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I've a 1990 740 GL Wagon in need of a new headliner. After searching lots of places on the web for sources & advice I came up with numerous sources & little helpful advice.
The source I used for the new headliner is wlsheadliners.com, but I'm sure others are just as qualified. One bit of information I learned from a number of online sources is to use a quality contact cement. This glue needs to withstand high heat, otherwise, you've wasted your time.
The headliner fabric is attached to a paper/fiberglass board that is held in place by the trim and a few 'buttons' in the ceiling. The buttons may exist only on wagons.
Removing the headliner board isn't terribly difficult. Having a wagon possibly made this easier, since the whole thing slide out the back. Remove or loosen the trim, sun visors, and mirror, then wiggle it out.
The biggest obstacle was repairing the headliner on the sunroof panels - I have a manual sunroof. The best instructions I found are in this sites FAQ under Body/Sunroof/Headliner. These instructions are helpful in removing the headliner, but not so helpful in replacing it.
After I removed the sunroof headliner panel I removed the old liner & cleaned it with Acetone. Volvo applied some sort of double sided sticky tape to attach the liner to the panels.
I cut new fabric & sprayed it & the panels where Volvo originally put the tape with contact cement provided by the headliner source, then pressed the 2 together.
Now comes the fun part - re-installing the sunroof headliner panels. I tried reversing my removal steps. After a lot of grunting & swearing I finally took the whole sunroof mechanism out of the car. I put it on my work table & this made the re-installation much easier. However, re-installing the entire unit will require an assistant to help hold the unit up, so that you can begin replacing the screws.
Now for the main headliner board. This thing is covered with the remaining deteriorated foam. It needs to be removed - all of it. Have the shop vacuum nearby. The instructions from the vendor were very helpful here. I also had to repair the headliner board with duct tape - again the vendor had helpful advice.
Re-installing the headliner board is pretty much a reverse course of its removal remember to wiggle it in; swearing & cold beer breaks are also helpful.
After all is said & done I've spent less than $60 & have a nice new headliner that doesn't sag or flap about with the windows or sunroof open.
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