Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Headliner

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REMOVAL & INSTALLATION



Coupe and Sedan

See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the bezel from the map lamp or lamp and sunroof switch console by prying at the notch on the outside edge.
  4.  
  5. Disconnect the dome lamp assembly form the headliner, then unplug the wiring harness and remove the lamp assembly from the vehicle.
  6.  
  7. Remove the screws, then remove the sun visor retainer/supports and the sun visors from the headliner.
  8.  
  9. Remove the screw covers from the assist straps, then remove the screws and the straps from the headliner. Be careful. If the front assist strap has different color screws, the black screw will have LEFT-HANDED threads.
  10.  
  11. Remove the coat hooks, then, for the Coupe, remove the rear upper garnish molding by pulling at the clip locations.
  12.  
  13. Remove the 2 dashboard upper trim panel screw caps (located near the windshield at either end of the dash or in the center of the dash toward the front) by carefully prying with a small flathead tool. Remove the upper trim panel screws.
  14.  
  15. Lift the upper trim panel to disengage the clips at the rear edge, then pull the panel rearward and out of the clips at the base of the windshield. Remove the upper trim panel from the vehicle.
  16.  
  17. If equipped with shoulder belt height adjusters:
    1. Unsnap the shoulder belt fastener cover and remove the shoulder belt mounting fastener.
    2.  
    3. Using an awl, unsnap the shoulder belt adjuster knob locking clip.
    4.  

  18.  
  19. On 1996-98 Sedan and 1997-98 Coupe models, remove the high mounted stop lamp cover by pulling down to disengage the mounting clips.
  20.  
  21. On 1991-95 Sedan and 1991-96 Coupe models, remove the 2 screws and instrument panel end cap/HVAC outlet assembly from the left side of the dashboard.
  22.  
  23. Check for any garnish molding mounting fasteners and remove. Remove the windshield garnish molding by firmly pulling at the attaching clip locations.
  24.  
  25. For the Sedan, pull the left rear seat bolster at the top to disengage the fastener, then remove the bolster from the vehicle. Remove the lower rear screw from the left rear garnish molding, then remove the molding by pulling at the clip locations.
  26.  
  27. If equipped, disengage the sunroof finish lace, then remove the lace from the headliner.
  28.  


WARNING
Be very careful when handling the headliner. Should the liner become bent it will break and leave a wrinkle which cannot be repaired.

  1. Disengage the Velcro attachments at the rear of the headliner, then fully recline the front seats and carefully remove the headliner through the right or left front door of the vehicle.
  2.  

To install:
  1. Carefully install the headliner through the right door, then position the headliner to the dome lamp opening, sun visor attachment points and, if equipped, to the sunroof opening. Engage the Velcro attachments at the rear of the headliner.
  2.  
  3. Install the sun visors.
  4.  
  5. For the Sedan, install the left rear garnish molding by pushing at the clip locations, then install the rear retaining screw. Position the rear seat side bolster onto the outboard pivot pin, then secure the bolster by aligning and engaging the guide pin and upper fastener.
  6.  
  7. If equipped, install the sunroof lace.
  8.  
  9. Install the front upper garnish molding.
  10.  
  11. For the Coupe, install the rear upper garnish molding.
  12.  
  13. Install the coat hooks.
  14.  
  15. Install the assist strap and strap covers. If equipped, the black left-handed thread screw should always be installed in the rearward attachment of the assist strap.
  16.  
  17. Install the instrument panel end cap and screws.
  18.  
  19. Install the upper trim panel by inserting into the clips at the windshield, then snapping the rear of the panel into place. Install the upper trim panel screws, then snap the screw covers into position.
  20.  
  21. If equipped with shoulder belt height adjusters:
    1. Install the shoulder belt, being careful not to twist it. Tighten the shoulder belt mounting fastener to 37 ft. lbs. (50 Nm).
    2.  
    3. Snap into place, the shoulder belt mounting fastener cover and install the adjuster knob.
    4.  

