Sunroof Installation Instructions Hollandia 100-II

Luft-Heizgeräte
03/2003
Sunroof
Installation Instructions
Hollandia 100-II
Hollandia 100-II
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Marking sunroof location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removing headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cutting sunroof aperture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sunroof cassette installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RSR-system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Final result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hollandia 100-II
NOTE
For installation and repair of Webasto sunroofs you will need technical documentation, a special
training by Webasto, special tools and special equipment.
Do NOT install or repair Webasto sunroofs, if you have not successfully finished the training by
Webasto for acquiring the necessary technical skills. Do NOT install or repair Webasto sunroofs,
if you do not have the necessary technical documentation, tools or equipment.
ALWAYS follow the Webasto installation and service instructions and mind all warning
indications.
Webasto does not assume any liabilities for defects or damages caused by persons that haven't
followed the installation training.
SYMBOLS
On each page you can find a symbol of the kind of tasks explained on that page.
Mechanical tasks
Electrical connections
Special parts of the text are marked with these symbols:
Indication of danger of injuries or accidents
Indication of danger of damaging the product
Indication of another source of information
Indication of technically special features
Watch carefully
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Hollandia 100-II
PERSONNEL
Basically, the Hollandia 100-II sunroof can be installed by one person.
PROTECTION
Improper use of tools can lead to injuries or damage to the vehicle or sunroof!
Thoroughly read tool instructions prior to using.
Before using any specialized tools, make sure to know all rules and regulations in your country.
Substances like glue, initiator or primer can be inflammable or harmful to your health when being touched or
inhaled. Carefully follow the instructions on the package of the product. Inform yourselves about the laws and
regulations in your country with reference to the use of this substance!
Wear a respiratory mask, make sure that the workplace is well ventilated and that there is a good functioning
aspiration system.
Also wear protective clothing like ear protection, safety shoes, safety goggles and protective gloves.
Cover interior and exterior of the ship with protection materials (covers, cloths, etc.) to reduce the risk of damage.
APPLICATION DATA
Check whether this sunroof can be installed in this vehicle:
USA:
Others:
http://www.techwebasto.com
http://dealers.webasto.com
=> showroom.
For application data (e. g. front distance) and vehicle specific installation instructions see:
=> applications
=> application data.
User name and password are required for this section.
Contact your Webasto subsidiary.
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Hollandia 100-II
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Hollandia 100-II
SCOPE OF DELIVERY
Check contents of box:
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Sunroof unit incl.
- glass panel
- latch handle
- hinges
- main seal
- upper frame
U-profile for lower frame
Lower frame
Headliner cover
Sealing tape
Lower frame screws M5 x 10, 24 pcs.
Paper template
Operating Instructions
Kraftfahrt-Bundesamt Type Approval
OTHER MATERIALS REQUIRED
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Masking tape
Sandpaper (fine)
Anti corrosion primer (e. g. red and black primer)
RSR brackets (depending on vehicle specific installation instructions)
NECESSARY TOOLS
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Awl
Utility knife
Scissors
Marker
Drilling machine
Drills
Filling knife with rounded corners
Electric metal shears
Oscillating saw
Tin snips
File
Measuring tape
• Torx® screw drivers
• Brushes for primer
• Disposable paper template with the roof cut-out marking and a headliner cut-out marking included in the
package
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Hollandia 100-II
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Introduction
Introduction
The Hollandia 100-II opens up fresh air comfort at an affordable price. The classic pop-up roof convinces with its
modern design and technical finesse: the glass panel can be completely removed. What's more, the Hollandia
100-II is suitable for almost every type of car.
The roof is equipped with a protective Venus® glass panel against UV radiation and solar heat and a folding
handle for individual open settings.
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Technical specification
Unit/frame dimensions.
[mm]
Model/type
H100-II
Curvature (cross)
8,800 / 9,400
Curvature (longitudinal)
11,000
Roof width
780
Roof length
410
Roof depth
23.6
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Preparation
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Hollandia 100-II
Preparation
Download and read application data:
USA:
http://www.techwebasto.com
Others:
http://dealers.webasto.com
Cover vehicle interior and exterior
 Seat covers
 Masking tape
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Marking sunroof location
(1) Place lower frame against headliner of vehicle.
(2) Use an awl to mark reference point “A”.
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Hollandia 100-II
Marking sunroof location
Place paper template.
Align reference point “A” with corresponding point
on paper template.
Fix template with tape.
 = 35 mm
Drill two ø 6 mm holes through roof skin and
headlining at positions “B”.
Cut out cardboard box template.
ATTENTION!
2 templates are on cardboard box.
Ensure to use correct template!
Temporarily attach cardboard template to headlining
with screws.
Cut out headlining with utility knife.
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Removing headlining
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Hollandia 100-II
Removing headlining
Remove headlining.
Remove sound absorbing material and roof stiffeners
if present.
Clean mastic remains from inside of car.
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Hollandia 100-II
Removing headlining
If electric cable is located in cut out area:
Do not cut cable when cutting out headlining!
Separate 3 wires of cable in the middle of the
aperture.
Cut wires separately to avoid shortcuts.
Extend cable.
Lead cable around aperture.
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Cutting sunroof aperture
Hollandia 100-II
If trimshell interferes with interior light:
Cut edge of trimshell as indicated.
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Cutting sunroof aperture
Cut and remove roof stiffener, if it is in mounting area
of sunroof unit.
Only do this if it’s indicated in the application data
(technical web site) or approved by Webasto
otherwise.
(1) Drill hole and (2) cut out sunroof aperture in car
roof.
Keep approx. 20 mm distance from cut line to prevent
distortion.
WARNING!
Avoid injuries from sharp metal edges!
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Hollandia 100-II
Cutting sunroof aperture
(1) Cut hole along cut line.
(2) File off edges of aperture.
(3) Sand edges of aperture.
WARNING!
Excess sheet metal can cause injuries!
Check aperture size with sunroof unit.
Clearance on each side must be approx. 0.75 mm.
ATTENTION!
Do not damage main seal!
(1) Apply anti corrosion primer to cutting edge.
(2) Let primer dry.
(3) Attach sealing tape to upper frame of sunroof
unit.
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Sunroof cassette installation
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Hollandia 100-II
Sunroof cassette installation
Place sunroof unit into roof aperture.
Place U-profile on lower frame.
Start and end at one of the short sides.
Install lower frame.
Mount lower frame screws.
Mount headliner cover.
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Hollandia 100-II
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RSR-system
RSR-system
If applicable, install RSR-system.
See Vehicle Specific Installation Advice on technical
web site.
USA:
http://www.techwebasto.com
Others:
http://dealers.webasto.com
See also Installation Instructions that come together
with RSR-system.
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Checking
Check installation and functionality.
See also Operating Instructions.
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Final result
Exterior of vehicle with Hollandia 100II sunroof.
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Ident-No. 1906091B • 02/12 • Errors and omissions excepted • Printed in The Netherlands • © Webasto AG, GCS 2012
Webasto Product International NL
Constructieweg 47
NL - 8263 BC Kampen
The Netherlands
Phone: +31 (0) 38 337 11 37
Fax:
+31 (0) 38 332 51 81
E-mail: [email protected]
Internet: www.webasto.com
http://dealers.webasto.com