SOLAIRE 3200 SERVICE MANUAL
Contents
1. roof skin 2 Sunroof inoperable 3 Rattling and or Creaking Noise n open position In closed position Only by operating times Only with optional sunshade SOLAIRE 3200 Probable Causes Rubber seal dirty Rubber seal torn or damaged Sunroof didn t close completely Guidance mechanism is faulty Foam seal not well fitted Clamping frame screws not properly fastened properly Fuse blown Inconsistent electrical function Motor faulty Relay faulty Switch faulty Guidance mechanism dirty Guidance mechanism faulty Guidance mechanism faulty Looking hooks dry Rubber seal dry Slide shoes faulty Guidance mechanism faulty Roof panel stiffener not fastened or insulated Car headliner cutout improper lies on the roof frame Car headliner not properly fastened Guidance mechanism faulty Foam buffer between sunshade and glass panel missing Sunshade deformed Jebasto sunroofs Trouble Shooting Guide Clean the rubber seal instructions Replace the rubber seal See Fault Code 2 Sunroof Inoperable Check the guidance mechanism clean the guide rails and if necessary replace the guidance mechanism assembly Refit the sunroof and replace the foam seal correctly a Check if the foam seal is placed correctly and not damaged b Tighten the screws of the lower frame properly C If necessary refit the sunroof and replace the foam seal Replace the fuse Verify all connections Rep2. 3200 Jebasto sunroofs Replacement of the Glass Panel Open the sunroof fully Remove the garnish screws Remember there are 1 M3x6 2 2 9 x 13 8 2 9 x 22 and 8 screw covers Remove the 4 glass mounting screws Remove the 2 rear glass mounting screws by closing the sunroof and putting the screw driver through the access holes in the mechanism as shown Remove the 2 front glass mounting screws Remove the glass from the sunroof Be careful not to operate the sunroof without the glass panel fully secured Now place the new glass panel into position on the vehicle Replace all 4 glass mounting screws From outside the vehicle visually check to see if the glass is spaced equally in the opening from front to rear and side to side If the spacing is not equal loosen the 4 glass mounting screws and adjust the glass panel then re tighten the 4 screws Now place the garnish in position and fasten with the appropriate screws Remember there are 1 M3x6 2 2 9 x 13 8 2 9 x 22 and 8 screw covers holding the garnish up to the sunroof Next replace the motor cover and drive the last remaining motor screw through the hole in the motor cover Now click the emergency cover into place Open and close the sunroof Test all functions Water test the sunroof Jebasto sunroofs SOLAIRE 3200 Installation with Soft Headliner Note This procedure is to be used for sun
3. Jebasto Feel the drive SOLAIRE 3200 SERVICE MANUAL Jebasto Revised 11 12 01 sunroofs SOLAIRE 3200 Table of Contents Procedure Page Solaire 32004 Table Contents ito ede 2 Identification and Dimensions ii ettet rera Let en aia ede a Ed ee ea e adeb eee 3 Replacemetntol Frame aos ate 4 Replacement Of MSE Or 290 cT 5 Cut Out Rubber Lip Around Interior sidan BQ 6 Replacement of Mechanism Assembly idit th davidenasiees 7 Replacement of the Glass Panel eclesie Heide 8 9 Installation with Soft Headliners uidit tup 10 Proced ra ag E Bea ay Bade 11 Wat r C 12 sdis sinere Dire MR E 13 14 SOLAIRE 3200 Dimension Qmmonouw Find the Product Number here uoo Inches 20 47 16 22 15 51 30 08 30 78 32 68 24 09 Millimeters 520 412 394 764 782 830 612 Dimension H I J K L M N Inches 13 35 7 68 1 38 7 68 6 50 29 44 X 14 88 1 69 Jebasto sunroofs Identification and Dimensions Millimeters 339 130 35 130 165 748 X 378 43 Jebasto sunroofs SOLAIRE 3200 Replacement of Frame Seal Check the se
4. d be used for re timing the drive mechanism on the SOLAIRE 3200 sunroofs 1 Operating the sunroof normally open the glass at least two inches from the front of the sunroof If the sunroof will not open at least this far call Webasto for technical support 2 Remove the motor 3 Place your hands on the front edge of the glass and gently push both sides to the full open position Take care to move both sides of the glass at the same time Verify that the leading edge of the glass panel is parallel with the rear edge of the sunroof mainframe At this point the mechanism is said to be Re Timed 4 Check screws on the drive tube retainer plates gold colored metal located behind where the motor mounts If loose check or re insert the ends of the cable drive and return tubes into place Apply a product such as blue Loc tite to keep the screws from working loose again Additional for the SOLAIRE 3200 Check the left and right drive tube clamps The clamps should hold the end of the drive tube securely in position If not remove the clamp bend straight or replace the part and re install the clamp over the ends of the drive tubes Caution Overtightening of the screws may strip the threads 5 Replace the motor and motor cover 6 Testthe function of the sunroof through several cycles Jebasto sunroofs I SOLAIRE 3200 Water Test Procedure Make sure the sunroof is fully closed 1 Usea garden hose with nozzle and f
