Webasto HOLLANDIA 700 - 40 Series User manual

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Service Manual
HOLLANDIA 700 glass panel
HOLLANDIA 700 steel panel
Edited for North American Market by WPNA Revision A 9/24/01

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READ THIS FIRST
The Webasto HOLLANDIA 700 roofs are available in two models:
1. The HOLLANDIA 700 - 40 series (glass panel)
2. The HOLLANDIA 700 - 20 series (steel panel)
This service manual can be used for both models.
The HOLLANDIA 700 - 40 series are available in four different models:
1. HOLLANDIA 700 - 42 C (panel width 700 mm / 27.6 inch)
2. HOLLANDIA 700 - 43 (panel width 800 mm / 31.5 inch)
3. HOLLANDIA 700 - 43.5 C (panel width 855 mm / 33.7 inch)
4. HOLLANDIA 700 - 44 (panel width 900 mm / 35.5 inch)
5. HOLLANDIA 700 - 49 (panel width 1000 mm / 39.4 inch)
The HOLLANDIA 700 - 20 series are available in two different models:
1. HOLLANDIA 700 - 23 (panel width 800 mm / 31.5 inch)
2. HOLLANDIA 700 - 24 (panel width 900 mm / 35.5 inch)

TABLE OF CONTENTS
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READ THIS FIRST .......................................................................................................................................................3
OPERATING INSTRUCTIONS .....................................................................................................................................5
1. FAILURES.....................................................................................................................................................................7
1.1. REPAIR ADVICE FOR MECHANICAL FAILURES ...............................................................................................7
1.2. REPAIR ADVICE FOR ELECTRICAL FAILURES..................................................................................................7
1.3. REPAIR ADVICE FOR RATTLES.............................................................................................................................8
1.4. REPAIR ADVICE FOR WIND NOISES ....................................................................................................................8
1.5. REPAIR ADVICE FOR LEAKAGE PROBLEMS .....................................................................................................9
2. ELECTRICAL FAILURES ...........................................................................................................................10
2.2 TESTING ELECTRICAL COMPONENTS.......................................................................................................................11
2.2.1 FUSE...................................................................................................................................................................11
2.2.2 WIRE HARNESS SUNROOF CONTROL (SCU) UNIT TO BATTERY ..........................................................................11
2.2.3 WIRE HARNESS SUNROOF CONTROL UNIT (SCU) TO CONTROL PANEL .............................................................11
2.2.4 MOTOR...............................................................................................................................................................12
2.2.5 SUNROOF CONTROL UNIT (SCU) ........................................................................................................................12
2.2.6 CALIBRATION OF THE SCU:................................................................................................................................12
2.2.7 ELECTRICAL TROUBLE SHOOTING TABLE............................................................................................................13
3. REPAIRS............................................................................................................................................................15
3.1 MOTOR REPLACEMENT ...........................................................................................................................................15
3.2 SUNROOF CONTROL UNIT REPLACEMENT (SCU).....................................................................................................16
3.3 DRIVE CABLE REPLACEMENT..................................................................................................................................17
3.4 TIMING THE DRIVE CABLES.....................................................................................................................................21
3.5 SEAL REPLACEMENT HOLLANDIA 700 -20 SERIES .............................................................................................24
3.6 SEAL REPLACEMENT HOLLANDIA 700 -40 SERIES .............................................................................................25
3.7 RETRACTION MECHANISM REPLACEMENT ..............................................................................................................25
3.8 GUIDE RAIL MECHANISM REPLACEMENT ................................................................................................................26
3.9 BLOCKING CATCH REPLACEMENT...........................................................................................................................28
3.10 SEAL ADJUSTMENT HOLLANDIA 700 -20 SERIES................................................................................................29
3.11 SEAL ADJUSTMENT HOLLANDIA 700 -40 SERIES ...................................................................................................30

