2014 Flex Workshop Manual

SECTION 501-00: Body System — General Information	2014 Flex Workshop Manual
DIAGNOSIS AND TESTING	Procedure revision date: 05/02/2013

Body System

Material
Item	Specification
Seam Sealer TA-2	—
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4

Inspection and Verification

Dust and Water Leaks

Most dust and water leaks occur due to missing or mis-installed body sealer or components. The source of the leak is detected by:

pressurizing the vehicle and testing with soapy water.
- Locate and tape off the body vents.
- Turn the blower motor on the high position.
- Turn the air recurculation to the off mode.
- Close the windows and doors.
- Open the hood and spray soapy water along body seams and grommets. Make sure to test the areas arround the A-pillar at the fender and the hood hinge area.
- Check for bubbles.
inspecting for a dust pattern or water path near and above the area in question.
removing any trim or carpet in the general area of the leak.
road testing or water-hose testing the vehicle.
placing a bright light under the vehicle, removing any necessary trim or carpet and inspecting the interior of the body at joints and weld lines.

Wind Noise

Most wind noise leaks occur at the corners of the windows or in the doors. Wind noise is detected by driving the vehicle at highway speeds or at speeds as specified by the customer. The vehicle should be driven in 4 different directions, with all the windows CLOSED, the radio OFF and the A/C blower motor OFF.

Squeak and Rattle

Squeak and rattle noises are generally caused by loose parts, contact or relative movement between 2 surfaces or loose wires and connectors. The source of the noise can be detected by stopping movement of the suspect part by hand or by using dampening or low friction materials.

