Webasto 700 Series Manual de usuario

WEBASTO PRODUCT NORTH AMERICA INC.700 SERIES SUNROOF V.S.W.

MAKE:DODGE MODEL:DURANGO ISSUE DATE:1/19/04

TYPE :S.U.V. YEAR :2004 LAST REVISED:4/12/04

GENERAL TECHNICAL INFORMATION:

700 SERIES MODEL:

743 RIBBED ROOF:

CUT LINE STANDARD: 11 ¼” MILLIMETERS:

WITH CONSOLE: MILLIMETERS:

VEHICLE PREP:

XREMOVE STIFFENERS

1 NUMBER REMOVED

BREAK HEADER &CANTRAILS LOOSE FROM ROOFSKIN

REMOVE INNER ROOF PANEL

HEADLINER BONDED,CUT FREE FROM ROOFSKIN

KIT PREP:

XLIFT REAR BONDING FLAP FOR ADDITIONAL CONTOUR

XADAPT BONDING FLAPS TO THE CONTOUR OF THE ROOFSKIN

TRIM BONDING FLAPS (MAX.5MM)(MAX..19 3/16 IN.)

HINGE SUNROOF

TRIM FRAME RUBBER IN REAR CORNERS

BEND MOTOR HOUSING DOWN

REMOVE SWITCH BRACKET

MOUNT DOME LAMP TO KIT

MOUNT CONSOLE /REAR AIR CONTROLS TO KIT

MOUNT REAR AIR CONTROLS BEHIND KIT

EXTRA GROUND FOR DOME LAMP

DRAIN HOSE ROUTING,FRONT:

XINSIDE A-PILLAR

BETWEEN A-PILLAR &GARNISH MOLDING

EXIT INTO WET AREA OF ROCKER OR FACTORY GROMMET

XEXIT AT BELT LINE

DRILL ENTRY HOLE IN A-PILLAR

DRILL EXIT HOLE IN A-PILLAR

DRILL A HOLE IN FLOOR

DRAIN HOSE ROUTING,REAR:

INSIDE C-PILLAR

XBETWEEN C-PILLAR &GARNISH MOLDING

EXIT AT WET AREA OF ROCKER OR FACTORY GROMMET

EXIT AT WHEEL WELL (DRILL HOLE)

ACCESS TRUNK,EXIT AT FACTORY GROMMET (DRILL HOLE)

DRILL ENTRY HOLE IN C-PILLAR

DRILL EXIT HOLE IN C-PILLAR

XSEE SPECIAL INSTRUCTIONS

BRACING:

XSTD.PROCEDURE;SEE INSTALLATION MANUAL PG.12 SEC.3.2

XATTACH REAR BRACES TO SUNROOF

TWO EXTRA SUPPORTS ARE NEEDED IN FRONT L+R

SEE SPECIAL INSTRUCTIONS

ELECTRICAL:

WIRE COLOR FUSE

ING.HAR /FUSE BOX /CHASSIS /SUNROOF WIRE

IGNITION –RED /BLK

CONSTANT –RED

XSYSTEM GND–GREEN

HEADLINER:

USE EXISTING HEADLINER (FILLET)

XUSE HEADLINER AROUND ENTIRE SUNROOF

CUT &CLOSE OFF REAR AIR DUCT

REUSE PIECE OF HEADLINER AROUND DOME LAMP /CONSOLE

RELOCATE REAR AIR VENTS

RELOCATE SWITCH BETWEEN VISOR &CONSOLE

RELOCATE SWITCH IN DASH

RELOCATE SWITCH IN CONSOLE

MISCELLANEOUS:

XVERY TIGHT,SUNROOF LOCATION IS CRITICAL

ROOF STIFFENER REPLACEMENT (RSR) RECOMMENDED

RIB MODIFICATION REQUIRED

SPECIAL INSTRUCTIONS:

REAR DRAINS DRILL A HOLE UNDER KICK SEAL

VEHICLE SPECIFIC INFORMATION:

•'A' PILLAR FOAM REMOVAL

•HEADLINER AIR DUCT REMOVAL

•IMPROPER FIT OF HEADLINER AFTER CUTTING

•DOME LAMP UNEVEN WITH SUNROOF SWITCH

•SUNROOF PAN EXTENDER

WEBASTO PRODUCT NORTH AMERICA INC.700 SERIES SUNROOF V.S.W.

MAKE:DODGE MODEL:DURANGO ISSUE DATE:1/19/04

TYPE :S.U.V. YEAR :2004 LAST REVISED:4/12/04

VEHICLE SPECIFIC INFORMATION:

The following information applies only to the vehicle model listed in this document. Below are multiple tips and work

arounds to assist the workshop or dealership installing a 700 series sunroof. Unique installation issues will be discussed

throughout this section. Webasto will not be held liable for damages acquired due to alterations in the subsequent

repair procedures.

ISSUES:

ISSUE:

Installation of drain tubes through the 'A' pillar filled with foam.

RESOLUTION:

Using an old sunroof cable frayed on one end, insert the damaged end into pillar while inserting the other into a

3/8 drill. This will quickly remove the foam for easy installation of the drain tubes.

ISSUE:

Difficultly reinstalling headliner air deflectors

RESOLUTION:

Remove the two air duct extensions from headliner and install deflectors first. After extension re-installation, seal

gap between extension and duct.

WEBASTO PRODUCT NORTH AMERICA INC.700 SERIES SUNROOF V.S.W.

MAKE:DODGE MODEL:DURANGO ISSUE DATE:1/19/04

TYPE :S.U.V. YEAR :2004 LAST REVISED:4/12/04

ISSUE:

During installation of headliner, the sides no longer fit correctly.

RESOLUTION:

Before proceeding with the following repair, ensure there are no obstructions such as side curtain air

bags.

Install a three inch screw through the original headliner board as shown to properly form headliner. Ensure screw

does not puncture outer roof skin.

ISSUE:

Dome Lamp uneven with sunroof switch.

RESOLUTION:

Insert a 3 x 1½ x 1 inch piece of foam above each side of the dome lamp assembly. This will level out the dome

lamp and sunroof switch.

WEBASTO PRODUCT NORTH AMERICA INC.700 SERIES SUNROOF V.S.W.

MAKE:DODGE MODEL:DURANGO ISSUE DATE:1/19/04

TYPE :S.U.V. YEAR :2004 LAST REVISED:4/12/04

TIPS:

TIP:

Prior to installing unit, a pan extender is recommended for this application. This hides the corners of the sunroof

motor bracket through the headliner.

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