SERVICE MANUAL Hollandia 300 Large

SERVICE MANUALHollandia 300 Large1

BEFORE BEGINNING THE SERVICE PROCEDURE1. Determine which model of the Hollandia 300 Large is installed in thevehicle.2. Diagnose the problem by using the “Trouble Shooting” tables in thismanual 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 outbefore beginning the required Service Procedure and Reinstallation of thesunroof after completion. If this is the case it is noted at the beginning andend 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 asymbol next to the number of that procedure.3

Table of ContentsChapter 1Troubleshooting tables 5Chapter 2Removing the Hollandia 300 Large 13Chapter 3Reinstalling the Hollandia 300 Large 19Chapter 4Replacing the seal 27Chapter 5Replacing glass holder 30Chapter 6Replacing cables and gear wheel 33Chapter 7Replacing locker slide, mechanism 35and/or glass panelChapter 8Replacing upper frame 39Chapter 9Replacing motor and/or SCU 40Chapter 10Replacing stop 424

1. Troubleshooting tablesREPAIR ADVICE FOR LEAKS BETWEEN GLASS PANEL AND SEALFailure Possible cause SolutionLeakage (general) Dirt on the seal.Clean the seal.Remains of mastic/dirt underneath theglass panelClean bottom of glass panel.Glass panel opened while there was wateron the roofRemove water.Sunroof not completely closed.Dry vehicle.Crank not stored in recess, causing glasspanel to not be mechanically blocked in Remove water.closed position (manual version only).Leakage at one ofthe rear cornersLeakage at theseam of the sealLocker slide is broken. (If this is the case, itis possible to push the rear corners of theglass panel up and down, more than 1 cm(3/8 inch)Excessive difference in height at the joint.Replace locker slide; if it is notpossible to open the glass panel,push the rear side of the glasspanel up while opening the roof.Replace seal.5

1. Troubleshooting tablesREPAIR ADVICE FOR MECHANICAL DEFECTSFailure Possible cause SolutionRear side of glasspanel cannot beclosed or onlypartially opens.Glass panel can beopened into the tiltposition but will notcycle to full open.Glass panel isblocked whensliding.Glass panel issliding unevenlywhen opening andclosing.Glass panel notparallel with theframe in the closedposition.Locker slide broken.The front side of the glasspanel is sticking to the seal.Stop is incorrectly installed.Obstacle in mechanism.Gear wheel is mounted thewrong way.Gear wheel housing is wornout.Incorrect adjustment of glasspanel.Replace locker slide; if it is not possible toopen the glass panel, push at the rear sideof the glass panel while opening the roof.Replace seal.Install the stop correctly.Remove obstacle.Install gear wheel housing accordingto the service manualInstall cable repair set.Adjust glass panel (using red bolts).REPAIR ADVICE FOR SOLVING BACKGROUND NOISESFailure Possible cause SolutionRattling noise nearwind deflector.Wind deflector is touchingglass panel when glass panelis in closed or in tilt position.Bend the wind deflector to flatten contour.Rod springs do not have Remove the wind deflector and bend theCracking and/orcreaking.Glass panel ischattering in thehalf-openedposition.sufficient tension.Roof opening cut, too small.Stretched headliner is causingflapping noise.Cracking noise when slidingthe glass panel over the seal.Stops are worn-out.rod springs slightly upwards.Enlarge the opening.Re-stretch the headliner.Apply talcum powder to the seal.Install new stops.6

1. Troubleshooting tablesREPAIR ADVICE MECHANICAL TROUBLE WITH ELECTRIC MODELFailure Possible cause SolutionGlass panel is Mechanism is dirty or needssliding slowly. lubrication.Clean and lubricate the mechanism.Battery voltage too low. Charge or replace the battery.Defective Motor.Replace motor (if necessary).Motor is running butthe glass panel isnot moving.Drive shaft broken.Replace motor.Motor is making arattling noise whensliding the glasspanel or in the endposition.Drive shaft not far enough ingear wheel (the drive shaft willbe protruding underneath themotor).Drive shaft not far enough ingear wheel (the drive shaft willbe protruding) underneath themotor.Remount the motor (open the roof halfway) and push the drive shaft upwards atthe bottom.Remount the motor (open the roof halfway)and push the drive shaft upwards at thebottom.7

1. Troubleshooting tables8

1. Troubleshooting tables9

1. Troubleshooting tables10

1. Troubleshooting tables11

2. Removing the Hollandia 300 Large01Open the roof at about 1 cm (3/8 inch)before full open position.02Remove the crank and the lockingplate.03Remove the trim shell.13

04Hollandia 300 Large electric hard trim:Remove the switch and the trim shell.05Hollandia 300 Large electric hard trim:Dismount the motor by removing the twoscrews.06Hollandia 300 Large electric soft trim:Remove the sunshade completely. To doso remove one guide by lifting the guidespring.07Hollandia 300 Large soft trim:Remove the edge finisher.14

