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Jaguar XJ6
Headliner Replacement
Tools Required
1. Phillips #2 screw driver
2. 10mm combo wrench or socket
3. Needle nose pliers
4. Pry/tuck tool (blunt putty knife)
Disassembly headliner board
1. Remove interior mirror by grabbing the stem and pulling firmly
2. Remove mirror bracket
3. Remove sunvisors and brackets
4. Remove dash end caps
5. Remove wind lace from cantrail
6. Pry vinyl covered molding from cantrail inner
7. Loosen but do not remove rear ¼ lights
8. Pry at clips and remove rear trim panel above rear window
9. Unscrew side and rear headliner retaining brackets
10. Remove sunroof surround wind lace.
11. Loosen headliner fabric glued to sunroof opening
12. Recline both seats and move to rearmost position
13. Place gearshift toward the rear.
14. Tape a piece of cardboard to console in front of gearshift for protection.
15. Remove headliner board through passenger front door by slightly bending and rocking back and forth.
Disassembly sunroof.
1. Disconnect sunroof gearbox drive behind rear seats.
2. Slide panel rearward and remove 4 Phillips screws along leading edge.
3. Slide exterior panel forward, up and away from car.
4. Slide inner panel forward and remove 4 10mm nuts and brackets from front of panel.
5. slide panel ½ way back and remove 2 middle bracket on panel and 2 stops on car.(8x10mm nuts) Note direction and location of each part as removed.
6. Slide panel fore ward and remove rear spring brackets on rear (4x10mm nuts)
7. Lift panel out of car and place on clean flat surface.
8. Remove 2 rear screws securing material to panel and remove lining. Note where originally glued.
Assembly of headliner board
1. Place board on clean surface fabric side up.
2. Gently scrape off old fabric taking care not to damage soft board. Lightly wire brush entire surface to remove any trace of old backing. Clean with solvent.
3. Turn board over and clean of any old fabric around edges. Clean with solvent.
4. Allow board to dry.
5. If board is damaged repair with fiberglass or epoxy and apply 1/8 inch layer of foam using contact adhesive to smooth out any imperfections.
6. If board is OK or repaired as above, apply 2 coats of contact adhesive to board and new headliner material allowing each to dry between coats.
7. Press fabric into board beginning in front, use a towel or other soft object to avoid dimples.
8. Allow to dry several hours before reinstalling through passenger door.
9. Replace all fasteners, moldings, clips, sunvisors and mirror before gluing around sunroof opening and replacing sunroof surround wind lace.
Assembly of sunroof panel
1. Clean any adhesive from edges.
2. Clip plastic pieces along front and rear edge.
3. Install 2 Philips screws in rear edge and mark position of 4 front screws.
4. Glue side edges and place back in car.
5. Replace all brackets and guides in opposite of removal.
6. Replace outer panel and secure with 4 screws.
7. Replace gearbox drive behind rear seats.
8. Reinstall seats.