Headliner

Removal Procedure

Note: Do Not remove the folding top cover when replacing the headliner.

Note: The folding top latch actuator linkage is not serviceable. The folding top number 1 bow and latch actuator linkage MUST be replaced as an assembly.

1. Remove the folding top frame from the vehicle. Refer to Folding Top Frame Removal and Installation.
2. Place the folding top frame (1) on a clean and dry surface, with the folding top cover face down and in the full close position.
   
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3. Remove the folding top number 1 bow garnish molding. Refer to Folding Top Number 1 Bow Garnish Molding Replacement.
4. Remove the folding top quarter outer drain panel from the folding top frame. Refer to Folding Top Quarter Outer Drain Panel Replacement.
5. Disconnect the headliner (1) from the number 1 bow retainers (2) across the inner lower edge of the bow.
   
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Warning: Use the proper eye protection when drilling to prevent metal chips from causing physical injury.

Note: Do Not remove the folding top cover from the frame to replace the headliner. The folding top frame must be removed from the vehicle to access the rivets under the headliner for the left and right side.

Note: Mark all locations or the side straps and side flaps before drilling out the rivets.

6. Drill out the rivet (1) that attach the side flap (2) to the folding top side rail on the left and right side, take Note how the side flap is fitted around the side rail before drilling out the rivet.
   
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7. Position the side flap (1) around the folding top side rail to access the rivet (2) in the left and right side of the number 5 bow.
   
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Note: Mark all locations or the side straps and side flaps before drilling out the rivets.

8. Drill out the rivet (2) that attach the side strap (3) to the folding top number 5 bow on the left and right side, take Note how the side strap is fitted around the side rail before drilling out the rivet.
Note: Mark all locations or the side straps and side flaps before drilling out the rivets.

9. Drill out the rivet retaining the headliner side strap (1) from the left and right sides of the number 2 bow brackets, Do Not remove the folding top cover side straps (2) and (3).
   
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10. Remove the headliner bead (1) from the inner track of the number 5 bow retaining edge.
    To assist in the removal, use a plastic flat blade tool (3).
    
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11. Remove the headliner bead (1) from around the rear window inner retaining track (2).
    To assist in the removal, use a plastic flat blade tool (3).
    
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12. Disconnect the electrical connectors (1) from the left and right side of the rear window defogger window.
    
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13. Remove the rear window defogger harness (2) from the headliner.
14. Position the headliner side flaps inward to expose the rivets in the number 5 bow bracket, drill out the rivet from the left and right side.
15. Position the headliner and side flaps inward to expose the rivets in the number 2 thru 4 bows on the left side (Driver Side).
Note: The replacement rivets MUST be steel/stainless steel to prevent corrosion. Always check scale to size before drilling, Do Not over size the hole. If the rivet hole is drilled through apply a layer of cloth tape over the hole before installing the top cover and headliner.

Note: Take note of the beveled edge and the direction of the headliner in each bow when removing for reinstalling.

16. Place a fender covers (4) under the number 2 thru 4 bows on left and right side, this will protect the folding top cover from metal shavings while drilling.
    
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Warning: Use the proper eye protection when drilling to prevent metal chips from causing physical injury.

Note: Mark the right side of each bow before removing the headliner for reinstalling.

17. Do this from the left side only, drill (1) out the two rivets (2) from the number 2 bow thru 4 bows to this dimension 4.79 mm (3/16 in) (10.9 mm (0.4.2 in), releasing the front top side rail from the bow.
    
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18. Pull the number 2 thru 4 bows loose from the folding top side rails.
Note: Take note of the beveled edge located at the end of each bow when removing the headliner.

19. Remove the headliner from the folding top frame as follows:
    
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1. On the left side (Driver Side), ensure that all rivets have been drill out and removed from the bows.
2. Grasping the headliner and beads, work the headliner and bead downward as one from the bows, until fully removed.
3. Vacuum all metal shavings from the folding top assembly before installing a new headliner.