OPERATING INSTRUCTIONS
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OPERATING INSTRUCTIONS
All HOLLANDIA 700 models are standard equipped with a Sunroof Control Unit (SCU) in which many
features and operating options are programmed or can be programmed.
Pre-programmed functions:
•Soft touch
By quickly pressing the switch the sunroof will open or close (depending on the position of the
panel). Movement of the panel can be stopped by quickly pressing the switch again.
•Variable tilt position
The panel can be closed from tilt in four steps by continuously pressing the switch and releasing in
the desired position.
•Jamming protection (Safety Feature)
The jamming protection becomes active when the sunroof is closed either by soft-touch control or in
ignition auto-close mode. Should the panel encounter an obstacle while closing, it immediately
opens again. The sunroof will continuously try to close until the obstacle has been removed.
•Auto-close function
When turning off your vehicle’s ignition, the sunroof will beep to remind you that the auto-close
function will be activated. After three seconds the sunroof will close automatically which will be
indicated by two beeps. Should you require the sunroof to stop, briefly press the switch. You can
also prevent the panel from closing by pressing the switch during the three seconds interval. You
can still close the sunroof when the ignition is off. When you switch the ignition on, the sunroof opens
and closes in the normal manner.
•One-way closing
This feature always closes the panel from above, assuring a flush fit of the panel.

OPERATING INSRTUCTIONS
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Programmable operation:
•Comfort position
With this feature you are able to program two additional stopping positions of the panel in the sliding range of
the sunroof. The panel will stop at the positions programmed when operating button 1 or 2.
PROGRAMMING THE COMFORT POSITION:
1. Place the panel in the desired preset position
2. Push and hold the 1 button for about 3 seconds until you hear a beep.
3. Place the panel in the second desired preset position.
4. Push and hold the 2 button for about 3 seconds until you hear a beep.
On opening the sunroof with the 1or 2comfort button the panel will stop in the preset position. Operating the
switch again will open the sunroof completely.

1. FAILURES
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1. FAILURES
1.1. REPAIR ADVICE FOR MECHANICAL FAILURES
PROBLEM POSSIBLE CAUSE SOLUTION
While closing the panel from the
tilt position, the panel begins to
slide rearward.
Blocking catch is broken. Replace blocking catch, see 3.9
While closing the panel from the
fully opened position, the panel
begins to tilt under the roof skin.
Blocking catch is broken. Replace blocking catch, see 3.9
Panel is misaligned side to side Timing of drive cables incorrect Retime drive cables, see 3.4
Glass panel stopping
prematurely.
Obstacle in mechanism or guide
rail.
Remove obstacle.
Sunshade fails to open when
glass panel is opened to tilt
position.
Retraction mechanism broken Replace retraction mechanism,
see 3.7.
1.2. REPAIR ADVICE FOR ELECTRICAL FAILURES
PROBLEM POSSIBLE CAUSE SOLUTION
Operating of the sunroof is
possible, no auto-close, no
Soft-touch.
Voltage-drop of power-supply.
(changing battery or bad battery)
Check power-supply ,
Reset programmable preset
positions
SCU makes clicking noise but ,
panel will not move.
Low Voltage of vehicle power
supply.
Check power-supply/ battery
SCU clicking in open position,
roof does not close while
continuously pressing button.
Low Voltage of vehicle power
supply.
Briefly cut off power to sunroof.
(pull fuse) Reset programmable
positions.
Panel is sliding too slowly. With
a 13.5 V power supply, the panel
should not take more than 7 sec.
to close from the fully opened
position.
1. Weak battery.
2. Misaligned panel creating
drag or friction.
3. Weak motor. Test as indicated
in 2.2.4
4. Dirty mechanism.
1. Charge or replace.
2. Re-time drive cables, see 3.4
3. Replace motor, see 3.1
4. Clean and grease mechanism
or replace if necessary, see 3.8