5. lace the motor Replace the relay Replace the switch with the wiring harness Clean the guidance mechanism See operating and maintenance instructions Replace the guidance mechanism Replace the guidance mechanism Lubricate the looking hooks Clean the rubber seal and lubricate with silicone spray Replace the guidance mechanism Replace the guidance mechanism Remove the garnish cover and fasten or insulate the remaining roof panel stiffeners Remove the garnish cover and correct the headliner cut out Check if the noises come from the headliner If yes fasten the headliner to the roof panel stiffeners Replace the guidance mechanism foam pad to the sunshade to stop rattling Replace the sunshade SOLAIRE 3200 Fault code 4 Glass Panel Misalignment 5 Excessive Wind Noise 6 Roof panel distortion 7 Sluggish operation 8 Misc Inner lamp removed and did not work Headliner miscut Panel or guidance mechanism isn t properly adjusted Motor not properly fastened Motor faulty Guuidance mechanism faulty Rubber seal dirty Rubber seal damaged Glass panel improperly adhered Mechanism dirty Guidance mechanism faulty Motor faulty Not enough pressure between glass panel an rubber seal Curvature between sunroof and roof aperature too different Lower frame fixing screws not well tightened Foam seal not well fitted Guidance Mechanism too dry Guidance Mechani
6. lood the sunroof for 10 15 minutes Take care to flood all areas of the glass seal and mainframe or trim ring depending on model to insure water has been in contact with all interfaces between mating parts 2 Check the inside of the vehicle for leaks Take special care to look where the glass panel meets the seal in spoiler models and in the drain trough of the Starlite models Note Some water may seep through a Starlite and the drain trough may be slightly damp Remember you are looking for a large leak since the Starlite has drain tubes to remove a small amount of water if some seeps through 3 Now take the vehicle for a test drive Make sure to test all normal driving conditions including right and left turns bumps driving in reverse and sudden stops Most of this test driving can be done in the parking lot but it is also recommended to drive the car at highway speeds The reason for the test driving is to insure that the seal and sealant used during the repair can withstand the windy conditions and flexing of a vehicle in motion Again check the inside of the vehicle for leaks 4 Ifnoleaks have been found your repair is complete If leaks have been found please refer to the Trouble Shooting List Fault code for the model you are repairing entitled Water Ingress for probable causes and remedies Now follow the instructions listed there Fault code 1 Water Leakage Between glass panel and rubber seal Between frame and
7. roof installation into a vehicle with a soft fabric headliner i e no fiberglass backing Cut and remove the interior rectangle This is Not shown Properly place outer template on roof packaging the interior template needed for installing the skin for installation Also drill holes through the roof sunroof with a soft vehicle headliner and template as indicated If you have any questions Measure 2 inches 50 mm in from the outer edge p ify yq eu please refer to frames 3 4 and 5 of the installation of interior template to form a rectangle nsfructions Place screws thru holes in roof and interior template Use wing nuts to hold interior template in place Cut fabric around outside of template space 57 5 1 E Install sunroof see installation instructions Wrap and cut headliner to fit as needed Now place the garnish in position and fasten with the appropriate screws Place glue as shown on the clamping frame and Remember there are 1 M3x6 2 2 9 x 13 fabric 8 2 9 x 22 and 8 screw covers holding the garnish up to the sunroof Next replace the motor cover and drive the last remaining motor screw through the hole in the motor cover Now click the emergency cover into place Note This is for exposed garnish ring installation with a soft headliner 10 Jebasto sunroofs SOLAIRE 3200 Re Timing Procedure The following procedure shoul
