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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