Headliner Removal (My2005) S40

[aldebaran]

OK, for what it's worth, here is a pictorial of how it's done. It's not quite as image intensive as my other write ups because I was getting a bit frustrated. All you need is a philips head screwdriver and a small flathead. I posted this up on SS, but I figured someone here might find this useful too.

This was how ratty the headliner started to look. Even push pins couldn't cut it no moah...

1. Move both front seats all the way back and then recline the backsupport all the way too. Then remove the headrests from the rear seats.

2. Disconnect battery. Wait half an hour.

3. Next order of business was to remove the overhead lighting console. Refer to my post on how to install the electro-chromatic mirror on the procedure. Sorry I'm too lazy to go through the whole process here. Click here.

4. Take the sun visors off by popping these covers. There are tabs on the sides so you need so pull them outwards at the bottom. You may not be able to take them completely off yet because the cable that supplies the vanity light is tucked inside the headliner and hot glued. So I just left them dangling until I got round to it later. Two philips screws hold this end down and one on the other side.

5. Pulled the A pillar covers out and then cut the single strap holding it on. The strap prevents the covers from flying out and smacking you in the eye in the event of airbag deployment. Cut this retaining strap at your own peril!!!!

6. The "intercooler Airbag" cover hides a Philips screw that holds the cover to the B pillar. I didn't take the cover off because it wouldn't budge and I could get the headliner off with it still attached. I want to know how to take this off though.

7. Next three tabs in the rear need to be turned 90 degrees and pulled off. If they don't turn clockwise, try turning them anti-clockwise.

8. The rear light cluster is pulled straight down and then unplugged.

9. Sunroof trim. Just pull it out. See the sunvisor dangling by its wire in the background?

10. The "Oh Sh!t" handles have a small tab covering the screws. Use a small flathead screwdriver to pop the cover and then unscrew it. Then pull all the weather seals around the tops of the doors. No need to pull it all the way to the bottom, just the tops.

10a. Pull the C pillar covers off the same way you did the A pillars. There are retaining straps here too.

11. Finally with all the anchors undone, you can pull the headliner down. Do it gently and mind the cables still cables still hot glued all over the headliner.

12. Here is the sunvisor power supply for the vanity mirror light. Once unplugged, you can remove the sunvisors completely. Unplug that and the rear overhead brake light after you have released the cables from their hotglue bondages.

13. Unplug the rear brake light.

14. This was how I managed to squeeze the headliner out. No need to remove the doors or seats. But I was very close to giving up and cutting the headliner in half.

Turn it sideways and use the full diagonal of the passenger door and you will be able to get the thing out. You will need to bend the headliner slightly but no folding necessary.

15. Voila!! Headliner off! Then I fixed myself a drink.

16. With the headliner off, I took a few pictures because I was surprised the sunroof was drained at all four corners.

Left Front

Left Rear

Right Front

Right Rear (ok not right rear.. whatever)

17. Side curtain air bag is one long piece all the way to the back.

18. Brushing the dry-rotted sponge backing only requires a stiff bristle brush. I used a dishwashing brush by OXO. Use long firm strokes, almost like scrubbing the floor. There is no risk of scrubbing through the headliner backing.

19. Done

That's it for tonight folks. Hope these photos are archived separately as it would be a shame to lose all the pictures if I cancel my flickr account.

Next..up

The reapplication of the new headliner.

[Oreo931]

Excellent write up so far! I look forward to your write up of the reapplication. What material are you going to use, and what adhesive?

[aldebaran]

Hi Adam. I bought some regular gray headliner material at Jo-Ann's but it may be too narrow. I want to go with the OEM look but bouncing other ideas around too. Maybe black leather/suede or pleather.

If it turns out I cannot use the material I bought, I will scout out the auto upholstery shops to see what else is available.

I want this done in a week because I don't like driving the R everyday and putting unnecessary miles on it.

[aldebaran]

The adhesive is a normal spray for headliners. I hear the ones from Jo-Ann do an excellent job.

[aldebaran]

Figured what rattled everytime I shut the door. It was the overhead rear brake light assembly that had become unglued from the headliner. Put some glue and riveted it for good measure.

[aldebaran]

The sliding sun shade needs to be removed in order to reupholster it. (thank you Kyle for the instructions)

The sunroof glass has to be removed. Hopefully at this juncture, you have the sunroof completely closed. Otherwise you may need to reconnect the battery and close the sunroof glass.

1. There are two T20 bolts on each side of the sunroof glass. The accordion privacy louvers need to come off. Remove by pulling them at their anchor points. Do not yank anywhere else or you may tear it like I did.

2. Once off, you can see the two T20 bolts. Unscrew them all while supporting the glass.

3. Take the glass off from the top and set it down someplace where you won't step on it.

4. Pull the sunshade forward and look through the top. There are a total of 4 T20 screws that hold it on the track. Unscrew the front two.

5. Then take the track guides off so you don't lose it.

6. Pull the shade forward some more to access the rear bolts.

7. The shade comes completely off. No hacksawing required!

8. The plastic piece comes off by pushing all of these tabs. Then the entire liner can be ripped off right down to the metal backing plate.

When upholstering the sun shade, leave extra fabric at the edges to fold over, just like the headliner. Cut a narrow strip out from the middle of the ventilation holes. Do not cut to the edge otherwise you will see ugly edges of your headliner material peeking out from under the plastic piece.

I also found it advantageous to leave some extra material around cutouts so they act as vibration dampeners. The clips also hold a little more securely.

Back and front after cutting out the sunroof hole

The finished result, a factory look.

Before:

After:

When light hits it a certain way, the headliner looks lumpy, but I'm very happy with the result and the amount of money I spent on this project.

_____The End____

[PyROTech]

i didnt do my rooflining b/c im afraid it will never look the same again. Will bunch and look lumpy when i try to reinstall it.

[MrWinkey]

Nice work!

;)

[aldebaran]

Thanks! All that for $48 (3 yards of headliner material) plus $12 (2 cans of headliner adhesive)

[Guest Berkvens]

Thanks for the write-up!! I followed step by step and got it accomplished in a little less than 4 hours (Including cleaning of the headliner backboard and replacement of new liner). One little hickup included not re-taping the wires to the headliner. When I put the Visors back on one of the wires was smashed and caused it to short out so my dome lights and visor lights did not work properly. So I went back, used some electrical tape, and viola! good as new!