Webasto 700 Series User Manual

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:
W
ITH CONSOLE: MILLIMETERS:
V
EHICLE PREP:
X REMOVE STIFFENERS
1 NUMBER REMOVED
BREAK HEADER & CANTRAILS LOOSE FROM ROOFSKIN
REMOVE INNER ROOF PANEL
HEADLINER BONDED, CUT FREE FROM ROOFSKIN
K
IT PREP:
X LIFT REAR BONDING FLAP FOR ADDITIONAL CONTOUR
X ADAPT BONDING FLAPS TO THE CONTOUR OF THE ROOFSKIN
TRIM BONDING FLAPS (MAX. 5 MM) (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
D
RAIN HOSE ROUTING, FRONT:
X INSIDE A-PILLAR
BETWEEN A-PILLAR & GARNISH MOLDING
EXIT INTO WET AREA OF ROCKER OR FACTORY GROMMET
X EXIT AT BELT LINE
DRILL ENTRY HOLE IN A-PILLAR
DRILL EXIT HOLE IN A-PILLAR
DRILL A HOLE IN FLOOR
D
RAIN HOSE ROUTING, REAR:
INSIDE C-PILLAR
X BETWEEN 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
X SEE SPECIAL INSTRUCTIONS
BRACING:
X STD. PROCEDURE; SEE INSTALLATION MANUAL PG.12 SEC.3.2
X ATTACH REAR BRACES TO SUNROOF
TWO EXTRA SUPPORTS ARE NEEDED IN FRONT L + R
SEE SPECIAL INSTRUCTIONS
E
LECTRICAL:
W
IRE COLOR FUSE
I
NG. HAR /FUSE BOX /CHASSIS /SUNROOF WIRE
F3
IGNITION – RED / BLK
F9
CONSTANT – RED
X
SYSTEM GND–GREEN
H
EADLINER:
USE EXISTING HEADLINER (FILLET)
X USE 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
M
ISCELLANEOUS:
X VERY TIGHT, SUNROOF LOCATION IS CRITICAL
ROOF STIFFENER REPLACEMENT (RSR) RECOMMENDED
RIB MODIFICATION REQUIRED
S
PECIAL 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 700 Series Specifications

General

Fuel	Diesel
Rated Voltage	12V/24V
Voltage	12V/24V
Heating Power	2.0 to 7.0 kW
Power Output	2.0 to 7.0 kW
Heating Capacity	7 kW
Weight	5.9 kg

Summary

General Technical Information and Vehicle Preparation

Vehicle Prep Steps

Steps for preparing the vehicle, including removing stiffeners and inner roof panel.

Kit Prep Steps

Steps for preparing the sunroof kit, such as adapting bonding flaps and mounting components.

Drain Hose Routing

Front Drain Hose Routing

Instructions for routing the front drain hoses through the A-pillar and to the exit point.

Rear Drain Hose Routing

Instructions for routing the rear drain hoses through the C-pillar and to the exit point.

Installation Components and Electrical

Bracing Requirements

Details on attaching braces and the need for extra supports during installation.

Electrical Connections

Information on wire color, fuse, and chassis connections for the sunroof system.

Headliner Installation

Guidance on using the existing headliner and modifying it for the sunroof.

Miscellaneous and Special Instructions

Miscellaneous Installation Notes

Key considerations like tight fit, roof stiffener replacement, and rib modification.

Special Installation Instructions

Specific guidance for rear drains and A-pillar modifications.

Vehicle Specific Information

Tips for foam removal, air duct modification, and dome lamp leveling.

Installation Troubleshooting and Tips

Drain Tube Installation Issue

Resolution for installing drain tubes through foam-filled A-pillars using a cable and drill.

Headliner Air Deflector Issue

Solution for reinstalling headliner air deflectors by removing extensions first.

Headliner Fit Issue

Method to ensure correct headliner fit by installing a screw through the headliner board.

Dome Lamp Leveling Issue

Fix for an uneven dome lamp and sunroof switch using foam pieces.

Pan Extender Tip

Recommendation to use a pan extender to hide sunroof motor bracket corners.