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General Procedures > < Roof Opening Panel - Vehicles Built Up To: 05-1999

Mondeo 1997 (08.1996-09.2000)

Roof Opening Panel - Roof Opening Panel—Vehicles Built From: 05/1999 Mondeo 1997 (08/1996-09/2000)
Diagnosis and Testing

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
  • Alignment
  • Fuse
  • Circuit(s)
  • Loose or corroded connector(s)
  • Roof opening panel control switch
  • Roof opening panel
  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. NOTE:
    NOTE:Make sure all electrical diagnoses in the pinpoint tests are carried out using a digital multimeter.
    If the concern is not visually evident verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
The roof opening panel has excessive wind noise
*
Alignment.
*
Seals.
*
GO to Pinpoint Test A.
The roof opening panel leaks
*
Alignment.
*
Drain tubes.
*
Seals.
*
Weatherstrip.
*
Roof opening panel damaged.
*
Roof opening panel cassette damaged.
*
GO to Pinpoint Test B.
The roof opening panel rattles
*
Alignment.
*
Seals.
*
Obstructions.
*
Guides and track.
*
Headliner.
*
GO to Pinpoint Test C.
The roof opening panel is noisy during operation
*
Glass.
*
Obstructions.
*
Guides and track.
*
Roof opening panel.
*
GO to Pinpoint Test D.
The roof opening panel does not open or close
*
Fuse
*
Circuit(s).
*
Roof opening panel control switch.
*
Roof opening panel.
*
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 in flush from any position
*
Roof opening panel.
*
Roof opening panel control switch.
*
Alignment.
*
CHECK the alignment.
REFER to Roof Opening Panel Alignment in this section.

Pinpoint Tests

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

When closed is the roof opening panel flush to within recommended tolerances (flush to ±1 mm at the front and flush to ± 1 mm at the rear)?
Yes
GO to A2.
No
ADJUST the roof opening panel.
REFER to Roof Opening Panel Alignment in this section.
A2: CHECK THE SEAL CONDITION
1
Open the roof opening panel and examine the roof opening panel seal for condition and correct fitting.

Is the 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
Close the roof opening panel. Check the clearance between the roof opening panel seal and the roof panel.

Does the gap exceed 0.25 mm around the seal?
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 ALIGNMENT
1
Operate the roof opening panel from fully OPEN to fully CLOSED.

When closed, is the roof opening panel flush to within recommended tolerances (flush to ±1 mm at the front and flush to ±1 mm a the rear)?
Yes
GO to B2.
No
ADJUST the roof opening panel.
REFER to Roof Opening Panel Alignment in this section.
B2: CHECK THE DRAIN TUBES
1
Open the roof opening panel. Check that the drain tubes are not blocked by pouring 500ml of water into the drain trough and watching the flow from under the vehicle rocker panels.

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

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

Does the gap exceed 0.25 mm around 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 roof 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 is the headliner free from watermarks?
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 the roof opening panel?
Yes
VERIFY the customer concern.
No
RECTIFY any misalignment or 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 ALIGNMENT
1
Operate the roof opening panel from fully OPEN to fully CLOSED.

When closed, is the roof opening panel flush to within recommended tolerances (flush to ±1 mm at the front and flush to ±1 mm at the rear)?
Yes
GO to C2.
No
ADJUST the roof opening panel.
REFER to Roof Opening Panel Alignment in this section.
C2: CHECK THE SEAL CONDITION
1
Open the roof opening panel and examine the seal for condition and correct fitting.

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

Are there any loose objects present?
Yes
REMOVE all loose objects. CHECK the mechanism carefully for missing components. REPAIR or INSTALL a new mechanism as necessary. TEST the system for normal operation.
No
GO to C4.
C4: CHECK THE GUIDES AND TRACK
1
Gain access to the front track rails and the roof opening panel guides. Check for correct installation of the roof opening panel front track rails and the roof opening panel guides.

Are the roof opening panel front track rails and the roof opening panel guides securely and correctly installed?
Yes
CHECK the headliner security. REFER to Section  501-05 Interior Trim and Ornamentation.
No
REPAIR or INSTALL a new roof opening panel 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 opening panel retaining screws and CHECK the alignment.
REFER to Roof Opening Panel Alignment in this section.
No
GO to D2.
D2: CHECK FOR LOOSE OBJECTS
1
Open the roof opening panel and Check the roof opening panel side channels and guides for loose objects.

Are there any loose objects present?
Yes
REMOVE all loose objects. CHECK the mechanism carefully for missing components. REPAIR or INSTALL a new mechanism as necessary. TEST the system for normal operation.
No
GO to D3.
D3: CHECK THE GUIDES AND TRACK
1
Gain access to the front track rails and the roof opening panel guides. Check for correct installation of the roof opening panel front track rails and the roof opening panel guides.

Are the roof opening panel front track rails and the roof opening panel guides securely and correctly installed?
Yes
GO to D4.
No
REPAIR or INSTALL a new roof opening panel cassette. TEST the system for normal operation.
D4: CHECK THE ROOF OPENING PANEL MOTOR
1
Remove the roof console to access the roof opening panel motor.
2
Operate the roof opening panel control switch and cycle the roof opening panel from fully OPEN to fully CLOSED.

Is the motor excessively noisy?
Yes
INSTALL a new roof opening panel motor or INSTALL the existing roof opening panel motor correctly. TEST the system for normal operation.
No
VERIFY the customer concern.

PINPOINT TEST E : THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK THE CENTRAL JUNCTION BOX FUSE 21 (40 A)
NOTE:
NOTE:Fuse 21 (40A) also feeds circuit 29 (power windows)
1
CHECK Fuse 21 (40A).
2
Check the central junction box fuse 21 (40A).