Symptom Chart

Symptom Chart — NVH
**NOTE:** NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is possible that any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
Condition	Possible Sources	Action
Draft/wind noise and water leak around door perimeter	Loose fit seal	PINCH seal carrier to improve retention on seal flange.
	Seal installed incorrectly	REINSTALL the seal.
	Door misaligned	REALIGN the door. CHECK door gaps and fit in door opening and ADJUST as necessary. REFER to Section 501-03 .
	Scuff plate installed incorrectly	REINSTALL the scuff plate.
	Seal or seal pushpins damaged	INSTALL a new seal/pushpins.
	Sheet metal joints in door or door opening	SEAL leaks with Silicone Gasket and Sealant.
	A-pillar, B-pillar or C-pillar appliques loose or damaged	REINSTALL or INSTALL a new applique.
	Exterior door trim upper applique loose or damaged	INSTALL a new exterior door trim upper applique. For additional information, refer to Section 501-08 .
	A-pillar plug missing or damaged (Located below the A-pillar and above the front top door hinge.)	REINSTALL or INSTALL a new A-pillar plug.
Draft/wind noise and water leak around glass run	Door glass misaligned	ADJUST door glass.
	Glass run installed incorrectly	REINSTALL glass run. INSERT foam in glass run carrier if necessary.
	Leak path behind glass run	INSTALL foam rope behind glass run.
	Glass run channel spread wide	PINCH glass run channel to reduce size of opening.
	Glass run damaged	INSTALL a new glass run.
	Fixed rear door window glass excessive gap to the top of the rear door frame	REINSTALL the fixed rear door window glass tightly against the top of the rear door frame. For additional information, refer to Section 501-11 .
Draft/wind noise and water leak at inner belt line	Belt line seal installed incorrectly on flange	ADJUST seal. (Do not bend the flange.)
	No contact with side glass	ADJUST door glass.
	No contact with glass runs at both ends of belt line seal	ADJUST belt line seal or ADD foam at seal ends.
	Belt line seal damaged	INSTALL a new seal.
Draft/wind noise and water leak at outer belt line	Belt line seal installed incorrectly on flange (no glass contact)	ADJUST seal.
	Belt line seal does not contact the glass	ADJUST door glass.
	No contact with glass runs at both ends of belt line seal	ADJUST belt line seal or ADD foam at seal ends.
	Belt line seal damaged	INSTALL a new seal.
Draft/wind noise at inner door handle/speaker opening	Exterior door handle seal misaligned/damaged	REALIGN or INSTALL a new seal as necessary. For vehicles without IA , REFER to Section 501-14A . For vehicles with IA , REFER to Section 501-14B .
	Speaker or speaker seal missing or damaged	REPAIR speaker seal or INSTALL a new door speaker.
Draft/wind noise and water leaks at floor pan/dash panel and grommets	Missing or damaged plugs/grommets	CHECK plugs/grommets for correct installation or damage. INSTALL new plugs/grommets, if necessary.
Road noise	Missing mastic insulators	CHECK for missing mastic insulators. REFER to Section 501-35 .
	Missing body insulators	CHECK for missing body insulators.
Rattles in body/doors and instrument panel	Loose wires/cables	CHECK that all wires/cables are correctly routed and inserted in correct retainers.
	Loose objects/components in door wells, pillars, quarter trim panels	CHECK doors by carefully striking underside of doors with a rubber mallet, while listening for rattles in doors and pillars. REMOVE or TIGHTEN loose objects/components.
	Buzz from instrument panel components	IDENTIFY which components of the instrument panel are buzzing. SECURE/FASTEN components as necessary, ADD foam or felt as needed if rattle persists.
Door drain holes collecting water	Holes clogged with mud or road tar	CLEAN drain holes of foreign material with a punch or screwdriver. CHECK drain holes regularly.
Wind noise from exterior rear view mirror	Exterior mirror housing misaligned	REALIGN with edges shingled to airflow, with no gaps.
	Mirror sail gasket folded/misaligned	REINSTALL with gasket unfolded and aligned correctly.
	Mirror housing trim cap installed incorrectly	REINSTALL with edges shingled to airflow.
	Air leak through mirror housing hinge	Fully ENGAGE mirror into its operating position. USE foam to block air path through hinge.
	Inner sail trim installed incorrectly	REINSTALL sail trim. ADJUST door trim.
	Inner sail gasket/barrier installed incorrectly	REINSTALL trim cover with gasket/barrier aligned correctly.
	Air path through wiring bundle/fastener access holes	BLOCK air path(s) with foam/tape.
	Exposed fastener access hole on mirror housing/sail	INSTALL a new cap if missing.
Rattle/vibration from exterior rear view mirror	Mirror glass adjustment screws loose	REMOVE mirror glass and TIGHTEN mirror glass adjustment motor screws. REFER to Section 501-09 .
	Mirror mounting nuts loose	TIGHTEN mirror mounting nuts. REFER to Section 501-09 .
	Aftermarket air deflector/stone shields	If possible, REMOVE aftermarket air deflector/stone shield, then ROAD TEST vehicle. If concern is no longer present, ADVISE customer that aftermarket component was causing concern.
	If equipped with power fold mirrors, power fold mirrors folded/unfolded manually or are not synchronized	If equipped with power fold mirrors, SYNCHRONIZE power fold mirrors. REFER to Section 501-09 .
Draft/wind noise and water leak around perimeter of all fixed glass	Gaps in the sealant bead	APPLY approved sealant.
	Air traveling up windshield molding along A-pillar	INSTALL foam rope full length of the A-pillar.
	Gaps in sealant bead of windshield	RESEAL windshield glass. REFER to Section 501-11 .
	Windshield glass misaligned or not installed correctly	REINSTALL windshield glass. REFER to Section 501-11 .
	Rear hood seal at base of windshield misaligned/damaged	REALIGN or INSTALL a new seal as necessary.
Air leak at cowl	Cowl seal misaligned/damaged	REALIGN or INSTALL a new seal as necessary.
Draft/wind noise and water leak around liftgate perimeter	Loose fit seal	PINCH seal carrier to improve retention on seal flange or INSERT foam in carrier.
	Seal misaligned or installed incorrectly	REINSTALL seal.
	Liftgate misaligned	REALIGN liftgate. CHECK liftgate fit in body opening and ADJUST as necessary.
	Scuff plate misaligned	REINSTALL scuff plate.
	Seal or seal pushpins damaged	INSTALL a new seal.
Draft/water leak or noise from roof opening panel	Roof opening panel/components	REFER to Section 501-17 for diagnosis.
Wind noise created by airflow over or behind body panels	Fender splash shield misaligned	REALIGN fender splash shield.
	Body panel misaligned (exposed edge)	REALIGN appropriate body panel.
	Hood misaligned (front margin)	CHECK hood gaps and fit. ADJUST hood as necessary.
	Front grille edge noise	APPLY foam in hollow areas behind louvers.
Wind noise created by grille opening panel	Grille relationship to leading edge on hood	If possible, ADJUST grille opening panel forward to eliminate wind noise.
	Sharp edges due to material imperfections	REMOVE sharp edges (no damage to visible surface).
Wind noise from air extractor	Air extractor housing seated incorrectly	REINSTALL air extractor housing.
	Air extractor housing or flaps damaged	INSTALL a new air extractor.
Noise from roof rack	Roof rack rails or crossbars loose	TIGHTEN fasteners.
	Roof rack fasteners missing	INSTALL approved fasteners.
	Roof rack crossbars installed backward	REINSTALL crossbars.
	Roof rack rub strips partially lifting from roof	REAPPLY adhesive or fasteners or INSTALL new rub strips as necessary.
	Roof rack gaskets loose or misaligned	REINSTALL gasket.
Wind noise from bug shield/exterior windshield sun visor	Turbulence created by location and shape	DETERMINE if an OEM part or aftermarket. If aftermarket, ADVISE customer accordingly. If OEM, VERIFY correctly installed. If noise is abnormal, REPAIR or INSTALL new as required.