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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