefore of the vehicle body also. Rear side member If a heavier rear impact occurs, in addition to the crossmember, the ends of the side members are deformed. The remaining energy is dissipated in a controlled manner in the area of the intentional yield points. Sectional replacement is possible if the damage does not extend past the deformation areas. Rear side member 3 - Pre-determined folding points NVH measures In order to prevent air conduction of noise to the vehicle interior, three NVH elements are installed on each side of the vehicle, clipped to the vehicle bodywork. When carrying out repair work, either the original NVH elements must be put back in position or new ones installed. On vehicles with a sliding roof, the opening must be left in the A-pillar NVH element for the water drain hose. NOTE:Gases harmful to health will be released if the insulation material is heated too much. Make sure that the insulation material installed in production is not damaged by cutting or sanding tools when cutting out bodywork parts. NVH measures 1 - C-pillar inner NVH element 2 - C-pillar outer NVH element 4 - Opening for sliding roof water drain hose Tailored blanks By employing a combination of materials with different thicknesses and properties, tailored blanks make it possible to produce an exact match to the required strength and rigidity in different areas within one bodywork component. The number of steel panels can be decreased by installing tailored blanks and so the weight of the bodywork can be reduced. Tailored blanks with laser welds 5 - Rear right-hand side member 6 - Rear left-hand side member 7 - Rocker panel reinforcement High-strength steel parts Reinforced high-strength steel parts are used on all Fiesta models. NOTE:The working methods given in Part I of the Body Repair Manual (501-25A) must be observed in all repair work. Overview of parts, front end 1 - Galvanised steel panels 2 - High strength and galvanised steel panels 3 - High-strength low alloy steel Overview of parts, floor pan (5-door version) 1 - Galvanised steel panels 2 - High strength and galvanised steel panels Overview of parts, side view (5-door version) 1 - Galvanised steel panels 2 - High strength and galvanised steel panels 3 - High-strength steel parts | 
