Lincoln Corsair: Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame
Lincoln Corsair 2020-2024 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame
The body consists of the following:
- Front bumper constructed of high-strength aluminum
- Rear bumper constructed of Boron ultra high-strength steel
- Front frame rails constructed of Dual Phase (DP) 600 high-strength steel
- Rear frame rails constructed of Boron ultra high-strength steel
- Fender reinforcement tube constructed of Dual Phase (DP) 800 high-strength steel
- Liftgate panel constructed of mild steel
- Body structure constructed of Boron, Dual Phase (DP) and high-strength steels
- Panoramic or steel roof panel options
- Roof panel reinforcements constructed of Dual Phase (DP) 800, laminated steel, High-Strength Low Alloy (HSLA) steels
- Bolted, removable front fenders, hinged doors and hood
- Bodyside outer panels constructed of mild steel
- Steel hood hinges
- Mastic pads used on floor pan for sound deadening
Body Margins
NOTE: Unless otherwise indicated, margin dimensions apply to RH (right-hand) and LH (left-hand) side of vehicle.
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| Item | Description | Margin Gap Specification | Flushness Specification | Parallelism Specification |
| 1 | Hood-to-fascia | 5.0 mm ± 2.0 mm (Gap Symmetry ≤ 2.4 mm) | 2.0 mm ± 2.0 mm (Flushness Symmetry ≤ 2.2 mm) | — |
| 2 | Front door header-to-bodyside (Head underflush) | 4.5 mm ± 2.2 mm | -2.0 mm ± 2.5 mm | Gap Parallelism ≤ 1.5 mm (Flush Parallelism ≤ 2.2 mm ) |
| 3 | Front door-to-rear door applique | 4.0 mm ± 2.0 mm | 0.0 mm ± 2.0 mm | — |
| 4 | Front door-to-rear door belt moulding | ≤ 2.2 mm (Up/down alignment) | — | — |
| 5 | Rear door-to-front door (Rear door underflush) | 3.4 mm ± 1.5 mm | -0.5 mm ± 2.0 mm | Gap Parallelism ≤ 1.5 mm (Flush Parallelism ≤ 1.8 mm) |
| 6 | A-pillar-to-fender | 3.4 mm ± 2.2 mm | — | — |
| 7 | Front door-to-fender (Door underflush) | 3.4 mm ± 1.5 mm | -0.7 mm ± 1.5 mm | Gap Parallelism ≤ 1.3 mm (Flush Parallelism ≤ 1.5 mm ) |
| 8 | Hood-to-fender | 3.0 mm ± 1.5 mm | — | Gap Parallelism ≤ 1.5 mm |
Body Margins
NOTE: Unless otherwise indicated, margin dimensions apply to RH (right-hand) and LH (left-hand) side of vehicle.
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| Item | Description | Margin Gap Specification | Flushness Specification | Parallelism Specification |
| 1 | Bodyside-to-spoiler (Spoiler underflush) | 5.8 mm ± 2.0 mm | 1.0 mm ± 2.4 mm | — |
| 2 | Roof-to-liftgate (Liftgate underflush) | 7.6 mm ± 2.0 mm | 1.5 mm ± 2.0 mm | — |
| 3 | Liftgate-to-fascia lower | 6.0 mm ± 3.0 mm | — | — |
| 4 | Liftgate-to-fascia side (Liftgate underflush) | 5.5 mm ± 3.0 mm | -1.1 mm ± 2.5 mm | Flush Parallelism ≤ 1.8 mm |
| 5 | Liftgate-to-bodyside (Liftgate underflush) | 4.7 mm ± 2.0 mm | -1.2 mm ± 2.0 mm | Gap Parallelism ≤ 2.0 mm (Flush Parallelism ≤ 1.8 mm ) |
| 6 | Bodyside-to-aerofin moulding (Bodyside moulding underflush) | — | 2.3 mm ± 2.6 mm | — |
| 7 | Bodyside-to-rear door | 3.4 mm ± 1.5 mm | 0.0 mm ± 1.5 mm | Gap Parallelism ≤ 1.0 mm (Flush Parallelism ≤ 1.6 mm ) |
| 8 | Rear door header-to-bodyside (Head underflush) | 4.5 mm ± 2.0 mm | -2.0 mm ± 2.5 mm | Gap Parallelism ≤ 1.7 mm (Flush Parallelism ≤ 2.2 mm ) |
Under Hood Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Front and Rear Door Opening Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Liftgate Opening Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Underbody Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Datum Height Dimensions
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Description and Operation - Vehicle Specific Body Construction
For recommended metal repair guidelines and recommendations, refer to the following illustrations and: For additional information, refer to: Specifications (501-25 Body Repairs - General Information, Specifications)...
Other information:
Lincoln Corsair 2020-2024 Service Manual: General Procedures - Cylinder Block Distortion
Special Tool(s) / General Equipment Feeler Gauge Check NOTE: Refer to the appropriate Section 303-01 for the specification. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent...
Lincoln Corsair 2020-2024 Service Manual: General Procedures - Compression and Cylinder Leakage Test
Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position...
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Second Stage: Checking Tire Pressure
WARNING: If the tire does not inflate to the recommended tire pressure within 15 minutes, stop and call roadside assistance.
WARNING: The power plug may get hot after use and should be handled carefully when unplugging.
Check the air pressure of your tires as follows:
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