SERVICE MANUAL Hollandia 300 Large
Contents
1. 04 Rotate the drive cable in such a way that the points of the oval cable end fit into the guides Slide the guides backwards over the driving slide until the driving slide is 1 cm 3 8 inch within the guide Remove the old top bearing from the frame Mount the new top bearing 06 Mount the roof as described in step 1 through 24 of chapter 3 Reinstalling the Hollandia 300 large Manual model lubricate the bearing bushing on the new drive box with temperature resistant grease molybdenum grease Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 7 Replacing locker slide mechanism and or glass panel Dismount the roof as described in step 1 through 16 of chapter 2 Removing and dismounting Hollandia 300 large Hereafter continue with the following steps 02 Remove the guides by sliding them forward Note do not bend the guides downward 03 Remove the drive cables Remove the driving slides 35 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 104 Rotate the lever forward and slide it together with the locker slide forward Force the lever carefully to the inside by inserting a screwdriver in between the mounting profile and the levers Remove the lever 06 Push the front end of the locker slide to the outside and slide it forward Apply lubricant to the following parts the guide t2. Chapter 8 Replacing upper frame 39 Chapter 9 Replacing motor and or SCU 40 Chapter 10 Replacing stop 42 4 Service Manual Provided by DONMAR www donmar com 1 Troubleshooting tables Jebasto Feel the drive REPAIR ADVICE FOR LEAKS BETWEEN GLASS PANEL AND SEAL IME Leakage general Possible cause Dirt on the seal Solution Clean the seal Remains of mastic dirt underneath the glass panel Clean bottom of glass panel Glass panel opened while there was water on the roof Remove water Sunroof not completely closed Dry vehicle Crank not stored in recess causing glass panel to not be mechanically blocked in closed position manual version only Remove water Leakage at one of the rear corners Locker slide is broken If this is the case it is possible to push the rear corners of the glass panel up and down more than 1 cm 3 8 inch Replace locker slide if it is not possible to open the glass panel push the rear side of the glass panel up while opening the roof Leakage at the seam of the seal Excessive difference in height at the joint Replace seal 5 Service Manual Provided by DONMAR www donmar com 1 Troubleshooting tables Jebasto Feel the drive Failure Rear side of glass panel cannot be closed or only partially opens REPAIR ADVICE FOR MECHANICAL DEFECTS Possible cause Locker slide broken Solut
3. Jebasto Feel the drive SERVICE MANUAL Hollandia 300 Large Service Manual Provided by DONMAR www donmar com Service Manual Provided by DONMAR www donmar com BEFORE BEGINNING THE SERVICE PROCEDURE 1 Determine which model of the Hollandia 300 Large is installed in the vehicle 2 Diagnose the problem by using the Trouble Shooting tables in this manual to determine what service procedures are required 3 Perform the Service Procedure per the instructions 4 Some Procedures such as Removal of the sunroof must be carried out before beginning the required Service Procedure and Reinstallation of the sunroof after completion If this is the case it is noted at the beginning and end of the of the required service procedure 5 Most Service Procedures are valid for both Manual and Electric models When a step is not valid for one of the models it will be indicated by a symbol next to the number of that procedure P Invalid for the manual version 39 Invalid for the electrical version 3 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Table of Contents Chapter 1 Troubleshooting tables 5 Chapter 2 Removing the Hollandia 300 Large 13 Chapter 3 Reinstalling the Hollandia 300 Large 19 Chapter 4 Replacing the seal 27 Chapter 5 Replacing glass holder 30 Chapter 6 Replacing cables and gear wheel 33 Chapter 7 Replacing locker slide mechanism 35 and or glass panel
4. Mount the crank Open the roof up to 3 4 of the fully opened position Remove the crank 2X Connect the motor to the 12 V power source Mount the motor Check the correct functioning of the roof Open the roof up to 3 4 of the fully opened position Remove the motor Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 16 Remove the retainer ring Apply a track of sealing mastic of o 3 mm 1 8 inch to the frame Use only butyl sealant FE Place the roof IE Mount the retainer ring M5 x 10 black along the sides M5 x 8 yellow along the front and rear Insert the screws finger tight Tighten the screws starting at the center of the roof When installing an electric sunroof the motor retaining points should be left clear 23 Service Manual Provided by DONMAR www donmar com m a rea state CR LM oa a il uil Lu Bas uM aA M x anA n RR u nnen ret TEES eee a a a ana ug rere e Jebasto Feel the drive 20 Hollandia 300 Large Soft trim Re install the sub frame 2x Mount the motor and motor cover Connect motor connection to sunroof control unit Hollandia 300 Large Soft trim x lt Apply glue to the headliner and edge trim of the sub frame Hollandia 300 Large Soft trim Stretch the headliner