  22.  
  23. On 1996-98 Sedan and 1997-98 Coupe models, install the high mounted stop lamp cover by pushing firmly upward to engage the mounting clips.
  24.  
  25. On 1991-95 Sedan and 1991-96 Coupe models, install the instrument panel end cap to the left side of the dashboard.
  26.  
  27. Install the map lamp/switch console bezel and the dome lamp assembly.
  28.  
  29. Connect the negative battery cable.
  30.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the dome lamp assembly from the headliner



Click image to see an enlarged view

Fig. Fig. 2: Remove the covers, screws and assist straps



Click image to see an enlarged view

Fig. Fig. 3: Pull down on the high stop lamp cover to disengage its mounting clips



Click image to see an enlarged view

Fig. Fig. 4: The headliner is fastened to the rear of the roof using Velcro hook and loop material

Wagon

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the dome lamp assembly from the headliner, then unplug the wiring harness and remove the lamp assembly from the vehicle.
  4.  
  5. Remove the screws, then remove the sun visor retainer/supports and the sun visors from the headliner.
  6.  
  7. Remove the screw covers from the assist straps, then remove the screws and the straps from the headliner. Be careful. If the front assist strap has different color screws, the black screw will have LEFT-HANDED threads.
  8.  
  9. Remove the coat hooks.
  10.  
  11. Remove the 2 dashboard upper trim panel screw caps (located near the windshield at either end of the dash or in the center of the dash toward the front) by carefully prying with a small flathead tool. Remove the upper trim panel screws.
  12.  
  13. Lift the upper trim panel to disengage the clips at the rear edge, then pull the panel rearward and out of the clips at the base of the windshield. Remove the upper trim panel from the vehicle.
  14.  
  15. Remove the 2 screws and instrument panel end cap/HVAC outlet assembly from the left side of the dashboard.
  16.  
  17. If equipped with shoulder belt height adjusters:
    1. Unsnap the shoulder belt fastener cover and remove the shoulder belt mounting fastener.
    2.  
    3. Using an awl, unsnap the shoulder belt adjuster knob locking clip.
    4.  

  18.  
  19. On 1991-95 Sedan and 1991-96 Coupe models, remove the 2 screws and instrument panel end cap/HVAC outlet assembly from the left side of the dashboard.
  20.  
  21. Check for any garnish molding mounting fasteners and remove. Remove the windshield garnish molding by firmly pulling at the attaching clip locations.
  22.  
  23. Pull the rear seat bolster at the top to disengage the fastener, then remove the bolster from the vehicle.
  24.  
  25. If necessary, remove the left rear shock tower cover.
  26.  
  27. Remove the rear headliner trim panel.
  28.  
  29. Remove the body rear corner trim panel assembly.
  30.  
  31. Remove the left latch pillar upper trim molding assembly.
  32.  


WARNING
Be very careful when handling the headliner. Should the liner become bent, it will break and leave a wrinkle which cannot be repaired.

  1. Disengage the Velcro attachments at the rear of the headliner and from the right garnish moldings, then fully recline the front seats and carefully remove the headliner through the rear of the vehicle.
  2.  
  3. Disengage the attachments at the rear of the headliner, fully recline the front seats and carefully remove the headliner through the right or left front door of the vehicle.
  4.  

To install:
  1. With the aid of an assistant and with the seats reclined, carefully install the headliner through the rear of the vehicle, then position the headliner to the dome lamp opening and sun visor attachment points. Engage the attachments at the rear of the headliner.
  2.  
  3. Install all of the interior garnish moldings/trim panels that were removed for this procedure. Be sure to apply firm pressure at the mounting points in order to positively engage the attachment clips.
  4.  
  5. Install the rear header trim.
  6.  
  7. Install the left rear shock tower cover.
  8.  
  9. Install the left seat side bolster.
  10.  
  11. Install the left windshield garnish molding.
  12.  
  13. Install the instrument panel end cap and screws.
  14.  
  15. Install the upper trim panel by inserting into the clips at the windshield, then snapping the rear of the panel into place. Install the upper trim panel screws, then snap the screw covers into position.
  16.  
  17. If equipped with shoulder belt height adjusters:
    1. Install the shoulder belt, being careful not to twist it. Tighten the shoulder belt mounting fastener to 37 ft. lbs. (50 Nm).
    2.  
    3. Snap into place, the shoulder belt mounting fastener cover and install the adjuster knob.
    4.  

  18.  
  19. Install the assist strap and strap covers. If equipped, the black left-handed thread screw should always be installed in the rearward attachment of the assist strap.
  20.  
  21. Install the coat hooks. Install the sun visor retainer/supports and the sun visors.
  22.  
  23. Install the dome lamp assembly.
  24.  
  25. Connect the negative battery cable.
  26.  



Click image to see an enlarged view

Fig. Fig. 5: Remove the sun visor screws, retainer/supports and sun visors

 
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