07Hollandia 300 Large soft trim:The soft headliner is glued all aroundthe aperture. Apply solvent to dissolvethe glue.08Hollandia 300 Large soft trim:Disconnect the electrical connectorfrom the motor. Remove the motorcover and the motor.09Hollandia 300 Large soft trim:Remove the soft trim.10Remove the retainer ring.15

11Remove the sunroof.12Remove the remains of sealing masticfrom roof skin and frame.13Unhook the sliding blocks along thefront of the wind deflector.Pull the mounting blocks out of theguides.14Place sunroof on a work-bench with anon-scratching surface.Place the sunroof on the work-benchwith the front facing you.16

15Remove the drive box, the drive shaftand the gear wheel.16Remove the drive box and the gear wheel.17Take the drive cables out of the frameand remove the guide tubes.18Mark the position of the guides inrespect to the frame.17

19Remove the four red screws.Slide the guides about 1 cm (3/8 inch)forward. The frame must be supportedduring this operation.20Rotate the frame with the front side downand remove the frame by sliding itforwards.18

3. Reinstalling the Hollandia 300 Large.01Slide the new frame over the guidesNote: Front side of frame down, bottom sidetowards you, guides between rear side andcams.Position the frame cams left and right in therecess halfway between the guides androtate the frame.02Slide the guide tubes over the drive cablesand push the guide tubes into the groove.The ends of the guide tubes must bepositioned in the recess.03Slide the guides towards the position, markedduring the dismounting.Fasten the guides by using the 4 red screws.Always check the proper position of the drivecables.19

04Replace the wind deflector.05Place the frame, in respect to the glasspanel, as far forward as possible.06Place the gear wheel above the topbearing.Note: the chamfered must be directedupwards.07Place the drive shaft and mount the drivebox.20

08Place the crank on the drive shaft.Close the roof.09Remove the crank. box.10Position the drive shaft so that the sidesof the drive shaft are parallel to theguides.11Remount the drive box and the crank.Check if the crank is in the correctclosed position. Adjust if necessary.Remove the crank.21

12Mount the drive box.13Place the retainer ring and fasten alongthe front side with 2 screws.14Mount the crank.Check the correct functioning of the roof.Open the roof up to 3/4 of the fully openedposition. Remove the crank.15Mount the motor.Connect the motor to the 12 V power source.Check the correct functioning of the roof.Open the roof up to 3/4 of the fully openedposition. Remove the motor.22

16Remove the retainer ring.17Apply a track of sealing mastic of ø 3 mm(1/8 inch) to the frame.Use only butyl sealant.18Place the roof.19Mount the retainer ring.M5 x 10 (black) along the sidesM5 x 8 (yellow) along the front and rearInsert the screws finger tight. Tighten thescrews, starting at the center of the roof.When installing an electric sunroof, the motorretaining points should be left clear.23

20Hollandia 300 Large Soft trim:Re-install the sub frame.21Hollandia 300 Large Soft trim:Mount the motor and motor cover.Connect motor connection to sunroof controlunit.22Hollandia 300 Large Soft trim:Apply glue to the headliner and edge trim ofthe sub frame.23Hollandia 300 Large Soft trim:Stretch the headliner. Use a spatula withrounded corners to push the headliner in thegroove of the edge trim.24

24Hollandia 300 Large Soft trim:Mount the edge finisher.25Hollandia 300 Large Soft trim:Install the sunshade. Position the sunshadeand lock the guides by pushing it into theguides of the sub frame.26Hollandia 300 Large Soft trim:Mount the motorConnect the wire harness.27Hollandia 300 Large Hard trim:Mount the trim shell.25

28Place the locking plate.Mount the crank.Note: the felt ring must be in the recess.Close the roof. The crank must fit in therecess.29Hollandia 300 Large Hard trim:Mount the trim shell.30Hollandia 300 Large:Remove excess sealer.26

4. Replacing the sealNote: When replacing the seal it is bestto:• open the roof completely whenworking along the front and the sides.• move the roof into its maximum tiltposition when working on the rearside.01Open the roof entirely.Carefully remove the old seal.02Remove the remains of sealant around thegroove and clean it very well.03Adhesive sealant 1: all round, on the outside ofthe groove 2 mm (1/16 inch) thick.Adhesive sealant 2: only along the front, onthe inside of the groove 2 mm (1/16 inch) thick.Preferably use acid-based silicone mastic.27

04Place the new seal in the frame without anypressure.Seam center front under the glass holder.05Start from the front (center under the glassholder) and push the seal from the sides to therear only 1 mm (1/32 inch) into the groove.This is done to prevent tension in the seal.06Push the seal entirely in the groove.Check if the seal is flush fitted in the frame.07Remove excessive sealing mastic and cleanthe seal.28