5. 1 16 inch thick Adhesive sealant 2 only along the front on the inside of the groove 2 mm 1 16 inch thick Preferably use acid based silicone mastic Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 04 Place the new seal the frame without pressure Seam center front under the glass holder Start from the front center under the glass holder and push the seal from the sides to the rear only 1 mm 1 32 inch into the groove This is done to prevent tension in the seal Push the seal entirely in the groove Check if the seal is flush fitted in the frame Remove excessive sealing mastic and clean the seal Service Manual Provided DONMAR www donmar com Jebasto Feel the drive 08 The roof has to be remained the opened position The curing time for silicone mastic is at least 8 hours 09 If the roof has to be closed directly it is advisable to apply a piece of tape center front over the seal before closing the roof carefully This is done to prevent the seal from pulling out of the groove 29 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 5 Replacing glass holder Open the roof halfway 02 Dismount the roof as described in steps 2 to 12 of chapter 2 Removing the Hollandia 300 Large After this continue with the following instructions 03 Lift the front drive cable with
6. Open the roof to about 1 cm 3 8 inch before the end position is reached 02 Carefully pry the stop out of the guide and remove possible remains 03 Insert the new stop in the guide Note the stops must clearly make a click when snapping into position and may not reach over the guide Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 04 Lubricate the stop with oil and check the correct functioning of the roof 43 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Service Manual Provided by DONMAR www donmar com
7. Use a spatula with rounded corners to push the headliner in the groove of the edge trim Hollandia 300 Large Soft trim Service Manual Provided bY DONMAR www donmar com Jebasto Feel the drive 24 2x Hollandia 300 Large Soft trim Mount the edge finisher 25 gt lt Install the sunshade Position the sunshade and lock the guides by pushing it into the guides of the sub frame Hollandia 300 Large Soft trim Hollandia 300 Large Soft trim Mount the motor Connect the wire harness 38 Hollandia 300 Large Hard trim Mount the trim shell 25 Service Manual Provided by DONMAR www donmar com Jebasto 28 Place the locking plate Mount the crank Note the felt ring must be in the recess Close the roof The crank must fit in the recess x lt Hollandia 300 Large Hard trim Mount the trim shell 30 Hollandia 300 Large Remove excess sealer Service Manual Provided DONMAR www donmar com 4 Replacing the seal Jebasto Feel the drive Note When replacing the seal it is best to open the roof completely when working along the front and the sides move the roof into its maximum tilt position when working on the rear side Open the roof entirely Carefully remove the old seal 02 Remove the remains of sealant around the groove and clean it very well 03 Adhesive sealant 1 all round on the outside of the groove 2 mm
8. el over the seal Apply talcum powder to the seal Glass panel is chattering in the half opened position Stops are worn out Install new stops Service Manual Provided by DONMAR www donmar com Jebasto 1 Troubleshooting tables Feel the drive REPAIR ADVICE MECHANICAL TROUBLE WITH ELECTRIC MODEL Failure Possible cause Solution Battery voltage too low Charge or replace the battery Motor is running but Drive shaft broken Replace motor the glass panel is Drive shaft not far enough in Remount the motor open the roof half not moving ear wheel the drive shaft will 9 protru ne linderneathane way and push the drive shaft upwards at motor the bottom 7 Service Manual Provided by DONMAR www donmar com Jebasto 1 Troubleshooting tables Feel the drive k he fuse of the red ts the motor running no contact wire bkwm YES 1 m Power 12V on red contact wire of switch Body grounded B the motor running ini ni Power 12V between bath directions brown and black wire of switch to SCU when y d yes ee ee the back and green wire from the SCU to ihe motor when operating the switch in both directions yes Service Manual Provided by DONMAR www donmar com Jebasto 1 Troubleshooting tables Feel the drive TROUBLESHOOTING TABLE FOR ELECTRICAL FAILURES FOR MODELS WITH SOFT TOUCH Has the fuse been Fu