Is the fuse OK?
Yes
GO to E2.
No
INSTALL a new fuse. TEST the system for normal operation. If the fuse fails again check circuit 15-AG12A (GN/BK) for short to ground.
E2: CHECK THE VOLTAGE TO THE ROOF OPENING PANEL CONTROL SWITCH
1
Disconnect Roof Opening Panel Control Switch C3009.
2
Ignition switch in position II.

3
Measure the voltage between the roof opening panel control switch C3009 pin 2, circuit 14-AG7 (VT/BU), and ground.

Is the voltage greater than 10 volts?
Yes
GO to E3.
No
GO to E8.
E3: CHECK CIRCUIT 31-AG7 (BK) FOR OPEN

1
Measure the resistance between the roof opening panel control switch C3009 pin 3, circuit 31-AG7 (BK) and ground

Is the resistance less than 5 ohms?
Yes
GO to E4.
No
GO to E10.
E4: CHECK CIRCUIT 31-AG6 (BK) FOR CONTINUITY
1
Disconnect Roof Opening Panel Control Unit C748b.

2
Measure the resistance between the roof opening panel control unit C748b pin 1, circuit 31-AG6 (BK), and the roof opening panel control switch C3009 pin 6, circuit 31-AG6 (BK).

Is the resistance less than 5 ohms?
Yes
GO to E5.
No
REPAIR circuit 31-AG6 (BK). TEST the system for normal operation.
E5: CHECK CIRCUIT 33-AG6 (YE) FOR CONTINUITY

1
Measure the resistance between the roof opening panel control unit C748b pin 3, circuit 33-AG6 (YE) and the roof opening panel control switch C3009 pin 1, circuit 33-AG6 (YE).

Is the resistance less than 5 ohms?
Yes
GO to E6.
No
REPAIR circuit 33-AG6 (YE). TEST the system for normal operation.
E6: CHECK CIRCUIT 32-AG10 (WH/BU) FOR CONTINUITY

1
Measure the resistance between the roof opening panel control unit C748b pin 2, circuit 32-AG10 (WH/BU), and the roof opening panel control switch C3009 pin 7, circuit 32-AG10 (WH/BU).

Is the resistance less than 5 ohms?
Yes
GO to E7.
No
REPAIR circuit 32-AG10 (WH/BU). TEST the system for normal operation.
E7: CHECK THE ROOF OPENING PANEL CONTROL SWITCH
1
Carry out the component test for the roof opening panel control switch. For additional information, refer to the Component Test in this section.

Is the roof opening panel control switch OK?
Yes
INSTALL a new roof opening panel control unit. TEST the system for normal operation.
No
INSTALL a new roof opening panel control switch. TEST the system for normal operation.
E8: CHECK THE VOLTAGE TO THE ROOF OPENING PANEL CONTROL UNIT
1
Ignition switch in position 0.
2
Disconnect Roof Opening Panel Control Unit C748a.
3
Ignition switch in position II.

4
Measure the voltage between the roof opening panel control unit C748a pin 1, circuit 15-AG12A (GN/BK) and ground.

Is the voltage greater than 10 volts?
Yes
GO to E9.
No
REPAIR circuit 15-AG12A (GN/BK). TEST the system for normal operation.
E9: CHECK CIRCUIT 14-AG7 (VT/BU) FOR CONTINUITY
1
Ignition switch in position 0.
2
Disconnect Roof Opening Panel Control Unit C748b.

3
Measure the resistance between the roof opening unit control unit C748b pin 5, circuit 14-AG7 (VT/BU), and the roof opening panel control switch C3009 pin 2, circuit 14-AG7 (VT/BU).

Is the resistance less than 5 ohms?
Yes
INSTALL a new roof opening panel control unit. TEST the system for normal operation.
No
REPAIR circuit 14-AG7 (VT/BU). TEST the system for normal operation.
E10: CHECK CIRCUIT 31-AG12 (BK) FOR OPEN
1
Ignition switch in position 0.
2
Disconnect Roof Opening Panel Control Unit C748a.

3
Measure the resistance between the roof opening panel control unit C748a pin 5, circuit 31-AG12 (BK) and ground.

Is the resistance less than 5 ohms?
Yes
GO to E11.
No
REPAIR circuit 31-AG12 (BK). TEST the system for normal operation.
E11: CHECK CIRCUIT 31-AG7 (BK) FOR CONTINUITY

1
Measure the resistance between the roof opening panel control unit C748b pin 4, circuit 31-AG7 (BK) and the roof opening panel control switch C3009 pin 3, circuit 31-AG7 (BK).

Is the resistance less than 5 ohms?
Yes
INSTALL a new roof opening panel control unit. TEST the system for normal operation.
No
REPAIR circuit 31-AG7 (BK). 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 THE 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 control switch to the OPEN/VENT position.

Did the 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
Operate the roof opening panel control switch to the CLOSE/DOWN position.

Does the roof opening panel pull down?
Yes
CHECK the alignment.
REFER to Roof Opening Panel Alignment in this section.
CHECK the roof opening panel motor synchronization.
REFER to Motor Synchronization in this section.
No
GO to Pinpoint Test E.

Component Test

Roof Opening Panel Control Switch

  1. Measure the resistance between the following:
Roof Opening Panel Control 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 control switch are as noted, return to the Pinpoint Test. Otherwise install a new roof opening panel control switch.

General Procedures > < Roof Opening Panel - Vehicles Built Up To: 05-1999