Focus L4-2.0L DOHC VIN 3 (2002)
a.
Wiring harness grommet not seated/loose.
Refer To Figure 5.
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Pull on both ends (body-side and liftgate-side) of wiring harness to check retention of grommet to sheet metal
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If grommets are loose, snap into place
b.
Left/right sheet metal flanges inboard.
Refer to Figure 7.
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Perform chalk test along flange area to confirm areas of lost contact between weatherstrip and liftgate
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Move flange outward in areas where inboard
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Perform chalk test again to verify contact with weatherstrip
C.
Top corner sheet metal flange height mismatches (at joints).
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Remove weatherstrip in suspected area of leak
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If observe step-joint (area where two sheet metal flanges come together) with height mismatches greater than 1/4" (6 mm), grind sheet
metal flanges to eliminate step-joint
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Prime/paint areas where grinding occurred Reinstall weatherstrip on flange
d.
Excessive sealer between sheet metal flange joints at bottom corners (weatherstrip leaks).
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Remove weatherstrip in suspected area of leak
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If observe excessive sealer on sheet metal flanges, remove sealer expulsion Prime/paint areas where sealer removed if necessary
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Reinstall weatherstrip on flange
e.
Liftgate fit (striker too far rearward).
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Perform chalk test to confirm areas of lost contact with weatherstrip
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Adjust the liftgate striker Perform chalk test again to verify contact with weatherstrip