08The roof has to be remained in the openedposition.The curing time for silicone mastic is at least 8hours.09If the roof has to be closed directly, it isadvisable to apply a piece of tape center frontover the seal before closing the roof carefully.This is done to prevent the seal from pullingout of the groove.29

5. Replacing glass holder01Open the roof halfway.02Dismount the roof as described in steps 2 to12 of chapter 2 “Removing the Hollandia 300Large”.After this continue with the followinginstructions.03Lift the front drive cable with guide tubes out ofthe frame.Remove the 2 Torx screws out of the glassholder.30

04Lift the front drive cable with guide tubes out ofthe frame.Remove the 2 Torx screws out of the glassholder.05Lift the front drive cable with guide tubes out ofthe frame.Remove the 2 Torx screws out of the glassholder.06Lift the front drive cable with guide tubes out ofthe frame.Remove the 2 Torx screws out of the glassholder.07Lift the front drive cable with guide tubes out ofthe frame.Remove the 2 Torx screws out of the glassholder.31

08Check for remains of sealing mastic near theglass holder.Remove if present.32

6. Replacing cables and gear wheel01Dismount the roof as described in step 1 to 16of chapter 2 “Removing the Hollandia 300Large”.After this continue with the followinginstructions.02Slide the guide forward to the position wherethe driving slide extends 4.5 cm (2 inches) outof the guide.Note: do not bend the guides downward.03Remove the old drive cables.Insert the new drive cables into the guides andfix them to the driving slide.33

04Rotate the drive cable, in such a way that thepoints of the oval cable end fit into the guides.Slide the guides backwards over the drivingslide, until the driving slide is 1 cm (3/8 inch)within the guide.05Remove the old top bearing from the frame.Mount the new top bearing.06Mount the roof as described in step 1 through24 of chapter 3 “Reinstalling the Hollandia 300large”Manual model: lubricate the bearing bushingon the new drive box with temperatureresistantgrease (molybdenum grease).34

7. Replacing locker slide, mechanism and/or glasspanel01Dismount the roof as described in step 1through 16 of chapter 2 “Removing anddismounting Hollandia 300 large”.Hereafter continue with the following steps.02Remove the guides by sliding them forward.Note: do not bend the guides downward.03Remove the drive cables.Remove the driving slides.35

04Rotate the lever forward and slide it togetherwith the locker slide forward.05Force the lever carefully to the inside byinserting a screwdriver in between themounting profile and the levers.Remove the lever.06Push the front end of the locker slide to theoutside and slide it forward.07Apply lubricant to the following parts:- the guide.- the curve of the driving slide.- the lever.- the locker slide.- the mounting profiles (bonded under glasspanel).36

08Place the locker slide, with the front to theoutside, over the mounting profiles and slide itrearward.09Slide the locker slide forward.Push the pin of the lever carefully (through themounting profiles) in the locker slide.10Slide the lever together with the locker sliderearward, and rotate the lever rearward.11Mount the driving slide to the lever and thefront tumbler.37

12Position the front tumbler and the driving slidein-line with each other.Slide the guide carefully over the front tumblerand driving slide until the driving slide extends4.5 cm (2 inches) out of the guide.Note: To avoid damaging, do not forceGuides.13Mount the drive cable on the driving slide.Rotate the drive cable, so that the points of theoval cable end fit into the guides.14Slide the guide rearwards until the end of thedriving slide is 1 cm (3/8 inch) within the guide.15Mount the roof as described in step 1 through24 of chapter 3 ”Mounting and replacingHollandia 300 Large”.38

8. Replacing upper frame01Dismount the roof as described in step 1through 16 of chapter 2 ”Removing theHollandia 300 Large”.Hereafter continue with the followinginstructions.Exchange the upper frame.02Mount the roof as described in step 1 through24 of chapter 3 “Reinstalling the Hollandia 300Large”.39

9. Replacing motor and/or SCU01Open the roof halfway and switch off theignition.Switch off the auto close function by operatingthe switch.02Remove the switch and the trim shell.03Disconnect the white connector block from theSCU.Dismount the motor by loosening the 2 screws(and the cover).40

04When replacing the SCU:Disconnect the black and white connector ofthe SCU and remove the SCU.Mount the new SCU and the connector.05Mount the new motor.Connect the wire harness.06Place the trim shell over the frame and fix thetrim shell with 2 screws to the motor.07Mount the cover when applicable.Push the connector block into the switch andmount the switch.Turn on the ignition key and check the correctfunctioning of the roof.41

10. Replacing stop01Open the roof to about 1 cm (3/8 inch) beforethe end position is reached.02Carefully pry the stop out of the guide andremove possible remains.03Insert the new stop in the guide.Note: the stops must clearly make a ‘click’when snapping into position, and may notreach over the guide.42

04Lubricate the stop with oil and check thecorrect functioning of the roof.43