1. FAILURES
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1.3.REPAIR ADVICE FOR RATTLING NOISE
PROBLEM POSSIBLE CAUSE SOLUTION
Drain channel rattles. Check if insulation tape is
applied between drain channel
and mechanism.
Add insulation tape.
Steel panel ventilation tray
rattling.
1. Curvature of front ventilation
tray incorrect.
2. Insufficient contact between
rail and ventilation tray tumbling
mechanism.
3. Wires insufficiently secured.
1. Manual adjust the curvature of
the ventilation tray.
2. Correct rear side ventilation
tray to improve rail contact.
3. Secure wires.
Rattle in motor area. Loose screws on motor cover
plate.
Tighten motor cover plate
screws.
1.4. REPAIR ADVICE FOR WIND NOISE
PROBLEM POSSIBLE CAUSE SOLUTION
Excessive wind noise when the
panel is in the closed position.
1. Panel seal not tight to trim
ring.
2. Blocking catch broken
1. Re-adjust the panel. (see
installation manual 5.3)
2. Replace blocking catch,
see 3.9
Whistling sound when panel is
placed in the tilt position.
Vinyl headliner material wrapped
around sunshade too thin,
creating large wind channel
between mechanism rail and
side of sunshade.
Place insulating tape along
either outboard edge of
sunshade to close channel.
See installation manual 4.1.6
Steel panel vented emitting
whistling sound.
Vinyl headliner material wrapped
around trim tray too thin,
creating large wind channel
between mechanism rail and
side of trim-tray
Place insulating tape along
either outboard edge of trim tray
to close channel. See installation
manual 4.1.6

1. FAILURES
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1.5. REPAIR ADVICE FOR WATER LEAKS
PROBLEM POSSIBLE CAUSE SOLUTION
Water coming through panel
opening area
1. Blocked drain tubes.
2. Misaligned or kinked drain
tubes
3. Housing frame distorted, seal
to rail disconnected
4. Rear rail bracket has broken
seal
1. Inspect drain tubes, clean
opening, blow out tubes
2. Correct routing of drain tubes.
See installation manual 3.4
3. Correct frame curvature if
necessary reseal rail to frame
4. Reseal at rear rail seal point,
see 3.8
Headliner wet in front frame seam leaking Reseal seam

2. ELECTRICAL FAILURES
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2. ELECTRICAL FAILURES
Use the electric troubleshooting guide to locate electric failures or related problems (see point 2.2.6).
The electric scheme is given in figure 2.1.
fig. 2.1
Min. 7.5 Amp
Max. 20 Amp. Red/Black
Green
Green
Black
Sunroof
Control
Unit
Red
1 2c
20 Amp
1
2
3

2. ELECTRICAL FAILURES
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2.2 Testing electrical components
Make sure that during the test of electrical components the HOLLANDIA 700 unit is connected to a 12 to 14V power
source with a minimum of 8 amperes.
If the unit is installed in a car, the battery needs to be connected and operable. During testing the ignition/accessory
switch must be on. This test can be accomplished with a voltage meter or test light.
Cable harness and motor inspection requires the removal of the headliner.
2.2.1 Fuse
Inspect and make sure that the fuse is not open.
2.2.2 Wire harness Sunroof Control Unit to battery
Check if the power supply on both the red and red/black wires is correct? Inspect for broken/damaged wires. Inspect
for proper connection to the sunroof control unit. The wire harness connector is numbered to aid in proper
installation:
Connector Power on wire if ignition is off Power on wire if ignition is on
Wire number 1 (red) 12 V 12 V
Wire number 2 (green) Ground Ground
Wire number 3 (red / black) 0 V 12 V
2.2.3 Wire harness Sunroof Control Unit to Control panel
Inspect for sufficient power supply to the HOLLANDIA 700 control panel, accomplished by using a voltage meter on
the connector pins.
Measurements with battery voltage of 13 V:
Connector Power on wire if ignition is off Power on wire if ignition is on
Wire 1 (red) 10.9 V 13 V
Wire 2 10.9 V 13 V
Wire 3 0 V 0 V
Wire 4 0 V 0 V
Wire 5 0 V 0 V
Wire 6 0 V 0.6 V

