The newly designed front end structure of the Fiesta consists mainly of the plastic front end module and the sheet steel crash element.
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Reinforcement with high-resistance foam
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Plastic front end module
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Sheet steel crash element (crossmember)
Plastic front end module
The plastic front end module acts among other things as a mounting for various components like the radiator, radiator fan and hood lock.
This design allows repairs to be performed easily and economically, as the complete front end module can be detached together with the flanged-on assemblies.
In areas subjected to more severe loads the plastic front end module is additionally reinforced with high-resistance foam.
Sheet steel crash element
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Designated yield points
The sheet steel crash element consists of a crossmember to which two crash boxes are welded.
The crash element absorbs the majority of the impact energy in a crash up to 15 km/h.
Flange plates on the longitudinal members allow the bolted crash element to be easily replaced.
Towing eye mounting
Front longitudinal member
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Designated yield points
As well as the sheet steel crash element, the front longitudinal members also contribute to the passive safety of the Fiesta.
Two additional designated yield points in the front part of the longitudinal members absorb further crash energy (above 15 km/h).
2-part frame construction in the deformation area - increased ease of repair.
Laser butt weld seam directly behind the crash area - optional sectional replacement.
In the front area of the longitudinal members (deformation area) there are no inward reinforcements - increased ease of repair.
Front bumper
The plastic bumper is positioned relative to the fenders with two plastic lugs on each side of the vehicle and bolted in place.
The fog lamps are integrated in the bumper, and the ventilation grille and the front apron are clipped onto the bumper.
The plastic material can be welded.
Rear end design features
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Designated yield points
Rear crossmember
The rear crossmember makes the connection between the two ends of the longitudinal members and therefore contributes to increased passive safety in the event of rear end damage. Due to the slightly curved basic shape of the bolted crossmember, any impact energy can more easily be converted into deformation energy. In lesser impacts this prevents deformation of the longitudinal members and therefore of the body structure.
Rear longitudinal member
In more serious rear impacts the ends of the rear longitudinal members are also deformed in addition to the crossmember. Designated yield points in this area allow the residual energy to be dissipated in a controlled manner and prevent follow-on damage on the body structure. Sectional replacements are possible in the area of the designated yield points.
NVH elements
As already featured on the Ford Focus and Ford Mondeo (as of model year 2001.25), the Fiesta now also features three elements on each side of the vehicle to reduce the transmission of airborne noise to the body.
If any body repairs are carried out in these areas then the NVH elements must also be reinstalled or renewed. Information on repair techniques will be published in the Student Information "Accident damage repairs" and in the Body Repair Manual (TIS).
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NVH element - C-pillar/inner wheel arch
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NVH element - C-pillar/outer wheel arch
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NVH element - A-pillar with leadthrough for the sun roof water drain hose
A-pillar area
Separation of wet and dry areas.
Leadthrough for the sun roof water drain hose.
C-pillar/wheel arch area
2-part element.
Mounting provided by a clip connection in the intermediate panel of the wheel arch.
Divides up the resonant space of the sill panel and the C-pillar.
Attached parts
Doors
The dividable door hinges are attached with two bolts each to the body and the door. Adjustment options are provided via the oversized bores in the halves of the hinge, allowing adjustments to be performed without removing trim panels.
The central electrical power supply to the doors is provided on the front doors via a round bayonet connector and on the rear doors via a rectangular clip connector.
The doors are only hung by the hinge halves on pivot pins and can be simply unhinged when open. The doors are locked in the closed position via a mechanical locking mechanism which is integrated into the hinge half on the body side.
Sealing for the doors is provided in the form of a surrounding rubber seal on the body side.
Due to the reinforcement of the panel areas (grey areas), there are limited options for performing dent removal techniques without damaging the paintwork.
Surrounding seals and sealing bead in the clinched flange area.
Windshield washer nozzles (1) integrated into the hood.
Mechanical hood prop (2) on the right-hand side of the vehicle.
Hinge on the body side (4) and hood side (3), each secured with 2 bolts. Adjustment options are provided via oversized bores,
The hood lock can be released via a cable from the passenger compartment.
Diesel vehicles are equipped with a hood insulation.
Forced ventilation