8. rvice parts package for the Sport 3 Position the sunroof in vent Completely clean the channel in the mainframe of Spoiler seal PN 7595 ME 5002 A and the silicone adhesive and any other debris A nylon proper instruction sheet 4 Finish removing the seal from the rear of the glazing stick or a soft wire brush would be helpful Read the instructions carefully before starting the repair mainframe in removing the silicone 1 Open the sunroof fully 2 Remove the seal from the front of the mainframe Note The sunroof glass may have to be removed in by pulling up order to clean the entire frame easily Add black non corrosive silicone adhesive under Insert the new Sport Spoiler seal PN 7595 ME Fully close the sunroof and wait 4 6 hours for the the entire outside edge of the seal 5002 A by pressing the seal into the mainframe silicone to dry channel Visually check the glass and seal in the full open and closed positions Open and close the sunroof Test all functions Jebasto sunroofs SOLAIRE 3200 Replacement of the Interior Light 1 Layout the hole for the sunroof by using the Template set 2 Remove the interior light assembly if needed to lay out the hole Now remove the roof bow 3 Measure 2 inches 50 mm to the rear of the hole and trace the cut out for the interior light Now cut the hole Cut away the headliner material which you traced stt the template Apply silicon to the rear of the in
9. sealing tape or other debris Close the sunroof manually using the emergency key or bench power supply Note This repair can be performed with the sunroof opened or closed Place the sunroof on a workbench glass down 1 Remove the 4 glass mounting screws 2 Remove 2 remaining motor screws and motor 3 Remove 5 mechanism mounting screws each side Remove guidance mechanism Manually test the function of the sunroof Note Never test the function of the sunroof glass side down This may cause damage 1 Replace new guidance mechanism retime mechnism see page 12 2 Replace motor 3 Replace glass panel Replace the foam sealing tape Clean off any debris left on frame Hint make sure that the sealing tape overlaps at a screw hole This will produce the best sealing results Install sunroof into vehicle See installation instructions if necessary Place the sunroof on a workbench glass up From above the sunroof visually check to see if the glass is spaced equally in the opening from front to rear and side to side If the spacing is not equal loosen the 4 glass mounting screws and adjust the glass panel then re tighten the 4 screws Jebasto SOLAIRE 3200 Replacement of the Glass Panel Check that the service glass panel includes the 4 glass mounting screws and the proper instruction sheet Read the instructions carefully before starting the repair SOLAIRE
10. sm faulty Damaged guidance mechanism Improper electrical connections ground power Fuse blown Lamp blown Necessary additional ground wiring not installed Improper electrical connections ground power Car headliner with special shape Jebasto sunroofs Trouble Shooting Guide Retime the sunroof Center glass panel by loosening 4 mounting screws centering and retightening Fasten the motor properly Replace the motor Replace the guidance mechanism Clean the rubber seal and lubricate with silicone spray Replace the rubber seal Replace the glass panel Clean the mechanism Replace the guidance mechanism Check the electrical connections Check the electric components switch relay etc Replace the motor Lower the mechanism Roof not recommanded by Webasto Tighten the screws Replace the foam seal Lubricate the mechanism Replace the guidance mechanism Replace the guidance mechanism Verify all electrical connections Replace the fuse Replace the lamp Check if an additional ground wire is necessary Install an additional ground wire if necessary Verify all electrical connections Garnish soft profile cut off
11. terior light bracket as shown Cut a length of the roof bow where the interior light fits This is now your interior light bracket 1 Glue the interior light bracket to the roof skin behind the hole you cut into the headliner 2 Run a ground wire to the header if needed Now snap the interior light through the headliner and into place Jebasto sunroofs SOLAIRE 3200 Cut Out Rubber Lip Around the Interior Light Note that the rubber lip hangs over the light 1 Now take the lens and place it into the light 1 Now remove the light fixture from the headliner fixture take care to keep the lens over the rubber of the car lip 2 Cut the outline traced on the rubber lip 2 Trace the outline of the lens onto the rubber lip of the headliner Now replace the light fixture back into the vehicle headliner Snap the lens into place Check to make sure the light turns on and off as intended The installation is now complete Jebasto sunroofs SOLAIRE 3200 Replacement of the Mechanism Assembly Check the service parts package for the guidance mechanism mechanism mounting screws and 1 roll of sealing tape Read the instructions carefully before starting the repair Note It is recommended that this repair be done on a work bench and not in the vehicle Remove the sunroof from the vehicle Reverse the procedure of the Installation Manual Clean the hole in the roof to remove any
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