2. ELECTRICAL FAILURES
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2.2.4 Motor
Disconnect the motor wire (green/black) from the sunroof control unit. Dismount the motor. Use a double wire of
sufficient length, connect directly to battery and inspect the motor for proper operation in both directions. This is
accomplished by reversing the connection of the double wire. The motor has an inbuilt thermal cut-out device that
automatically switches the motor off during periods of overload. After a cooling down period the motor will function
properly.
2.2.5 Sunroof control unit
Testing is covered in the electric trouble shooting guide. The following failures could be the result of a defective
Sunroof Control Unit (SCU).
•Auto close function inoperative.
•Soft touch operation inoperative.
•Comfort position can not be programmed.
•4 step down option inoperative.
•One way closing defective.
After replacing the SCU, the SCU must then be calibrated. Proceed with the trouble shooting table if the problem is
not solved by the calibration.
2.2.6 Calibration of the SCU:
The first time the SCU is connected to the power supply, the maximum vent position must be defined. Proceed as
follows:
1. Turn on the ignition.
2. Open the panel to the maximum vent position (until it reaches the mechanical stop) (continuous control
of the switch). The maximum vent position is now stored in the SCU and all electrical features are
available.
3. To complete the calibration, the panel must be moved to the fully open position by soft touch operation.

2. ELECTRICAL FAILURES
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2.2.7 Electrical trouble shooting table
Panel moves
when holding
switch?
Test Sun
Roof,
Ignition Switch
Does SCU
make
a click sound?
SCU: red,red/black
and green wires
measure12V?
SCU powerline
measures 12v
when body
grounded?
Red/black
powerline
12V when body
grounded?
In both
directions?
Tilting and
sliding
functional
? Motor operating
correctly
co
properly?
Soft touch
operation
possible?
Is the auto close
function
working
Comfort
position
working?
One way closing
working?
Switch O.K.?
(chapter 2.2.3.)
Fuse10 A O.K?
(chapter 2.2.1.)
Wire harness
O.K.?
Motor stops,
SCU clicks in
max. slide and
max tilt
Sun roof
O.K.
Power on red /
black wire when
ignition is
switched off
no n
o
no no
yeye
ye
ye
ye
ye
ye
ye
ye
no
no
no
ye
n
o
no
ye
ye
no
ye
no
yes no
no
ye
yes
n
o
ye
no
n
no
Re-program
Preset stops

2. ELECTRICAL FAILURES
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Fuse 20 A
O.K.? fuse 20 A
replaced? Replace fuse 20 A
Fuse 10 A
replaced Replace fuse 10 A
Wire harness
O.K.?
(chapter 2.2.2.) Improve
powerline
connections
Replace switch
Replace wire
harnes
ReplaceSunroof
Control Unit
(chapter 3.2 3.2.)
Inspect and
correct wire
Short circuit
Replace wire
harness
Improve ground
wire connection
no
yes
no
yes
no
yes
no
Solve mechanical
failure
(chapter 1.1)
Improve
connection red /
black
wire
no
Replace motor
(chapter 3.1)
Sufficient power
over red wire
when operating
the
Improve
connection
red
yes

3. REPAIRS
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3. REPAIRS
This chapter describes all repairs for the HOLLANDIA 700 - 20 series and the HOLLANDIA 700 - 40 series.
If possible the part numbers are mentioned behind the parts.
3.1 Motor replacement
1. Remove or drop rear of headliner to access motor cover (48).
2. Remove cover, motor (46) now drops down.
3. Disconnect the motor wire from the SCU (51).
4. Connect new motor to the SCU.
5. Inspect motor for proper operations in both directions.
6. Remount motor and motor cover.
7. Inspect the unit for proper electrical and mechanical functions.
8. Re-install headliner.

