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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