Attachment III - Technical Information
OVERVIEW
This program involves lowering the headliner enough to inspect the structural foam blocks which are mounted above the front corners of the headliner. Depending on the results of the inspection, dealers will either release the vehicle, or modify the structural foam blocks using a special tool and a 5/8 inch auger bit. See Figure 1.
SERVICE PROCEDURE
CAUTION:
Failure to perform all disassembly steps as outlined increases the possibility of damaging the headliner.
CAUTION:
Make sure your hands are clean before performing this repair.
NOTE:
Although the headliner does not have to be removed to carry out the inspection or modification, a number of trim panels and components must be removed or repositioned in order to lower the front of the headliner for access.
Performing all steps as outlined will position the headliner adequately for access to the repair area.
NOTE:
If the vehicle is equipped with any aftermarket or dealer-installed options, such as a DVD player that interferes with adequately lowering the headliner, they must be removed.
DISASSEMBLY FOR INSPECTION
NOTE:
Perform the following steps on both sides of the vehicle.
1. Open the A-pillar assist handle bolt covers, then remove the bolts and the assist handles.
2. Remove the A-pillar trim panels.
3. At the B-pillars, remove the D-ring covers and the safety belt bolts.
4. Remove the upper B-pillar bolt covers and the bolts, then remove the B-pillar trim panels.
5. If equipped, remove the overhead console retaining screws and disconnect the electrical connector, then remove the console from the vehicle.
6. Remove the sunvisors and sunvisor clips. If equipped, disconnect the electrical connectors.
7. Open the rear seat overhead assist handle bolt covers, then remove the bolts and the assist handles.
8. Position the front and rear door weatherstrips down away from the headliner.
9. Allow the headliner to hang down loosely at the front corners. Do not pull down on the headliner or otherwise stress it, or damage may result.
INSPECTION
1. Without pulling the headliner down beyond its natural hanging rest position, carefully inspect the structural foam blocks mounted at the passenger and drivers side front corners on the top of the headliner to see if they have one (1) or two (2) indentations. See Figure 2.
^ If the blocks have only one (1) indentation, proceed to DISASSEMBLY FOR MODIFICATION.
^ If the blocks have two (2) indentations, no modification is required. Proceed to ASSEMBLY.
DISASSEMBLY FOR MODIFICATION
1. Remove the interior lamp lens.
2. Remove the two (2) screws and the interior lamp, then disconnect the electrical connector.
3. Proceed to STRUCTURAL FOAM BLOCK MODIFICATION.
STRUCTURAL FOAM BLOCK MODIFICATION
1. Using fender covers, seat covers or suitable rags, cover the defroster and instrument panel ducts so chips cannot fall into the heater plenum while drilling.
2. Install a drill stop or apply suitable tape onto the drill bit 140 mm (5-1/2 in) from the end of the cutting portion of the bit (not from the threaded tip). See Figure 3.
3. CAUTION: The weight of the tool when positioned on the foam block increases the risk of headliner damage. Hold the headliner up when the tool is positioned on the foam block.
Starting on either side of the vehicle, position the supplied drill guide onto the foam block so that the locating pin is set into the indentation on top of the block and the "wings" are resting on either side of the block, preventing the guide from moving side-to-side. See Figure 4.
4. WARNING: WEAR SAFETY GLASSES.
CAUTION:
DO NOT USE an air-powered drill for this operation. Oil spray from the tool may damage the foam block or other interior trim.
CAUTION:
Be sure to keep the drill motor at full speed and frequently clear the chips from the bit while drilling each hole. Bore the holes at a slow to moderate pace using light to moderate pressure on the drill. Attempting to bore the holes at a fast pace using excessive pressure on the drill, or failing to clear the chips from the bit, may cause the foam blocks to crack.
NOTE:
Be sure to allow the drill motor to achieve full speed before attempting to bore the hole.
Drill the holes as follows:
A. Holding the drilling guide securely in place, position the drill bit in either of the two (2) guide holes. See Figure 5.
B. Start the drill motor and allow it to achieve full speed.
C. Drill the hole at a slow to moderate pace, occasionally pulling the bit out to clear the chips.
D. Drill the hole to the proper depth using the stop on the bit as your depth gauge. See Figure 6.
E. Drill the second hole in the same foam block in the same manner.
F. Repeat steps A - E on the foam block on the other side of the headliner.
5. Remove the covers from the instrument panel and clean all foam chips from the vehicle. Proceed to ASSEMBLY.
ASSEMBLY
1. Position the B-pillar trim panels and install the bolts. Tighten to 7 Nm (62 lb-in), then install the bolt covers.
2. Position the safety belt and install the safety belt bolts at the B-pillar. Tighten to 53 Nm (39 lb-ft), then install the D-ring covers.
3. Install the A-pillar trim panels.
4. Install the passenger A-pillar assist handles and bolts. Tighten to 5 Nm (44 lb-in), then install the bolt covers.
5. Install the front and rear door weatherstrips.
6. Connect and install the overhead console, if equipped.
7. Install and connect the interior lamp and screws.
8. Install the interior lamp lens.
9. Install the sunvisors, connecting the electrical connectors if equipped, and the sunvisor clips.
10. Install the rear seat overhead assist handles and bolts. Tighten to 8 Nm (71 lb-in), then install the bolt covers.