3. REPAIRS
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3.2 Sunroof control unit replacement (SCU)
1. Remove or drop rear of headliner to access motor cover (48).
2. Remove cover, motor (46) now drops down.
3. Disconnect the motor wire from the SCU (51) and remove the motor.
4. Disconnect the wire harness from the SCU
5. Remove the SCU with screw (53), drop the front, slide back.
6. Install the new sunroof control unit by dropping the front of the SCU low enough for cable clearance,
slide forward, engage lip of cable plate in SCU slot. Straighten SCU horizontally and tighten screw.
7. Reconnect both wire connectors to the SCU and remount motor and cover.
8. Calibrate the SCU: The first time the SCU is connected to the power supply, the maximum tilt
position must be defined. Proceed as follows:
4. Turn on the ignition.
5. Open the panel to the maximum vent position until it reaches the mechanical stop (continuous
control of the switch). The maximum vent position is now stored in the SCU and all electrical
features are available.
6. To complete the calibration, the panel must be moved to the fully opened position by soft touch
operation.
9. Check proper functioning of sunroof
10. Install headliner.
11. For the HOLLANDIA 700 - 20 series, slide the trim tray forwards and connect the trim tray (103) to
the drain channel. For HOLLANDIA 700 - 40 series, remount the LH mechanism cover.

3. REPAIRS
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3.3 Drive cable replacement
1. Remove covers (7), panel (1, 100), drain channel (3), wind deflector (3) and sunshade (5) or trim tray
(103) and ventilation tray (105) and adjustment bracket (106).
2. Place mechanism in closed position.
3. Remove rear of headliner to access motor cover (48).
4. Remove motor cover, motor (46) now drops down.
5. Disconnect the motor wire from the SCU (51).
6. Remove the SCU with screw (pos. 53), drop the front, slide back.
7. Remove the gearwheel housing (44) by removing the two screws (45).
8. Remove gearwheel (pos. 40) by inserting screwdriver, push forward, until it drops down (figure
3.4.1).
Figure 3.4.1
9. Place a screwdriver in the mechanism as indicated in figure 3.4.2. Push this mechanism rearward
into the slide position. Continue pushing backward by placing hand on front of mechanism, 3 locator
(13) screws become accessible.

3. REPAIRS
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Figure 3.4.2.
10. Remove the locator (13) being careful to remember the positioning of screws and the blocking
catch (26).
11. Pull mechanism all the way forward.
12. Push the mechanism into tilt position as in point 9.
Be sure you do not inadvertently dislodge the mechanism. Keep the front of the mechanism down.
13. (For the HOLLANDIA 700 - 40 series) Remove the front screw (31, 32) and slide the retraction
mechanism (33) forward. Do not take out.
14. Slide mechanism further forward in tilt position.
15. You can now see the cable (25). Lift out cable and pull forward out of the guide rail track.
16. Inspect for proper length of new cable, grease and slide into rail. Make sure the oval shaped copper
head of the cable seats firmly and diagonally across the guide channel (figure 3.4.3).

3. REPAIRS
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Figure 3.4.3
17. To check that cable is positioned properly grasp long lever in tilt position with one hand, the pivoting
adjustment bracket in the other hand and slide backwards, it should slide into place (if blocked turn
cable slightly to reseat copper oval head properly).
18. Push mechanism into slide position as in point 9.
19. Slide whole mechanism rearward to allow remounting of locator (13).
20. Slide the retraction mechanism rearward; remount screw and locator.
21. Repeat points 10 through 22 to replace other cable.
22. Slide both LH/RH mechanisms to the front position.
23. Push LH/RH mechanisms to closed position. Insert a pin in each 2.5 mm brass hole. (pointed
object). Slide mechanism forward until pin stops the mechanisms movement at the desired location
(figure 3.4.4).
drive cable

3. REPAIRS
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Figure 3.4.4
24. Mount the new gearwheel. Being sure to center it evenly between the walls of the hole in the motor
bracket. Note that the core or center of the gear has splines (teeth). The splines do not extend
completely to one side of the gears inner core. This is the down (bottom) side in car position for
mounting (Figure 3.4.5).
Figure 3.4.5
25. Mount the new gearwheel housing.
26. Mount the SCU. Dropping the front of the SCU low enough for cable clearance slide forward, engage
lip of cable plate in SCU slot. Straighten SCU horizontally and tighten screw.