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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #1 (Edited)
Headliner Replacement in Alcantera and Roof rattle fix.

Here we have a 1999 E 430 "the victim" due to old age, and major disruption,
the headliner is falling.
DCP41264.jpg
I did a roof rattle repair 2 years ago, and that may have caused some of my
headliner problems.
DCP41265.jpg
As well I had the windows tinted last summer and after that the headliner fell.
DCP41266.jpg
I think the disruption played a part, but the headliner fabric has a foam backing and
that is what deteriorates over time. Touching it or rubbing it will cause it to come lose
before it's time.
DCP41267.jpg
First thing I needed was the sun roof door. The forward inside edge has a black plastic
cover that opens the sun roof door when you open the sun roof. It has little tabs on the ends
pry them inward and pull down on the plastic cover to remove it.
DCP41271.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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1,906 Posts
Discussion Starter #2 (Edited)
Here I have released the end tab and am pulling the part down.
DCP41272.jpg
Here is what it looks like removed.
DCP41274.jpg
Now open the sunroof.
DCP41275.jpg
Close the sunroof door.
DCP41276.jpg
This is one of the 4 sliders that support the sunroof door.
DCP41277.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #3 (Edited)
To remove the sunroof door you need to compress the sliders.
DCP41278.jpg
Here I use a knife and lift the door up while the slider is out of the track
do same for the other sliders, and remove door in a forward motion.
DCP41279.jpg
To remove the vents I bent them.
DCP41322.jpg
This is how much you need to bend them to remove, careful.
DCP41323.jpg
The door handle just snaps apart.
DCP41324.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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1,906 Posts
Discussion Starter #4 (Edited)
Now that I have the sunroof door I can take it with me to match the color.
At this point I don't know if I will use OEM fabric or Alcantera, I have priced both,
more on that later when I find the best color match.
DCP41325.jpg
Remove the rear lamp and support clip it is behind the lamp.
DCP41326.jpg
Open little doors in the handles
DCP41327.jpg
Unscrew handles, to remove rotate up, they are hooked in.
DCP41328.jpg
Remove sun visors.
DCP41329.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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1,906 Posts
Discussion Starter #5 (Edited)
Remove the sun visor catches, you only need to remove the screws
the catch is two pieces.
DCP41330.jpg
Now remove the lens on the over head lights, you will see the metal
release catch on the over head console.
DCP41331.jpg
Release the catches and swing the console down and remove the wires.
DCP41332.jpg
Unplug the wires to the rear view mirror and pull the mirror straight
down.
DCP41333.jpg
To remove the door seals it is best to remove the thresholds first.
DCP41334.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #6 (Edited)
There are two pieces in the rear, see the clip location.
DCP41335.jpg
Front door one piece note clip location. Once the thresholds have been removed
you can remove the door bead/seal and mark them with their location.
DCP41336.jpg
The "A" pillar has 6 clips that are tight, start by pulling at the top, straight away
from the pillar. Don't use any tool to pry the cover off, there are many wires and
an airbag inside.
DCP41337.jpg
Here is a better pic of the angle to pull at.
DCP41338.jpg
This is why you should not any pry tool, wires and airbag.
DCP41339.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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1,906 Posts
Discussion Starter #7 (Edited)
In your OEM tool kit you will have a sunroof emergency tool
to open or close your sunroof. for the next item the roof
needs to be open.
DCP41340.jpg
Along the front edge of the sunroof is a channel with a rubber
seal on it, this piece locks the headliner in place. to remove it
pry it straight up.
DCP41341.jpg
Now you can release the 4 clips on the "B" pillar, and move
them out of the way. I plan to recover all the pillars "A,B,C"
I will remove them later.
DCP41342.jpg
To remove the "B" an "C" panels you need to disconnect the seat belts.
DCP41343.jpg
The "C" pillar has 4 clips 3 in the forward section and one in the rear.
once released from the clips pull the panel forward to release the
locking tab in the lower section.
DCP41344.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #8 (Edited)
At this point you can swing the "C" panel out of the way.
DCP41345.jpg
Next we drill out the pop rivets
DCP41346.jpg
Now the headliner is hanging on the rear sunroof interlock.
DCP41347.jpg
To lower the headliner it is a good idea to have a helper
one person on the left one on the right. holding the forward
part of the headliner down slide it forward, and in one
inch it will release from the rear interlock in the sunroof support.
Now that it is free you can withdraw it through the front passenger door.
I don't know if that is the best way or not, I did have to give it a bend
like a taco. It is not easy to remove, but it can be done. try to avoid
bending the metal frame around the sunroof opening.
DCP41348.jpg
Poof it's out, sorry no pics in process, I had my hands full.
DCP41349.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #9 (Edited)
The old fabric comes off quite easily, but the foam backing
is a huge mess.
DCP41350.jpg
Once the fabric was removed we cleaned what was left of old
foam and adhesive, took hours to get it smooth. This part was
important because I have decided to go with Alcantera with out
a foam backing so I did not want imperfections to show through.
DCP41355.jpg
Sunroof door cleaned up nice.
DCP41356.jpg
Here is the first glue, only did the large center part to start with.
DCP41357.jpg
This is the adhesive I used note High Temp, it is a contact cement
and requires a few minutes to tack.
DCP41358.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #10 (Edited)
Here you can see I slowly worked the Alcantera in to the couture
of the headliner shell. (glue, stretch, clamp) This was very difficult
because the Alcantera has very little stretch.
DCP41359.jpg
Many times I would stretch and clamp the Alcantera over night
just to make it fit better.
DCP41360.jpg
Here from the start was my greatest fear, the recess for the sun visors
I glued and clamped right up to it. Then I stretched it and stretched it and
stretched it.
DCP41365.jpg
Much to my surprise the rear over head handles fit the contour of
the sun visor, so I used them as a tool and clamped them to hold
the Alcantera in place. (for a week)
DCP41367.jpg
To pass the time I started to cover the "A" pillars
went right over the OEM covering, no problem.
DCP41369.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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1,906 Posts
Discussion Starter #11 (Edited)
OK between my previous rattle repair and this complete removal,
the headliner shell has suffered some damage. The black lines you
see are cracks. I repaired this condition with some fiberglass mat
and west system epoxy.
DCP41370.jpg
This is the site of the two metal clips in the aft center section.
During my rattle repair I glued the clips on with 3M 5200 (forever)
when I removed the headliner part of the shell stayed on the clips
so I had to glass over that damage.
DCP41371.jpg
Patch over the "B" pillar, This is a natural flex point.
DCP41372.jpg
Stretch and clamp the sunroof opening.
DCP41376.jpg
Like my tool, I have lots of prescription bottles. So ya, see a
sober person would never DIY a headliner. That is my best
advise.
DCP41377.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #12 (Edited)
More stretch, glue & clamp......
DCP41378.jpg
The corner radius in the sunroof opening is all the Alcantera can do
it is stretched to the max.
DCP41379.jpg
The forward edge of the sunroof frame requires the Alcantera to be glued
to the underside of the frame.
DCP41380.jpg
All most done, time to trim all openings and reinstall forward overhead
console metal frame.
DCP41381.jpg
The rear clips were found to be removable, so I pop them out to
remove the old rivets.
DCP41382.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #13 (Edited)
Here we install the metal frame for the rear lamp.
DCP41383.jpg
Test fit new hole for rivet
DCP41384.jpg
Test fit rivet and clip.
DCP41385.jpg
At this point I know that I will not have to do a "do over"
and will now have enough Alcantera to cover the "B & C"
pillars. So to remove the "B" pillar I will have to disconnect
the seat belt from the seat
DCP41386.jpg
The "B" pillar is ready to be striped.
DCP41387.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #14 (Edited)
"B" pillar in process
DCP41390.jpg
Other panels begin recover process.
DCP41391.jpg
TaDa the headliner is DONE and ready to be re-installed.
DCP41392.jpg
Other parts all most finished.
DCP41393.jpg
Inspection before re-installation.
DCP41394.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #15 (Edited)
OK this is looking at the sunroof and sunroof frame in side the car.
The part with the 6-7 white dots is the frame that causes the rattle.
I put 7 dabs of 3M 5200 marine sealant to fix my rattle it worked and
I intend to use the same method again (headliner glued to frame). If
you look at the rear of the frame you can see the the two clips (gray)
they will be glued to the headliner by same means with 5200. I did
install the headliner but I have no pics yet cause I have a support
in the car to hold the headliner up while the 5200 dries (7 days)
I will post up pics of the finished product and other information next week.
DCP41395.jpg
 

