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Roof Opening Panel - Vehicles Built From: 05-1999 > < Roof Opening Panel

Cougar 1999 (08.1998-01.2001)

Roof Opening Panel - Roof Opening Panel—Vehicles Built Up To: 05/1999 Cougar 1999 (08/1998-01/2001)
Diagnosis and Testing

General Equipment
Multimeter

Electrical Schematic Reference(s)

Refer to the Wiring Diagram, Section 501 - 17, Roof Opening Panel for schematic and connector information.

Inspection and Verification

  1. Verify the customer concern, by operating the system.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Roof opening panel damaged/leaking
  • Seals
  • Guides
  • Cables
  • Adjustment
  • Fuse 21 (40A)
  • Wiring harness
  • Connectors
  • Roof opening switch
  • Roof opening unit
  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.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
The roof opening panel has excessive wind noise
*
Adjustment.
*
Seals.
*
Go to Pinpoint Test A.
The roof opening panel leaks
*
Adjustment.
*
Drain tubes.
*
Seals.
*
Weatherstrip.
*
Roof opening panel damaged.
*
Roof opening panel cassette damaged.
*
Go to Pinpoint Test B.
The roof opening panel rattles
*
Adjustment.
*
Seals.
*
Obstructions.
*
Guides and track.
*
Headliner.
*
Go to Pinpoint Test C.
The roof opening panel is noisy during operation
*
Obstructions.
*
Guides and track.
*
Roof opening unit.
*
Go to Pinpoint Test D.
The roof opening panel does not open or close
*
Fuse 21 (40A).
*
Circuit(s).
*
Switch.
*
Roof opening unit.
*
Go to Pinpoint Test E.
The roof opening panel does not open or close in vent position
*
Linkage.
*
Go to Pinpoint Test F.
The roof opening panel does not stop flush from any position
*
Roof opening unit.
*
Switch.
*
Adjustment.
*
REFER to Horizontal Adjustment, General Procedure in this Section

Pinpoint Tests

PINPOINT TEST A : THE ROOF OPENING PANEL HAS EXCESSIVE WIND NOISE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE ADJUSTMENT
1
Operate the roof opening panel from fully OPEN to fully CLOSED.

When CLOSED is the roof opening panel flush to within recommended tolerance ± 1 mm?
Yes
GO to A2.
No
REFER to Horizontal Adjustment, General Procedure in this Section
A2: CHECK THE SEAL CONDITION
1
OPEN the roof opening panel and examine roof opening panel seal for condition and correct fitting.

Is seal in good condition and fitted correctly?
Yes
GO to A3.
No
INSTALL a new or INSTALL the existing seal correctly. TEST the system for normal operation.
A3: CHECK THE SEAL CLEARANCE
1
CHECK the gap between the roof opening panel seal and the roof panel.

Does the gap exceed 0.25 mm around most of the seal and the roof panel?
Yes
INSTALL a new seal. TEST the system for normal operation.
No
Verify the customer concern.

PINPOINT TEST B : THE ROOF OPENING PANEL LEAKS
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE ADJUSTMENT
1
Operate the roof opening panel from fully OPEN to fully CLOSED

When CLOSED is the roof opening panel flush to within recommended tolerance ± 1 mm?
Yes
GO to B2.
No
REFER to Horizontal Adjustment, General Procedure in this Section.
B2: CHECK THE DRAIN TUBES
1
Check that the drain tubes are clear by pouring 500 ml of water into the drain trough and watching the flow from under the vehicles rocker panels.

Is the water flow restricted?
Yes
REPAIR the water tube(s). INSTALL a new water drain tube(s) as appropriate. TEST the system for normal operation.
No
GO to B3.
B3: CHECK THE SEAL CONDITION
1
Open the roof opening panel and examine seal for condition and correct fitting.

Is the seal in good condition and fitted correctly?
Yes
GO to B4.
No
INSTALL a new seal or INSTALL existing seal correctly. TEST the system for normal operation.
B4: CHECK THE SEAL CLEARANCE
1
Check the gap between the roof opening panel seal and the roof panel.

Does the gap exceed 0.25 mm around most of the seal?
Yes
INSTALL a new seal. TEST the system for normal operation.
No
GO to B5.
B5: CHECK THE WEATHERSTRIP
1
Check the weatherstrip between the roof panel and the opening panel frame for signs of splitting or cracking and for signs of water marks on the headliner.

Does the weatherstrip appear to be in good condition and free from water marks on the headliner?
Yes
GO to B6.
No
INSTALL a new weatherstrip. TEST the system for normal operation.
B6: CHECK FOR DAMAGE OR DISTORTION
1
Check the contours of the roof panel for damage or distortion.

Do the roof contours match the contours of roof opening panel?
Yes
CHECK for leaks. TEST the system for normal operation.
No
RECTIFY misalignment. INSTALL a new roof opening panel. TEST the system for normal operation.

PINPOINT TEST C : THE ROOF OPENING PANEL RATTLES
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE ADJUSTMENT
1
Operate the roof opening panel from fully OPEN to fully CLOSED.

When CLOSED, is roof opening panel flush to within recommended tolerance ± 1 mm?
Yes
GO to C2.
No
REFER To Horizontal Adjustment, General Procedure in this Section.
C2: CHECK THE SEAL CONDITION
1
Open the roof opening panel and examine roof opening panel seal for condition and correct fitting.

Is the seal in good condition and fitted correctly?
Yes
GO to C3.
No
INSTALL a new seal or INSTALL the existing seal correctly. TEST the system for normal operation.
C3: CHECK FOR LOOSE OBJECTS
1
Open the roof opening panel and examine the housing side channels and guides for loose objects.

