ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

501-02 Front End Body Panels > < 501-00 Body System - General Information|Body
Body System - General Information - Body System Focus RS 2003 (09/2002-)
Diagnosis and Testing

Inspection and Verification

  1. Verify the customer concern by operating the system.
  1. Visually inspect for obvious signs of mechanical or electrical damage.
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Visual Inspection Chart

Mechanical
  • Dust Leaks
  • Water Leaks

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Dust Leaks
*
Displaced sealer.
*
Refer to the service procedure below.
*
Damaged body parts.
*
Refer to the service procedure below.
*
Missing underbody grommets.
*
Refer to the service procedure below.
*
Misaligned doors.
*
Refer to the service procedure below.
*
Misaligned glass.
*
Refer to the service procedure below.
Water Leaks
*
Displaced sealer.
*
Refer to the service procedure below.
*
Damaged body parts.
*
Refer to the service procedure below.
*
Missing underbody grommets.
*
Refer to the service procedure below.
*
Misaligned doors.
*
Refer to the service procedure below.
*
Misaligned glass.
*
Refer to the service procedure below.

Sealer locations should be considered when checking for dust or water leaks. The forward motion of the vehicle causes any unsealed small opening in the lower section of the body to permit air and dust to be drawn into the body. Opening the ventilator air ducts will equalise these pressures. Dust accumulates in the luggage compartment body opening and may move into the luggage compartment.

To eliminate dust leakage, determine the exact point at which the dust enters. Under certain conditions, water may also enter the body at any point where dust can enter.

To determine the exact location of a dust leak, it may be necessary to remove the following trim panels from the vehicle:

After removing the trim panel(s), the location of most leaks will be evident. The entrance of dust is usually indicated by a point of dust or silt. Seal these leaks, then road test the vehicle on a dusty road to ensure all leaks are sealed. A suitable Leak Detector can locate dust leaks, wind and water leaks.

After the road test, check for indications of a dust pattern around the door openings, cowl side trim panel, lower part of the quater panel and in the luggage compartment.

Sometimes leaks can be located by putting bright lights under the vehicle, with the above components removed, and checking the interior of the body joints and weld lines. A light will show through where leaks exist.

501-02 Front End Body Panels > < 501-00 Body System - General Information|Body