9. guide tubes out of the frame Remove the 2 Torx screws out of the glass holder Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 04 Lift the front drive cable with guide tubes out of the frame Remove the 2 Torx screws out of the glass holder 05 Lift the front drive cable with guide tubes out of the frame Remove the 2 Torx screws out of the glass holder 06 Lift the front drive cable with guide tubes out of the frame Remove the 2 Torx screws out of the glass holder Lift the front drive cable with guide tubes out of the frame Remove the 2 Torx screws out of the glass holder 31 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Check for remains of sealing mastic near the glass holder Remove if present Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 6 Replacing cables and gear wheel Dismount the roof as described in step 1 to 16 of chapter 2 Removing the Hollandia 300 Large After this continue with the following instructions 02 Slide the guide forward to the position where the driving slide extends 4 5 cm 2 inches out of the guide Note do not bend the guides downward Remove the old drive cables Insert the new drive cables into the guides and fix them to the driving slide 33 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive
10. he curve of the driving slide the lever the locker slide the mounting profiles bonded under glass panel Service Manual Provided byDONMAR www donmar com Jebasto Feel the drive Place the locker slide with the front to the outside over the mounting profiles and slide it rearward Slide the locker slide forward Push the pin of the lever carefully through the mounting profiles in the locker slide 10 Slide the lever together with the locker slide rearward and rotate the lever rearward Mount the driving slide to the lever and the front tumbler 37 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Position the front tumbler and the driving slide in line with each other Slide the guide carefully over the front tumbler and driving slide until the driving slide extends 4 5 cm 2 inches out of the guide Note To avoid damaging do not force Guides Mount the drive cable on the driving slide Rotate the drive cable so that the points of the oval cable end fit into the guides E Slide the guide rearwards until the end of the driving slide is 1 cm 3 8 inch within the guide Mount roof as described step 1 through 24 of chapter 3 Mounting and replacing Hollandia 300 Large Service Manual Provided by DONMAR www donmar com 8 Replacing upper frame 39 Jebasto Feel the drive Dismount the roof as descr
11. ht in the recess halfway between the guides and rotate the frame 02 Slide the guide tubes over the drive cables and push the guide tubes into the groove The ends of the guide tubes must be positioned in the recess Slide the guides towards the position marked during the dismounting Fasten the guides by using the 4 red screws Always check the proper position of the drive cables 19 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 04 Replace the wind deflector 05 Place the frame in respect to the glass panel as far forward as possible 06 Place the gear wheel above the top bearing Note the chamfered must be directed upwards 38 Place the drive shaft and mount the drive box Service Manual Provided DONMAR www donmar com Jebasto Feel the drive 38 Place the crank on the drive shaft Close the roof 09 38 Remove the crank 10 38 Position the drive shaft so that the sides of the drive shaft are parallel to the guides Remount the drive box and the crank Check if the crank is in the correct closed position Adjust if necessary Remove the crank 21 Service Manual Provided by DONMAR www donmar com Jebasto Fee the drive 2X Mount the drive box Place the retainer ring and fasten along the front side with 2 screws 14 38 Check the correct functioning of the roof
12. ibed in step 1 through 16 of chapter 2 Removing the Hollandia 300 Large Hereafter continue with the following instructions Exchange the upper frame 02 Mount the roof as described in step 1 through 24 of chapter 3 Reinstalling the Hollandia 300 Large Service Manual Provided by DONMAR www donmar com Jebasto Fee the drive 9 Replacing motor and or SCU Open the roof halfway and switch off the ignition Switch off the auto close function by operating the switch 02 Remove the switch and the trim shell e oe a lE Disconnect the white connector block from the SCU Dismount the motor by loosening the 2 screws and the cover b Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive When replacing the SCU Disconnect the black and white connector of the SCU and remove the SCU Mount the new SCU and the connector a NE P P NS P M NN M S eee FR 05 M Mount the new motor Connect the wire harness 06 Place the trim shell over the frame and fix the trim shell with 2 screws to the motor Mount the cover when applicable Push the connector block into the switch and mount the switch Turn on the ignition key and check the correct functioning of the roof 41 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 10 Replacing stop
