Ford Falcon. Manual — part 402

501-00-4 General

Information 501-00-4

DIAGNOSIS AND TESTING

Body System

Inspection and Verification

1. Verify the customer concern by operating the

system. the symptom and refer to the Symptom

2. Visually inspect for obvious signs of mechanical

or electrical damage.

3. If an obvious cause for an observed or reported

concern is found, correct the cause (if possible)

before proceeding to the next step.

4. If the concern is not visually evident, verify the

symptom and refer to the Symptom Chart.

Visual Inspection Chart

Mechanical

Dust Leaks

Water Leaks

Symptom Chart

Condition

Source

Action

Dust Leaks

Displaced sealer.

Refer to the service procedure below.

Damaged body parts.

Refer to the service procedure below.

Missing underbody grommets.

Refer to the service procedure below.

Misaligned doors.

Refer to the service procedure below.

Misaligned glass.

Refer to the service procedure below.

Water Leaks

Displaced sealer.

Refer to the service procedure below.

Damaged body parts.

Refer to the service procedure below.

Missing underbody grommets.

Refer to the service procedure below.

Misaligned doors.

Refer to the service procedure below.

Misaligned glass.

Refer to the service procedure below.

Sealer locations should be considered when checking

Spare tire

for dust or water leaks. The forward motion of the

Roof opening panel.

vehicle causes any unsealed small opening in the

After removing the trim panel(s), the location of most

lower section of the body to permit air and dust to be

leaks will be evident. The entrance of dust is usually

drawn into the body. Opening the ventilator air ducts

indicated by a point of dust or silt. Seal these leaks,

will equalise these pressures. Dust accumulates in the

then road test the vehicle on a dusty road to ensure

luggage compartment body opening and may move

all leaks are sealed. A suitable Leak Detector can

into the luggage compartment.

locate dust leaks, wind and water leaks.

To eliminate dust leakage, determine the exact point

After the road test, check for indications of a dust

at which the dust enters. Under certain conditions,

pattern around the door openings, cowl side trim

water may also enter the body at any point where

panel, lower part of the quater panel and in the

dust can enter.

luggage compartment.

To determine the exact location of a dust leak, it may

Sometimes leaks can be located by putting bright

be necessary to remove the following trim panels from

lights under the vehicle, with the above components

the vehicle:

removed, and checking the interior of the body joints

Scuff plate. Section 501-05

and weld lines. A light will show through where leaks

C - Pillar trim. Section 501-05

exist.

Rear seat backrest and frame, and rear seat

cushion and frame. Section 501-10
Luggage compartment floor covering

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501-02-1

Front End Body Panels

501-02-1

SECTION : 501-02 Front End Body Panels

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501-02-2

DESCRIPTION AND OPERATION

Front End Body Panels . . . . . . . . . . . . . . . . . . . . . . . . . . .501-02-3

GENERAL PROCEDURES

Hood Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501-02-4

Fender Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..501-02-4

REMOVAL AND INSTALLATION

Air Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..501-02-7

Fender Splash Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . 501-02-7

Cowl Panel Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..501-02-7

Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...501-02-8

Modestry Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501-02-8

Hood Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501-02-8

Hood/Hood Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501-02-9

501-02-2

Front End Body Panels

501-02-2

SPECIFICATIONS

Torque Specifications

Description

Nm

Cowl grille screws

3

Fender bolts

10

Fender splash shield bolts

12

Air deflector

4.5

Hood hinge to dash panel bolts

30

Hood hinge to hood bolts

30

Wiper pivot arm nuts

—

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501-02-3

Front End Body Panels

501-02-3

DESCRIPTION AND OPERATION

Front End Body Panels

The front end body panel components consist of the

following:

air deflectors
cowl grille
fenders
fender splash shields
hood
hood hinges
hood prop

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