Ford Falcon. Manual — part 440
501-17-13 Sunroof 501-17-13
GENERAL PROCEDURES (Continued)
4. In the areas marked, a spacer will be inserted
9. Check functioning and adjustments.
inside the rubber seal. Use a vinyl tube with outer
Wind Deflector Adjustment
diameter of 3 mm (0.12 in) for spacer material.
1. Slide panel backwards.
2. Bring deflector in position.
3. Adjust deflector to 4mm between trim profile and
deflector.
4. Tighten two capnuts (2 Nm).
5. Check operation of deflector.
Mechanism Covers Adjustment
1. Before mounting mechanism covers, check
functioning of completed roof on sunshade,
mechanism, wind deflector and adjustments of
glass panel. Correct if necessary.
2. Put mechanism in tilt position.
3. Place cover top part over 3 pins on side
adjustment brackets and lower part in rail under
drain channel.
5. Glue the spacer material to the seal with super
glue.
4. Check
functioning.
6. Remount panel and adjust.
Ventilation Tray Adjustment
1. Slide the steel panel to tilt position.
2. Slide the ventilation tray completely to the rear
(release the 2 springs from the drain channel if
necessary).
3. Place the ventilation tray in the rail, starting with
the front guides, and slide it to the front. When the
ventilation tray slides completely to the front it can
occur that the guides come loose from the rail.
4. Place the left and right tumble mechanism over
the middle support pin of the steel panel.
5. Tumble the hook of the tumble mechanism into
the slot in the ventilation tray and fasten the
mechanism with a parker.
6. Place the panel in closed position.
7. Make sure the ventilation tray is parallel to the
trim tray. The rear corners of the ventilation tray
can be bend slightly if necessary.
8. The springs of the trim tray are automatically
locked to the drain channel during sliding open.
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501-17-14 Sunroof 501-17-14
REMOVAL AND INSTALLATION
3. Remove rear of headliner to access motor cover.
Motor
4. Remove motor cover, motor now drops down.
Removal and Installation
5. Disconnect the motor wire from the sunroof
1. Remove or drop rear of headliner to access motor
control unit.
cover.
6. Remove the S.C.U. with screw, drop the front,
2. Remove cover, motor now drops down.
slide back.
3. Disconnect the motor wire from the sunroof
7. Remove the gearwheel housing by removing the
control unit.
two screws.
4. Connect new motor to sunroof control unit.
8. Remove gearwheel by inserting screw-driver,
push forward, it drops down.
5. Inspect motor for proper operations in both
direc-tions.
6. Remount motor and motor cover.
7. Inspect the unit for proper electrical and
mechanical functioning.
8. Re-install
headliner.
Sunroof Control Unit (SCU)
Removal and Installation
1. Remove or drop rear of headliner to access motor
cover.
2. Remove cover, motor now drops down.
3. Disconnect the motor wire from the S.C.U and
remove the motor.
9. Place a screwdriver in the mechanism as
4. Disconnect the wire harness from the S.C.U.
indicated. Push this mechanism rearward into the
5. Remove the S.C.U. with screw, drop the front,
slide position. Continue pushing backwards by
slide back.
placing hand on front of mechanism, 3 locator
screws become accessible.
6. Place the new sunroof control unit by dropping the
front of the S.C.U. low enough for cable clearance
slide forward, engage lip of cable plate in S.C.U.
slot. Straighten S.C.U. horizontally and tighten
screw.
7. Reconnect both wire connectors to the S.C.U. and
remount motor and cover.
8. Calibrate the SCU: The first time the S.C.U. is
connected to the power supply, the maximum tilt
position must be defined. Proceed as follows:
Turn on the ignition. Open the panel to the
maximum tilt position till it reaches the mechanical
block (continuous control the switch). The
maximum tilt position is now stored in the Control
Unit and all electrical features are available. To
complete the calibration, the panel must be
10. Remove the locator being careful to remember
moved to the complete opened position by soft
the positioning of screws and the blocking catch.
touch operation.
11. Pull mechanism all the way forward.
9. Check proper functioning of sunroof.
12. Push the mechanism into tilt position. Be sure you
10. Mount headliner.
do not inadvertently dislodge the mechanism.
Keep the front of the mechanism down.
11. Remount the LH mechanism cover.
13. Remove the front screw and slide the retraction
Drive Cables
mechanism forward. Do not take out.
14. Slide mechanism in tilt position further forward.
Removal and Installation
15. You can now see the cable. Lift out cable and pull
1. Remove covers, panel, drain channel, wind
forward out of the guide rail track.
deflector and sunshade or trim tray and ventilation
tray and adjustment bracket.
2. Place mechanism in closed position.
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501-17-15 Sunroof 501-17-15
REMOVAL AND INSTALLATION (Continued)
16. Inspect for proper length of new cable, grease
24. Mount the new gearwheel. Being sure to center it
and slide into rail. Make sure the oval shaped
evenly between the walls of the hole in the motor
copper head of the cable seats firmly and
bracket.
diagonally across the guide channel.