13. ion Replace locker slide if it is not possible to open the glass panel push at the rear side of the glass panel while opening the roof Glass panel can be opened into the tilt position but will not cycle to full open The front side of the glass panel is sticking to the seal Replace seal Glass panel is blocked when sliding Stop is incorrectly installed Install the stop correctly Obstacle in mechanism Remove obstacle Glass panel is sliding unevenly when opening and closing Gear wheel is mounted the wrong way Install gear wheel housing according to the service manual Gear wheel housing is worn out Install cable repair set Glass panel not parallel with the frame in the closed position Incorrect adjustment of glass panel Adjust glass panel using red bolts REPAIR ADVICE FOR SOLVING BACKGROUND NOISES Rattling noise near wind deflector Possible cause Wind deflector is touching glass panel when glass panel is in closed or in tilt position Solution Bend the wind deflector to flatten contour Rod springs do not have sufficient tension Remove the wind deflector and bend the rod springs slightly upwards Cracking and or creaking Roof opening cut too small Enlarge the opening Stretched headliner is causing flapping noise Re stretch the headliner Cracking noise when sliding the glass pan
14. m Remove the soft trim 10 Remove the retainer ring 15 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Remove the sunroof Remove the remains of sealing mastic from roof skin and frame Unhook the sliding blocks along the front of the wind deflector Pull the mounting blocks out of the guides 14 Place sunroof on a work bench with a non scratching surface Place the sunroof on the work bench with the front facing you Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 38 Remove the drive box the drive shaft and the gear wheel 16 Remove the drive box and the gear wheel Take the drive cables out of the frame and remove the guide tubes FE Mark the position of the guides in respect to the frame 17 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Remove the four red screws Slide the guides about 1 cm 3 8 inch forward The frame must be supported during this operation 20 Rotate the frame with the front side down and remove the frame by sliding it forwards Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 3 Reinstalling the Hollandia 300 Large Slide the new frame over the guides Note Front side of frame down bottom side towards you guides between rear side and cams Position the frame cams left and rig
15. ogram the SLUT lobstacte in mechanism m High resistance of mechanism whereby ihe anti jamming pro tection will be actreabed 11 Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive 2 Removing the Hollandia 300 Large Open the roof at about 1 cm 3 8 inch before full open position 02 35 Remove the crank and the locking plate 03 38 Remove the trim shell 13 Service Manual Provided by DONMAR www donmar com Feel the drive 104 2X Hollandia 300 Large electric hard trim Remove the switch and the trim shell 05 2X Hollandia 300 Large electric hard trim b Dianne Dismount the motor by removing the two screws 06 2X Hollandia 300 Large electric soft trim Remove the sunshade completely To do so remove one guide by lifting the guide spring uU eee e i Hollandia 300 Large soft trim Remove the edge finisher Service Manual Provided by DONMAR www donmar com Jebasto Feel the drive Hollandia 300 Large soft trim The soft headliner is glued all around the aperture Apply solvent to dissolve the glue 108 L Hollandia 300 Large soft trim Disconnect the electrical connector from the motor Remove the motor cover and the motor 09 2X Hollandia 300 Large soft tri
16. se than E Mount fuse replaced before wes 20 Amp ys 20 Amp 13 Replace fusa yes Gina deg Replace motor Power 12 ower fuse ar red contact wine Body grounded Switch broken Replace switch ee Bad Ground connection Repar at SCU pan Jd Power 124 an yes Bani NTICIM with the ignition an Greven wire grounded i Fus blown ol yt ned black wine no Power 12V om fuse off yes ned black wine with Th i on Gane wire routed 74 9 Service Manual Provided by DONMAR www donmar com 1 Troubleshooting tables Feel the drive n3 ls the motor running Yes normal 1 n7 Is the motor alter operating the switch Is the comfore position nn Power 12V on yes working red biack wire CL with ignition off yes Body grounded py is possible to open the root in its maximum Service Manual Provided by DONMAR www donmar com Jebasto 1 Troubleshooting tables Feel the drive the problems sofved Shut off ignition for at alter program the SELF E s igast 10 seconds and MK e Mn Lj the softaouch stil eurn in Red contact wire is not vens Connect rad contact connected directly to wire directly to battery the batt with 20 fuse Rid wane is camected ia ingniban Replace SCU Problems solved after Y Problem solved pr
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