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Prepare headliner for installing interior sensor - AR68.30-P-4300-05P

WORKSHOP EQUIPMENT

WE58.40-Z-1004-03A Body saw (electric/pneumatic)

Illustrated on model 203.0 with code (543) sun visors with illuminated mirror and code (220a) Parktronic system (PTS) and code (810) sound system 

Fig 1: Preparing Headliner For Installing Interior Sensor
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  1. Lay old headliner (1) down on suitable subsurface.
  2. Remove interior protection system transmitter/receiver (A26/14) from old headliner (1) and disconnect electrical connector.

    IMPORTANTInstallation:  Install interior protection system transmitter/receiver (A26/14) only after routing new IRS wiring harness (9) on new headliner (1).

  3. Bend open mounting lugs for IRS installation frame (2) and remove IRS installation frame (2) from old headliner (1).

    IMPORTANT Note installed positions.

  4. Detach main wiring harness (8) and IRS wiring harness (9), PTS wiring harness (7) (with code (220a) Parktronic system (PTS)) and foam rubber roll (3) (with code (220a) Parktronic system (PTS)) in cutting area (4) from old headliner (1) and lay down to side
  5. Fabricate template (6), for this purpose first cut old headliner (1) in cutting area (5) and then in cutting area (4)

    IMPORTANT Use metal saw blade.

  6. Lay new headliner (1) down on suitable clean subsurface.
  7. Shim new headliner (1) with suitable clean spacers, e.g. foam rubber or Styrofoam pads.

    NOTES Do not use any hard or sharp-edged objects, otherwise the cover of the new headliner (1) can be damaged

    IMPORTANT The foam rubber and Styrofoam pads prevent the new headliner (1) from sagging when performing the following steps.

  8. Position template on new headliner (1), align and transfer cutout for IRS installation frame (2) from template (6) to new headliner (1)

    IMPORTANT Ensure that cutout for IRS installation frame (2) is positioned correctly

  9. Remove template (6) from new headliner (1) and saw cutout for IRS installation frame (2) out of new headliner (1)

    IMPORTANT Ensure that size of cutout for IRS installation frame (2) is correct.

    Use metal saw blade.

  10. Insert old IRS installation frame (2) into new headliner (1) and on press mounting lugs for IRS installation frame (2) with suitable tool

    NOTES Position tool carefully on IRS installation frame (2), otherwise the new headliner (1) can be soiled or damaged

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