NOTE: The core or center of the gear has splines
(teeth). The splines do not extend completely to
one side of the gears inner core. This is the down
(bottom) side for mounting
25. Mount the new gearwheel housing.
26. Mount the sunroof control unit. Dropping the front
of the S.C.U. low enough for cable clearance slide
forward, engage lip of cable plate in S.C.U. slot.
Straighten S.C.U. horizontally and tighten screw.
27. Connect the motor to the sunroof control unit (wire
one way connector).
28. Remount motor and cover, replace screws.
29. Calibrate the SCU as described in the Electrical
Trouble Shooting Section.
17. To check that cable is positioned properly grasp
30. Inspect the sunroof for proper electrical and
long lever in tilt position with one hand, the
mechanical functioning.
pivoting adjustment bracket in the other hand and 31. Remount headliner.
slide backwards, it should slide into place (if
32. Remount sunshade or ventilation tray and trim
blocked turn cable slightly to reseat copper oval
tray, drain channel, panel, wind deflector and
head properly).
mechanism covers.
18. Push mechanism into slide position as in point 9.
33. Final inspection of unit.
19. Slide whole mechanism rearwards to allow
remoun-ting of locator.
Drive Cables Timing
20. Slide the retraction rearwards, remount screw and
Removal and Installation
locator.
1. Fully
tilt
panel.
21. Repeat points 10 through 22 to replace other
cable.
2. Remove LH/RH mechanism covers.
22. Slide both LH/RH mechanisms to the front
3. Fully close panel.
position.
4. Drop rear of headliner to access motor cover
23. Push LH/RH mechanisms to closed position.
plate.
Insert a pin in each 2.5 mm brass hole. (pointed
5. Remove motor cover, motor now drops down.
object). Slide mechanism forward until pin stops
6. Disconnect sunroof control unit wires and remove
the mechanisms movement at the desired
the motor.
location.
7. Dismount sunroof control unit with screw, drop the
front and slide back.
8. Remove the gearwheel housing by removing the
two screws.
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501-17-16 Sunroof 501-17-16
REMOVAL AND INSTALLATION (Continued)
9. Remove gearwheel by inserting screwdriver, push 2. Remove seal from panel.
forward, it drops down.
3. Remove all foreign debris from around glass
frame.
4. Install new seal, beginning at center front of glass
panel retaining channel.
5. Utilizing your thumbs, insert seal with enough
pressure to be sure of flushness (tight to panel).
6. Trim the glass seal length. when cutting excess
leave approximately 6 mm extra then work it into
retaining channel.
7. Remount the panel.
8. Mount the LH / RH mechanism cover.
Retraction Mechanism
Removal and Installation
Item
Description
1. Retract panel completely.
1
SCU spots on gear wheel view finders
2. Remove the wind deflector.
2
SCU spots on gear wheel view finders
3. Remove the two screws and take the retraction
mechanism forwards out of rail.
10. Push mechanisms LH/RH to closed position.
4. Install new retraction mechanism in rail.
Access each 2.5 mm brass hole with a pin
(pointed object). Slide mechanism forward until
5. Remount the wind deflector.
pin stops the mechanisms movement at the
6. Inspect for proper functioning.
desired location.
11. Mount the new gearwheel. Being sure to center it
Guide Rail Mechanism
evenly between the walls of the hole in the motor
Removal and Installation
bracket. Note that the core or center of the gear
has splines (teeth). The splines do not extend
1. Remove LH/RH mechanism covers, panel, drain
completely to one side of the gears inner core.
channel, wind deflector and sunshade.
This is the down (bottom) side for mounting.
2. Fully retract mechanism.
12. Mount the new gearwheel housing.
3. Remove the locator, retraction mechanism and
13. Mount the sunroof control unit. Dropping the front
rail screw.
of the S.C.U. low enough for cable clearance slide 4. Remove wind deflector mounting nuts.
forward, engage lip of cable plate in S.C.U. slot.
5. Slide rail sideways to unlock, then lift front up.
Straighten S.C.U. horizontally and tighten screw.
6. With rail front up, remove retraction mechanism.
14. Connect the motor to the sunroof control unit.
7. Fully
close
mechanism.
(wire one way connector).
8. Lift and pull rail slowly forward over mechanism,
15. Remount motor and cover, replace screws.
as soon as the front of drive cable appears at end
16. Calibrate the SCU as described in the Electrical
of guide, lift out cable, now pull mechanism
Trouble Shooting Section.
carefully forward and lift out. Inspect the new
17. Inspect the sunroof for proper electrical and
replacement mechanism for cleanliness and
mechanical functioning.
completeness.
18. Remount headliner.
9. Slide the new mechanism rearward out of rail for
19. Remount the LH mechanism cover.
cable installation access.
20. Final inspection of unit.
10. Install cable, then push mechanism forward on rail
(maintain access to rear rail area).
Glass Panel Seal
Removal and Installation
1. Dismount LH / RH mechanism covers, glass
panel and exterior covers.
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