DIY Network

Headliner Repair: Removing the Old Headliner Panel From "Weekend Mechanic" episode WKM-302

In this segment, Weekend Mechanic host Bruce Bonebrake, with some help from auto-interior expert Tony Fleming, begins repair on a sagging headliner in a 1990 Volvo. After removing the seats from the vehicle for better access, he begins removing the headliner panel from the vehicle, as well as the sunroof headliner. Though this is the most difficult part of the project, this step is necessary to properly repair a sagging headliner.

DIY Difficulty Rating for Repair: This job is fairly straightforward, and something that seasoned or novice do-it-yourselfers can undertake. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale. Allow yourself about 12 hours to complete this project. Estimated cost for the repair is around $100.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Materials:

Standard mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, etc.)
Headliner tool (or wooden spatula)
Scissors
Marker
Needle-nosed pliers

advertisement

Figure A

Removing the Headliner Panel

• Begin by removing the trim pieces in the front of the car using a torx driver (figure A).

  Tip: Loosen, but do not remove, the vertical trim pieces that can simply be pushed out of the way.

• Remove the rear-view mirror.

• Remove the sun-roof motor cover.
  
• Since the sun visors are mounted into the headliner, they will need to be removed also (figure B), as well as the sun visor clips (figure C).

  Figure B

  Figure C

  
  

  Figure D

• On the passenger-side sun-visor, there may be a wiring harness for the visor's vanity mirror. Most will have a disconnect plug, making it easy to detach the wiring harness when you remove the visor. Avoid cutting the wiring harness.

  Tip: You can use a pair of scissors to cut a slit in the headliner board and fabric to make it easier to move the wiring harness out of the way (figure D). The cut can later be concealed under the plastic trim piece.
  

• In the back seat, remove the covers from the grab-bars so that the mounting screws can be removed in order to take down the grab bars. Remove the rear courtesy light and detach it from its wiring harness.

• Remove the side trim-panel (figure E) first, followed by the rear trim panel.

• Use a headliner tool (or wooden spatula) to loosen and remove trim panel pieces (figure F). These pieces are removed by popping out the retaining clips behind each panel.

  Figure E

  Figure F

  
  

  	Figure G
  	Figure H

• Remove the dome light (figure G), taking care not to avoid chipping the cut-out in the headliner board that accommodates the light assembly.

  Tip: This is a good time to check the wiring connections in the dome light, inspecting closely for any cracks or breaks.

• Remove the flexible edging around the sunroof that anchors the headliner cloth to the opening in the roof (figure H).

  Note: Replace the sunroof edging if it is hard, cracked or broken.
  

  Figure I

• With the sunroof liner and all of the other trim pieces removed, the process of dropping and removing the headliner can begin by pulling downward in the center of the headliner board (figure I). Flex the board gently from the center, allowing the board to bow and begin to come loose.

• Take your time as you remove the headliner board. The corners of the board are the areas most likely to break.
  

  	Figure J
  	Figure K

• Important: The headliner board can be taken out in one piece by curving or bending it, but only if this is done slowly and carefully. Bending the board too abruptly will cause the board to crack (figure J), particularly if it is old and brittle.

• Since our board did, in fact, break apart upon removal (figure K), repair would be required. According to auto-interior expert Tony Fleming, this situation is not uncommon since sun and heat damage typically causes headliner boards to become brittle and increasingly fragile over time. Many are simply made from a pressed-cardboard material. However, in our case Tony determined that the damage to this board was repairable.

  Note: Breaks around the sunroof opening are among the most difficult to repair.
  

  	Figure L
  	Figure M
  	Figure N
  	Figure O

With the main headliner board removed, the sunroof panel can now be removed as well.

• With the sunroof in the vent position, use needle-nose pliers to release the springs so that the sunroof headliner will lay flat.

• Slide the panel back so that the top can be removed.

• Mark the locations of the sunroof mounting screws carefully (figure L), then remove the screws.

• With the screw removed, carefully lift off the top of the sunroof (figure M).

• Remove the sunroof air-dam.

• With the top portion of the sunroof removed, the sunroof headliner simply pops out (figure N).

• Inspection of our sunroof headliner reveals that it is in fairly good shape. The fabric on the sunroof headliner is actually attached to a metal framework (figure O). Repair for the sunroof headliner should be fairly simple when compared to the overall headliner repair.
  

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools.

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Automotive Detailing: A Complete Car Care Guide for Auto Enthusiasts and Detailing Professionals
1557882886
Don Taylor
To order this title from Amazon, click here.
H.P. Books