Installation Procedure

1. Place the folding top frame (1) on a clean and dry surface, with the folding top cover face down and in the full close position.
   
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Note: On the left side (Driver Side), ensure that all the old bow rivets have been removed from the bows before installing the headliner to prevent rattles in the bows.

Note: Take Note of the beveled edge located at one end of the each bow on the left side (Driver Side) before installing the headliner.

Note: Trial fit the folding top cover retaining beads into their corresponding roof bows. If installation is extremely difficult, it may be necessary to remove material from all of the beads, prior to their full installation. Use an appropriate tool or sand paper to remove material from the tops of the beads to reduce/eliminate interference.

2. Install the headliner and bead into the number 2 bow thru 4 bows, ensure that the headliner beads are going in the direction for each bow, note when removed.
   
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3. Grasp the headliner and beads, work the headliner and bead into each track of the bows until it has been fully seated to the right side marks taken when removed.
4. Do this from the left side only, using a appropriate tool, install two rivets (3) to the ends of the number 2 bow thru 4 bows, to this dimension 4.79 mm (3/16 in) (10.9 mm (0.4.2 in).
Note: Position the side strap to the number 5 bow marks when removed.

5. Using the appropriate tool, install the rivet (1) to the headliner side strap (2) on the left and right side of the number 5 bow (3).
   
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Note: Position the side flap to the side rail marks when removed. Ensure that the side flap and side strap are place over the side rail before installing the rivet.

6. Using the appropriate tool, install the rivet to the headliner side flap (1) on the left and right side of the side rail as shown in graphic above.
   
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Note: Position the side strap to the number 2 bow bracket marks when removed.

7. Using the appropriate tool, install the rivet to the headliner side strap on the left and right side of the number 2 bow bracket.
   
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8. Install the rear window defogger harness to the headliner.
   
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9. Connect the electrical connectors (1) to the rear window defogger window.
10. Install the headliner bead (1) to the rear window bead track (2).
    To assist in the installing, use a plastic flat tool (3).
    
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11. Install the headliner bead (1) to the retaining edge (2) of the number 5 bow.
    To assist in the installing, use a plastic flat tool (3).
    
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12. Install the headliner (1) to the number 1 bow retainers (2) across the inner lower edge of the bow.
    
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13. Install the folding top quarter outer drain panel from the folding top frame. Refer to Folding Top Quarter Outer Drain Panel Replacement.
14. Install the folding top number 1 bow garnish molding. Refer to Folding Top Number 1 Bow Garnish Molding Replacement.
15. Install the folding top frame to the vehicle. Refer to Folding Top Frame Removal and Installation.
16. Place the folding top in the lock position, check it for appearance and fit.
17. Inspect the front edge of the folding top to windshield frame for a good seal.
18. Water test the vehicle to ensure a proper water tight seal front and rear.

Removal Procedure

1. Take note of the wiring harness locations and measure the harness lead length prior to removing. Mark harness routing locations on new headliner prior to harness removal.
Note: Use a camera to take pictures and use a pencil to mark the new headliner.

2. Use fiber or plastic trim tool to assist in removing the wiring harness from the headliner, taking care not to damage the harness.
3. Remove excess glue and material from the wiring harness and re-tape areas where the tape was removed or damaged.

Installation Procedure

1. Lay the wiring harness on the new headliner assembly to confirm correct routing and ensure harness leads are proper length for mating connections prior to gluing.
Warning: Do not change the wiring harness routing locations. Correct harness routing is critical for air bag deployment. Possible personal injury or vehicle damage could result if the harness routing is changed.

Note: When installing a new headliner harness, tape any unused connector to the headliner with a high adhesive tape.

2. Use hot melt adhesive to install the wiring harness. Adhesives, Fluids, Lubricants, and Sealers
3. Apply insulator tape over glued locations to prevent squeaks and rattles as needed.