Are there any loose objects present?
Yes
REMOVE all loose objects. If these consist of or contain possible roof opening panel hardware, EXAMINE the mechanism carefully for missing components. REPAIR or INSTALL a new mechanism as necessary. TEST the system for normal operation.
No
INSTALL a new opening panel frame cassette. TEST the system for normal operation.

PINPOINT TEST D : THE ROOF OPENING PANEL IS NOISY DURING OPERATION
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE ROOF OPENING PANEL
1
CHECK the roof opening panel for security.

Is the panel loose?
Yes
TIGHTEN the roof panel and CHECK adjustment. REFER to Horizontal Adjustment, General Procedure in this Section.
No
GO to D2.
D2: CHECK FOR LOOSE OBJECTS
1
Open the roof opening panel and examine the housing side channels and guides for loose objects.

Are there any loose objects present?
Yes
REMOVE all loose objects. If these consist of or contain possible roof opening panel hardware, EXAMINE the mechanism carefully for missing components. REPAIR or INSTALL as necessary. TEST the system for normal operation.
No
GO to D3.
D3: CHECK THE ROOF OPENING PANEL MOTOR
1
Disassemble the overhead console to access the roof opening panel motor.
2
Operate the switch and cycle the roof opening panel from fully OPEN to fully CLOSED.

Is the motor excessively noisy?
Yes
CHECK roof opening motor unit for correct installation. INSTALL a new roof opening motor unit. TEST the system for normal operation.
No
Verify customer concern.

PINPOINT TEST E : THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK FUSE 21 (40A)
NOTE:
NOTE:Fuse 21 also feeds circuit 29 (electric window)
1
Ignition switch in position 0.
2
CHECK .

Is the fuse OK?
Yes
GO to E2.
No
INSTALL a new fuse 21 (40A). TEST circuit for normal operation. If the fuse fails again check for short to ground. REPAIR as necessary.
E2: CHECK THE VOLTAGE TO THE ROOF OPENING UNIT CIRCUIT 14-AG12 (VT/BK)
1
Ignition switch in position 0.
2
Disconnect Roof opening unit C748.
3
Ignition switch in position II.

4
Measure the voltage between the roof opening motor unit C748-2, circuit 14-AG12 (VT/BK) and ground.

Is voltage greater than 10 volts?
Yes
GO to E5.
No
GO to E3.
E3: CHECK FOR OPEN ON CIRCUIT 14-AG12 (VT/BK)
1
Ignition switch in position 0.
2
Disconnect CJB C367.

3
Measure the resistance between the roof opening motor unit C748, circuit 14-AG 12 (VT/BK), and the central junction box (CJB) C367 pin 3, circuit 14-AG 7 (VT/BK).

Is the resistance less than 5 ohms?
Yes
INSTALL a new central junction box (CJB). TEST the system for normal operation.
No
REPAIR circuit 14-AG12 (VT/BK), and circuit 14-AG (VT/BK). TEST the system for normal operation.
E4: CHECK FOR OPEN CIRCUIT 31-AG12 (BK)
1
Ignition switch in position 0.

2
Measure the resistance between the roof opening motor unit C748-1, circuit 31 - G12 (BK) and ground.

Is the resistance less than 5 ohms?
Yes
GO to E5.
No
REPAIR circuit 31-AG12 (BK). TEST the system for normal operation.
E5: CHECK THE ROOF OPENING SWITCH
1
TEST the roof opening switch. For additional information, refer to the procedure in this Section: Roof Opening Switch Test .

Is the roof opening switch OK?
Yes
GO to E6.
No
INSTALL a new roof opening adjust switch. TEST the system for normal operation.
E6: CHECK THE ROOF OPENING RELAY
1
TEST the relay, refer to Roof Opening Relay Test in this Section.

Is the roof opening relay OK?
Yes
INSTALL a new roof opening motor unit.
No
INSTALL a new roof opening relay. TEST the system for normal operation.

PINPOINT TEST F : THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE IN VENT POSITION
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
F1: CHECK ROOF OPENING PANEL REAR LIFTING MECHANISM
1
Manually wind the roof opening panel to the closed position if possible.
2
Ignition switch in position II.
3
Operate the roof opening panel switch to the OPEN/TILT position.

Did roof opening panel lift at the rear?
Yes
GO to F2.
No
Go to Pinpoint Test E.
F2: CHECK ROOF OPENING PANEL VENT CLOSED OPERATION
1
Ignition switch in position II.
2
Toggle the roof opening panel switch to CLOSE/DOWN position.

Does the roof opening panel pull down?
Yes
REFER to Horizontal Adjustment, General Procedure in this Section. ADJUST as necessary. TEST the system for normal operation.
No
Go to pinpoint Test E.INSTALL a new roof opening panel frame. Test the system for normal operation.

Component Test

Switch-Roof Opening Panel

  1. Measure the resistance between the following:

Roof Opening Switch Position Terminals Measurements
Neutral 3-7 Less than 5 ohms
Neutral 1-6 Less than 5 ohms
Neutral 2-7 Greater than 10,000 ohms
Neutral 1-2 Greater than 10,000 ohms
Up/Close 1-2 Less than 5 ohms
Up/Close 3-7 Less than 5 ohms
Up/Close 1-6 Greater than 10,000 ohms
Down/Open 1-6 Less than 5 ohms
Down/Open 2-7 Less than 5 ohms
Down/Open 3-7 Greater than 10,000 ohms

  1. If all measurements of the roof opening panel switch are as noted, return to the Pinpoint Test. Otherwise INSTALL a new roof opening panel switch.

Relay-Roof Opening

Refer to the Wiring Diagram.

Roof Opening Panel - Vehicles Built From: 05-1999 > < Roof Opening Panel