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:
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
F3
IGNITION –RED /BLK
F9
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.