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E-ZGO 53 HP., 99 E 430 sport, 04 E55 AMG, 2008 Tahoe LTZ Sold Porsche to Brother
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Discussion Starter #16 (Edited)
Well the hard part is done, and for the most part I am happy. No matter how careful you are there will always be a few flaws, the only finishing touches will be, a finish bead at the top of "B" pillar. I used Alcantara only no foam backing so there is a slight gap at the top of "B". and I have not decided what to do with my sun visors, I would like to put some kind of screen, movies on the right and GPS nav screen on left.:nix:

So far so good the Alcantara is holding on the pronounced contours.

I did not take the time to brush the nap one direction.

The color match was much better than OEM could not have been better.


I would like to Thank Joe and Lucy at Gulf Fabrics, Inc.
They are the US importer for Alcantara and located in Tampa FL.
The headliner as depicted here requires 4 yards of pannel.
Contact information,
Gulf Fabrics, Inc.
3709 N. Armenia Avenue
Tampa, Florida 33607-1303

P.O.Box 7725
Tampa, Florida 33673-7725

813-875-2707 local
813-348-9540 fax
800-237-6677

Gulf Fabrics Home Page

[email protected]com
 

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1997 W210 E320 Avantgarde
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You have done a fantastic job with the instructions. I am jealous of your work shop. It looks like you have a really good set up. I wish I had the space to attempt this project at home...not to mention the patience.

Thanks

Drew
 

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'01-E320 & 02-ST2
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So what'd that take you, an hour or so? :D :D

Seriously, thanks for the post, as always. There is lots of good information in there otherwise even for those that don't want to pull the entire headliner.

But where is the AM/FM amplifier? :rolleyes:

Take care and enjoy the new 'n improved ride,
Greg
 
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