Good workup 180, I did mine a few years ago it really is easier than it seems at first thought. Not forcing it is important as you might crease the board.

 

Post #1 has been updated and a PDF file produced.

 

Dave,

Thank you for taking the time to document this reinstall with vendor references and your de-install of the headliner! Very much appreciated. Just another quality reference added to my library.. Kudoos to you!

Regards,

 

Some notes after recently completing the task and noting the great tips on this site and on you-tube:

• 2 yards of headliner material
• I removed my seats to 1.) avoid scratching material and 2.) if your headliner is shot - it's probably time to clean under those seats anyway. Need E35 Torx for removal.
• As noted in previous posts, remove dome light assembly prior to removing headliner. CAREFULLY unplug garage door opener wiring, but leave module on headliner until out of car. Re-install in same fashion.
• While the previous headliner had literally fallen off, removing the gooey residue was not the breeze others experienced. About an hour with a flexible plastic scraper did the trick.
• I wrapped the headliner material completely around the edges on all 4 sides of the headliner. Made for smoother transitions and reduced the sharp edges that can scratch interior surfaces during installation. Extra material on edges caused no fit issues AND reduced the amount of trimming with the razor blade.
• Don't fuss with carefully trimming the holes for the visors. As long as you have a hole for the screws, the visor mounts will fit in and cover up the rest.
• Note the Velcro strip at the rear of the headliner - about 4 inches in from the center of the rear window. It will likely pull away from the headliner and remain on the metal roof. You'll want this reinstalled properly to prevent headliner sag.
• I used the 3M High Temp Headliner adhesive. More expensive and comes in a slightly larger can than the Permatex adhesive. I found I used just about the complete can of 3M so had I attempted to save a few bucks with the Permatex. I would have ended up buying two!
• Avoid loosening any more of the hard plastic upper trunk trim than necessary. Brittle trim clips will ruin your day(s).
• A-pillar trim removal and re-install is a piece of cake.

Turned out GREAT!