Ford Falcon. Manual — part 491
501-25C-5
Body Repairs — Plastic Repairs
501-25C-5
DESCRIPTION AND OPERATION (Continued)
Item
Description
1
Rear bumper side retainer
2
Rear bumper absorber
3
Rear bumper cover
4
Lower bumper retainer - Rear
5
Rear lower valance panel
Item
Description
1
Rear bumper cover mounting bracket
2
Rear bumper mounting bracket
3
Rear bumper cover
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501-25D-1
Body Repairs — Water Leaks
501-25D-1
SECTION : 501-25D Body Repairs — Water Leaks
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS
PAGE
DESCRIPTION AND OPERATION
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...501-25D-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..501-25D-2
Practical execution of tests and checks . . . . . . . . . . . . . . . . . . . 501-25D-2
Rectifying the leak using recommended tools, auxiliary equipment and materials . . ...501-25D-3
Water leaks according to mileage or running time . . . . . . . . . . . . . . . 501-25D-3
Water leaks after body repairs . . . . . . . . . . . . . . . . . . . . . . ..501-25D-3
Water drainage system . . . . . . . . . . . . . . . . . . . . . . . . . .501-25D-3
Water leaks, diagnosis and corrective action: Front passenger compartment . . . . .501-25D-4
501-25D-2
Body Repairs — Water Leaks
501-25D-2
DESCRIPTION AND OPERATION
At various speeds.
Water Leaks
On various road surfaces.
General
With loaded or unloaded vehicle.
If water leaks occur after bodywork repairs, the
Driving through puddles (splash water).
cause can be established using the checks
Test with UV lamp
described below. A systematic and logical
procedure is required to locate water leaks.
Wet the test area with clear water from the
Before beginning extensive checks, a thorough
outside.
visual inspection must be carried out.
Prepare test liquid (see Owner’s Handbook) and
Visual Inspection
apply it from the outside using a suitable water
sprayer.
The following characteristics may indicate
existing leaks:
Illuminate the relevant area from the inside using
the UV lamp.
Check the clearance and accurate fit of
ancillary components such as the hood,
The test liquid will make the leak visible.
tailgate, doors, and so on.
UV lamp
Check for correct fit and possible damage to
sealing elements such as blanking plugs,
rubber door seals, and so on.
Check water drain holes for unhindered flow.
Various tests can be used to provide further
information on possible leaks:
Water test
Washer test
Road test
Test with UV lamp
Special mirror test
Chalk (powder) test
Flow tube (smoke) test
Benefits of the UV lamp:
Practical execution of tests and checks
No need to dry out wet areas before the test.
Water test
The ingress of water and its subsequent path
can be identified precisely.
NOTE: Never aim a jet of water directly at a rubber
No need to remove most ancillary
seal.
components from the vehicle.
Carry out the water test with a second person
present (passenger compartment).
Mirror test
Use variable washer nozzles (concentrated water A mirror can be used to see into hard-to-reach areas.
jet to fine spray mist).
Mirror
Start in the lower section and spray the whole
area, working upwards in stages.
Benefits
The following are suitable for the water test:
A switchable light built into the mirror area.
softened water (liquid soap additive)
The angle of inclination of the mirror can be set
manually using the handle.
Automatic car wash
The connector between the handle and the mirror
Further tests can be carried out in the washer
is flexible.
system.
Chalk test (Powder test)
Some leaks originate here, or only occur here.
The relevant passenger compartment should be
In this test, the clamping load and the bearing
checked using a torch during the wash procedure.
surface of the seal are checked.
Performing the test:
Road test
Dust the sealing surface with chalk powder.
If no leaks are located during the tests above,
Slowly close the liftgate/door and open it
road tests should be carried out on wet roads.
again.
Road tests under various conditions:
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501-25D-3
Body Repairs — Water Leaks
501-25D-3
DESCRIPTION AND OPERATION (Continued)
Check the width and continuity of the chalk
Age-related factors:
imprint to ensure the seal is operating
Environmental factors
effectively.
UV radiation
Smoke test
Extreme climatic conditions
Corrosion can have a serious impact on
Test for locating leaks.
bodywork, in particular as a result of:
Set the interior ventilation to the maximum
Lightly or heavily rusted seal carriers
setting.
Rusted body seal welds
Use a smoke generator machine to create
smoke in the test area (interior).
Perforation corrosion
A second assistant locates points at which the
Water leaks after body repairs
smoke escapes on the outside.
If a vehicle develops a leak after body repairs, the
Other test equipment
following points must be taken into consideration in
Other equipment such as stethoscopes or
particular:
ultrasound measuring instruments can be used to
The correct seating of ancillary components and
locate leaks.
their seals (e.g. rear lamps, etc.) must be
checked.
Rectifying the leak using recommended
The correct alignment of doors and luggage
tools, auxiliary equipment and materials
compartment lids/tailgates must be checked. The
Tools and auxiliary equipment:
associated seals must not be damaged and must
be installed correctly.
Dry, absorbent cloths
Check that welded seams are correctly sealed.
Variable washer nozzle
The correct seating of rubber grommets must be
Torch, fluorescent tube
checked.
Mirror
The windows must be installed precisely and the
Compressed air
sealer must take contact with the body all the way
Seal lip installer
round.
Wet/dry vacuum cleaner
Seals are fitted correctly as per PCP.
Sealing compound compressor
Water drainage system
Remover for interior trim
If a vehicle develops water leaks, then areas into
Cutter blade or pocket knife
which water is routed or drained should be checked
Wedge (wood or plastic)
first. (eg. sunroof)
Hot air blower
Water drainage, front
UV lamp
Stethoscope
Air flow checker
Ultrasonic measuring instrument
Water leaks according to mileage or
running time
Increasing mileage has an effect on the problem of
leaks in a vehicle. Possible influencing factors are:
Servicing and maintenance of seals:
No maintenance, lack of maintenance or
incorrect maintenance
Using an incorrect agent (ie. cleaner etc.)
Damaged seals:
As a result of aging, wear or incorrect
handling/assembly. (eg. door sag/demage)
Heavy soiling of the vehicle:
Heavy soiling of a vehicle can seriously impair
the function of water drainage channels in
particular, and also of rubber seals.
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