Ford Fiesta (2011 year). Manual — part 104

Smoke test

Flow checking device

Description

Des

cript

ion

Test pipe

1

Test pipe opener

2

Puffer ball

3

Operating principle

The flow checking device is a set made up of a
flow-testing pipe, a test pipe opener, puffer ball
and closing-off caps for the pipe.

The test pipe contains a filling layer which is
impregnated with fuming sulfuric acid. When air is
blown through the pipe by the puffer ball, sulfuric
acid is emitted as an aerosol in the form of a white
smoke.

NOTE: Pay attention to the instructions for use and
the safety directions issued by the manufacturer.
The smoke test can only be performed in a
draft-free environment.

This test can be used to detect leaks visually.
Procedure:

• Break off both tips of the pipe in the pipe opener,

in exceptional cases in the top of the packaging.

• Insert the pipe into the puffer ball so there are

no leaks.

• Close the hole in the puffer ball with your thumb

and press the air contained in the ball through
the pipe.

• Set the ventilation blower in the passenger

compartment to the highest setting.

• Close all doors so that a slight overpressure can

build up in the passenger compartment.

• Move the smoke pipe along the outside of the

body to the areas to be checked.

• Leaks can be detected through the irregular

movement of the smoke.

Stethoscope test

This procedure is very similar to the smoke test.
Instead of the smoke pipe, move a stethoscope
past the areas of the body that are at risk. Leaks
can now be detected acoustically.

Stethoscope

G468074en

501-25-

70

Body Repairs - General Information

501-25-

70

DESCRIPTION AND OPERATION

201

Ultrasonic detection

This test uses ultrasonic waves to locate the
positions of leaks. When an ultrasonic transmitter
is placed inside the vehicle, it sends out ultrasonic
waves. A leak is located by running a detector
along the suspected area. The position with the
loudest reception of the escaping ultrasonic waves
is the location of the leak.

Procedure:

• Place the ultrasonic transmitter in the vehicle.

• Completely close the vehicle.

• Search the exterior of the vehicle using the

detector.

• The detector provides a simple indication of a

leak.

Ultrasonic test device

Workflow for tracing water entry

Action

Res

ult

Testing

Sta

ge

Dry out the
vehicle and
repair the
damage.
Perform a water
test as a check

(see test
method).

Yes

Ask customer for
a detailed list of
possible reasons
for the water
entry. Does this
information allow
the cause of the
leak to be identi-
fied?

1st

Action

Res

ult

Testing

Sta

ge

Step 2.

No

Dry out vehicle.
Repair damage.
Perform a water
test as a check

(see test
method).

Yes

Perform an initial
visual inspection
on the vehicle.
Look for signs of
water entry. Can
the cause of the
leak be identified
immediately?

2nd

Step 3.

No

Check the seal
for damage.
Check the
creation of the
seal using the
chalk test

(see

test methods).

Step 4.

Is it possible that
water is getting
into the vehicle
through a seal
(door seal, trunk
lid seal)?

3rd

Step 5.

No

Step 5.

Yes

Is the contact
area for the seal
adequate?

4th

Perform work as
described under
Areas with
possible water
leaks - Door
seals. Dry out
vehicle. Repair
damage.
Perform a water
test as a check

(see test
method).

No

Dry out vehicle.
Repair the
damage using
the information
found. Perform a
water test as a
check

(see test

method).

Yes

Before starting
any further work,
use the VIN to
look for model-
specific informa-
tion in eTIS.
Perform Oasis
query and check
TSIs. Does this
information allow
the cause of the
leak to be identi-
fied?

5th

Step 6.

No

G468074en

501-25-

71

Body Repairs - General Information

501-25-

71

DESCRIPTION AND OPERATION

201

Action

Res

ult

Testing

Sta

ge

Dry out vehicle.
Repair leak.
Perform a water
test as a check

(see test
method).

Yes

Establish the
extent of the
damage. To do
this, expose wet
areas. Remove
parts. Investigate
the suspected
area for signs of
water. Does an
investigation of
the suspected
area allow the
cause of the leak
to be identified?

6th

Step 7.

No

Dry out vehicle.
Repair leak.
Perform a water
test as a check

(see test
method).

Yes

Check exterior
areas (seals,
seal welds).
Check interior
areas: Signs of
water, plugs,
seal welds. Can
the cause of the
leak be identi-
fied?

7th

Step 8.

No

Dry out vehicle.
Repair leak.
Perform a water
test as a check

(see test
method).

Yes

Perform water
test or ultra-
sound test. Can
the cause of the
leak be found?

8th

The water entry
may only occur
under dynamic
driving condi-
tions. This
requires
intensive tests to
be repeated with
the corres-
ponding climatic
influences (rain).

No

Possible complaints and corrective
actions

NOTE: Water leaks and changed vehicle acoustics
can have similar causes. For this reason,
information from the Wind noise or Noise,

vibrations, roughness chapters may be useful in
identifying the fault.

An outline of the possible complaints due to water
leaks is provided below. The causes of water leaks
and the possible remedies are presented using
selected examples. They are intended to provide
troubleshooting tips and suggestions for the user
but do not represent an exhaustive faults list.

Glued windows

A broken pasted seam can cause water to enter
around the window. A broken pasted seam can be
located using a water test or by carefully blowing
compressed air onto the inside of the window seal.

Corrective action

Broken adhesive seams -Arrow- can be sealed
from inside using PU glass adhesive.

If this seal does not resolve the problem or the
broken pasted seam is too extensive, it is
necessary to remove the window and glue it back
into place.

Door seals

If water appears at the bottom of the door, it is
possible that the door seal behind the door trim is
damaged. If the door is intact, water can enter
through the window weatherstrip and flow out
through gaps on the underside of the door. If the
door seal adhesion is faulty or the door seal is
damaged, water can get into the interior.

G468074en

501-25-

72

Body Repairs - General Information

501-25-

72

DESCRIPTION AND OPERATION

201

Description

Des

cript

ion

Seal/adhesion

1

Clips

2

Door speaker

3

Fastening bolts could be loose or clips incorrectly
positioned on door modules.

Corrective action

Depending on the door seals used, different sealing
methods can be used.

NOTE: The drainage holes on the underside of the
door may not be blocked - if they are, clean them.
Defective films and foam seals must be replaced.

Once the adhesive surfaces have been cleaned,
plastic films must be stuck with double-sided
adhesive tape or replaced.

Leaky foam seals are sealed with Butyl tape or
replaced.

Plastic door modules are fitted with a weatherstrip,
which cannot be replaced. Seal the leaky point with
Butyl tape or replace the part.

Door weatherstrip

Leaks can be caused by badly fitted seals. In
particular, areas with radii -Arrow- must be
thoroughly checked.

Door seals can develop leaks due to:

• Damaged or expanded seals.

• Ageing.

• Insufficient contact pressure.

• Inadequate contact area for seal on body part.

• Uneven welded flange thickness because of

several layers of body panels or production
tolerances.

• Kinks.

The contact pressure of a seal can be determined
using a strip of paper. If a strip of paper trapped in
the closed door can be pulled out easily, the
contact pressure is too low.

To resolve

G468074en

501-25-

73

Body Repairs - General Information

501-25-

73

DESCRIPTION AND OPERATION

201