Ford Falcon. Manual — part 492
501-25D-4
Body Repairs — Water Leaks
501-25D-4
DESCRIPTION AND OPERATION (Continued)
Diagnosis:
Water drainage, side and rear
Ingress of water into A-pillar area or
instrument cluster area
Cause:
Breaks in adhesive beads
Corrective action:
Breaks in adhesive beads can be located
from inside by using compressed air. The leak
can be identified from outside by the escaping
air.
A second test method is by means of a water
test.
Diagnosis of a water leak
Sliding roof drainage
Drainage water tank
Item
Description
1
Compressed air test
2
Water test
Water leaks, diagnosis and corrective
action: Front passenger compartment
Side windows
Windscreens
In the case of fixed side windows (directly glazed), the
same problems can arise as for a windscreen. The
NOTE: The repair must be carried out in line with
same corrective actions must therefore be used.
approved methods.
NOTE: In both air/water tests the roof rail
weather/strip must be removed first.
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501-25D-5
Body Repairs — Water Leaks
501-25D-5
DESCRIPTION AND OPERATION (Continued)
Item
Description
Side windows
3
Interior door trim
Door seals
NOTE: When adjusting the clamping load, the edge
alignment of the relevant components must always be
taken into consideration.
NOTE: Do not realign the flange too far in the
direction of the door, as this can reduce the bearing
surface of the seal to the door.
Diagnosis:
Ingress of water into the rocker panel area
Cause:
Insufficient clamping load between seal
Door seal
footprint and sealing surface.
Corrective action:
NOTE: If a foam watershield becomes damaged in
any way, then it must always be renewed.
Check clamping load: Refer to Chalk Test.
Adjust the clamping load:
Diagnosis:
The clamping load is normally adjusted using
Water ingress in the lower part of the interior
the striker. When doing so, the edge
door trim or in the rocker panel area.
alignment from the door to the side panel, or
Cause:
from the front door to the rear door must be
The foam watershield fitted behind the interior
taken into account.
door trim exists to drain off water that has
Another setting method is to realign the panel
entered the door via the drainage holes, either
flange for the seal mounting. The clamping
downwards or outwards. If the water shield or
load is increased by moving the flange
foam watershield is damaged or has been
towards the door.
fitted incorrectly, then water can get into the
Check the bearing surface:
passenger compartment.
Apply chalk evenly to the surface of the seal.
In addition to this, the drainage holes can
Evenly coat the bearing surface of the door
become clogged with leaves, dirt or excess
with vaseline.
cavity protection agents. Water gathers in the
door and ingresses into the passenger
Close the door fully, the lock must engage.
compartment.
Open the door. The imprint of the chalk
(bearing surface) can be identified in the film
Check foam watershield for damage or
of grease.
correct fitting.
The bearing surface should be at least 5mm
Door seal
across at all points.
Item
Description
1
Door sheetmetal
2
Foam watershield
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501-25D-6
Body Repairs — Water Leaks
501-25D-6
DESCRIPTION AND OPERATION (Continued)
Checking the seal
Correct installation of the door seal
NOTE: If the seal has a connecting joint, this must
always be at the bottom of the door surround.
Other cause:
The door seal is attached to the welded
flange all the way round. If this welded flange
is uneven or damaged at any point (usually in
areas with narrow radii) then this point could
be subject to leaks.
A stretched seal carrier can also cause a
leak.
In both cases, water gets into the vehicle
interior under the seal carrier.
Corrective action:
Align the deformed welded flange using a
hammer and anvil block, prevent and if
Item
Description
necessary repair any paint damage.
1
Panel flange bent too far inwards: small
A stretched seal carrier must be realigned by
bearing surface
hand. If this is no longer possible, the seal
2
Panel flange adjusted correctly: correct
must be renewed.
bearing surface
Sliding roof/tilting roof
3
Check clamping load with a strip of paper
NOTE: In the case of a sliding or tilting roof, the
Other causes:
external rubber seal and the lock actuator or latch
The door seal must completely seal the door
mechanism must be checked first of all.
where it meets the bodywork.
Diagnosis:
Water can ingress directly or indirectly into the
interior of the vehicle if the seal is damaged at
Ingress of water at sliding roof aperture
any point.
Cause:
Corrective action:
The sliding roof/tilting roof is installed in a
A damaged or worn door seal must always be
water trap. The water drains off via the water
renewed in full.
trap, water drain holes and drain hoses. The
drain hoses lead downwards on both sides via
When renewing the seal, the following must
the A-pillar and C-pillar.
be taken into account:
The drain holes or drain hoses can become
Always fit the seal first in the area of the
clogged with leaves, dirt, underbody
narrow radii (corner points).
protection and so on.
Next, secure the seal to the flange evenly by
Corrective action:
tapping lightly with a rubber hammer. The
installed seal must not be kinked at any point.
Check the water trap for leaks.
NOTE: The prescribed length of a seal must not be
Check the drain hoses for leaks and for
shortened.
correct connection to the water trap.
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501-25D-7
Body Repairs — Water Leaks
501-25D-7
DESCRIPTION AND OPERATION (Continued)
Check the drainage system for unhindered
flow, and blow out with compressed air if
necessary.
Check the external seal and the correct
adjustment of the sliding roof.
Corrective action:
Seal the broken seal welds.
If a leak is found in the heater or ventilation
housing, the drain holes must be checked
first.
The housing may have to be removed to
Item
Description
check the foam watershield and its bearing
1
Roof sheetmetal
surface for damage.
2
Headliner
Checking foam watershields and water drain holes
Apron panel and heating/ventilation
Diagnosis:
Ingress of water into the front footwell area
Cause:
The apron panel is sealed in several places to
adjacent components, such as at the joints to
the A-pillar or to the floor pan. These seals
can be broken.
The heater and ventilation housing is attached
to the apron panel. The through area is
sealed with a foam watershield that is fixed to
the housing.
The housing has drain holes to allow the
Other causes:
water to drain off.
Fastening bolts and routing holes for cables
If the foam watershield is defective or the
and hoses must be checked for leaks in the
drain hole is clogged, water can ingress into
area of the apron panel and instrument cluster
the front footwell area.
(rubber grommets in particular).
Heater and ventilation housing seal
If the footwell area is wet, then the door hinge
NOTE: Damaged foam watershield must always be
seal, the door light switch and cable routing
renewed.
holes must also be checked.
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