Repair Procedure

This bulletin involves replacing the structural headliner membrane.

1. Remove instrument panel end caps.

2. Disengage clips attaching trim to A-pillar by pulling on trim. Remove the right and left A-pillar trim panels.

3. Remove the screws attaching the inboard visor retainer to the overhead system.

4. Remove the screws holding the outboard visor pivot base to the roof. Disconnect the visor vanity lamp wire, if so equipped. Remove the sun visors.

5. Remove the screw from the windshield side of the overhead console.

6. Grasp front of console and pull downward to disconnect retaining clips.

7. Disconnect the wire connectors and remove the overhead console.

8. Disconnect the headliner harness along the left A-pillar and connector from the junction box.

9. Disengage right and left front shoulder belt turning loop cover.

10. Remove the right and left bolt holding the turning loop to the shoulder belt height adjuster.

11. Remove the right and left turning loop from the adjuster and the adjuster knob.

NOTE:
PULLING OR PRYING THE KNOB OFF MAY DAMAGE THE KNOB OR THE ADJUSTABLE TURNING LOOP SLIDER MECHANISM. TO REMOVE THE KNOB INSERT SNAP RING PLIERS INTO THE SLOT IN THE BOTTOM SIDE OF THE KNOB. THE PLIERS MUST BE CLOSE TO THE OUTSIDE SURFACE OF THE KNOB AND BE INSERTED APPROXIMATELY 3/8" INTO THE SLOT. THIS WILL PARTLY DISENGAGE THE KNOB WHICH CAN BE PULLED OFF (IT MAY HAVE TO BE ROCKED). SOME DISTORTION WILL OCCUR TO THE RETAINER FEATURE ON THE SLIDER MECHANISM, BUT WILL STILL ALLOW PROPER FUNCTION.

12. Disengage clips holding right and left upper B-pillar trim.

13. Pull and hold the right front assist handle down. Remove the two attaching screws and remove the front assist handle.

14. Pull down the coat hooks. Remove the right and left screw holding the assist handles to the roof from behind the coat hooks.

15. Pull and hold the rear assist handles down, remove the left front screw attaching the assist handle to the roof. Assist handles/lamps will stay with headliner.

16. Disengage the clips holding the upper C-pillar trim to the inner quarter panel. Slide the trim panel down over the seat belt and let it rest on the rear seat cushion.

17. Place the front seats in full forward position and the tilt steering wheel to the full up position (On Concorde vehicles the right front seat must be removed from the vehicle).

18. Disengage clip attaching headliner to roof at the center above rear window using Miller Special Tool # C-6967.

19. Carefully pull down on headliner until the four glue bonds between the headliner and structural membrane break free.

NOTE:
THE HEADLINER MAY BE STUCK TO THE STRUCTURAL MEMBRANE. GENTLY PRY IT AWAY, TOO MUCH FORCE WILL DENT/DING/CREASE/FLEX THE ROOF PANEL AND CAUSE PERMANENT DAMAGE.

20. Remove the headliner from the vehicle through the rear door, using two people (21 x 25" cardboard structural membrane will remain attached to the roof panel).

NOTE:
SEATS, CENTER CONSOLE AND CARPET UNDER THE STRUCTURAL MEMBRANE SHOULD BE COVERED TO PREVENT POTENTIAL DAMAGE FROM UNCURED ADHESIVE DURING REMOVAL.

21. With 3-M Molding Removal Tool, 3-M p/n 08978, and air chisel, carefully pull down the corner of structural membrane enough to insert Molding Removal Tool between roof panel and adhesive. It may be easier to cut the structural membrane into strips between the adhesive and remove the strips individually.

22. Activate the air chisel, while keeping the blade at a slight angle to the roof, make sure not to flex the roof panel. Evenly separate the adhesive strips from the roof panel until the structural membrane is removed.

NOTE:
USE EXTREME CAUTION WHEN PULLING ON THE STRUCTURAL MEMBRANE, THE ROOF PANEL MAY DENT/DING/CREASE/FLEX AND CAUSE PERMANENT DAMAGE.

23. Using a razor blade scraper tool, scrape off the remaining adhesive residue.

24. Ensure that the roof panel distortion is eliminated. If there is any noticeable distortion the roof panel will have to be repaired in the body shop.

25. Place the headliner in the vehicle placing in a down position on the seats.

26. Remove the protective cover previously placed over the interior components.

27. The new membrane is cut into five equal strips. Outside of the vehicle, using the adhesive supplied in membrane kit, apply a 10 mm (3/8 in.) diameter bead of adhesive the length of each of the new cardboard structural membrane strips, stopping 38 mm (1.5 in.) before each end of the membrane strip.

NOTE:
ADHESIVE MUST BE APPLIED UNIFORMLY IN 10 mm (3/8 in.) BEADS. TOO MUCH OR TOO LITTLE ADHESIVE WILL CAUSE ROOF PANEL TO WARP AS ADHESIVE CURES.

28. Apply a 25 mm (1 in.) diameter hot glue spot to each location where the glue bond between the headliner and structural membrane had previously been broken free. Apply additional 25 mm (1 in.) diameter hot glue spots to secure all five structural membrane strips to the headliner. This bond is not critical to performance but allows the membrane strips to remain in place while the headliner is reinstalled.

29. Place the structural membrane strips, adhesive side up, onto the headliner over the glue spots to attach the membrane to the headliner. The five structural membrane strips placed 15 mm (9/16 in.) apart should cover the same area as the original membrane.

30. For installation reverse the above procedures.

NOTE:
IT IS NOT NECESSARY TO APPLY LOCAL PRESSURE IN THE AREA OF THE STRUCTURAL MEMBRANE, THE SHAPE AND STIFFNESS OF THE HEADLINER WILL PROVIDE PROPER PRESSURE TO ALLOW THE ADHESIVE TO CURE PROPERLY.

31. Refit the door weatherstrips around the headliner.

32. While reinstalling the rear assist handles, make certain that the headliner wire harness is not pierced when reinstalling the two screws.

33. The seat belt bolts must be torqued to 23 to 39 Nm (204 to 345 in. lbs.).

34. Verify function of applicable accessories.

35. Vacuum excess material from structural membrane removal.