Discovery 2 Headliner & Sunroof

This is my first post, so go easy haha.

My sunroofs were leaking in my Discovery 2, I don't think they designed the sunroofs on these to compensate for our crazy weather here in Canada! Anyways long story short, the drains cracked and the headliner started to sag. One day I got bored and started removing the headliner!

Headliner:
Unfortunately I didn't document the removal process, but it is pretty straightforward. Essentially you just need to remove the front sun visors, the sun visor 'pocket' assembly and sunroof controls in the front.

Then you remove the rear sunroof control switch (it pops out nicely) and undo a fastener screw there. All thats left is the rear finisher and the A and B pillar covers. The A pillars just snap off using metal clips, whereas the B pillar covers are held on with metal retainers that clip onto the pillar and are held in place by the weather strip, so you just have to remove that. Then its just the small finishers like the sunroof clips and pull handles, volumetric sensor cover etc.

Once thats all done you can drop the headliner. Its not the easiest to pull out with one person, but a big help is to remove the weatherstrip from the rear door at least halfway down. It just gives you an extra 4cm or so of space to remove.

Once I got it out, I removed the old fabric and started scrubbing the old glue off. I just took a big plastic brush and scrubbed for a while until the whole thing was a nice green colour.

What I decided to do was paint the headliner with truck bed liner because I'm no good with fabrics. I figured the foam which the headliner consist of would do a good job deadlining sound. So off I started painting! Now all thats left to do is reinstall everything.

Sunroof repair:
I can't take credit for this fix, I saw some guy on YouTube do this. I kept the headliner out for a while and waited for a good rainstorm. Once it started I sat inside and waited from some drips to start. I was able to track it down to being cracks in the drains on the sunroofs. Anyways, I'm cheap and getting that whole new assembly is not exactly an affordable option so what I did was buy a two part marine epoxy. I choose marine epoxy because it dries in water. While it was raining I removed the silicon that was put there from the factory and I mixed the stuff up and applied the epoxy on all the joints and covered the cracks in the moulding. Once I was sure there was no leaks and I had blown any blockages out of the drainage hoses I let it set and waited for another rainstorm to ensure it was fixed. Nice and easy $20 CAD fix to a pretty annoying issue.


Other things to check:
My rear windshield washer sprayer was not working, at least not well, this was due to a cracked hose above the headliner. While you have the headliner out its a good idea to check all the wiring bundles (which include the hose for the rear washer) as well as any harnesses. Tidy up and lock down any loose cables and replace any of the foam wire covers which are starting to wear. Basically make sure that you won't have to open this thing up for another 16+ years! I also ran a cable for a reverse camera if I ever chose to add one.


I'll upload more pictures once it is installed, but here it is with no headliner, the painted headliner etc.

Welcome to the ‘zone! Great effort on your first post!
I’m not sure I like the textured appearance of your head lining but I do like the look of the light fittings on the black lining.
It’s reassuring to see that it isn’t too difficult to remove, I’m planning a few extras (covert amber strobes in the rear clusters, camera etc) in mine when I get it later in the week and was wondering how to get wiring from the front to the back so that question is now answered, thank you.
I’ll also check the motors/drains/piping whilst I’m there too.

Welcome to the forum and thanks for a great write up I've got this job to do on my daughters D2 soon and will be using you thread for refrence

Spot1 said:

Welcome to the ‘zone! Great effort on your first post!
I’m not sure I like the textured appearance of your head lining but I do like the look of the light fittings on the black lining.
It’s reassuring to see that it isn’t too difficult to remove, I’m planning a few extras (covert amber strobes in the rear clusters, camera etc) in mine when I get it later in the week and was wondering how to get wiring from the front to the back so that question is now answered, thank you.
I’ll also check the motors/drains/piping whilst I’m there too.

Click to expand...

TorsionBhudda said:

Welcome to the forum and thanks for a great write up I've got this job to do on my daughters D2 soon and will be using you thread for refrence

Click to expand...

Thanks! The lighting makes it look more textured than it is. I went with truck bed lining because its super thick, tough and gave my headliner a bit more strength (it was starting to crack in a few places). I was originally going to put in a camera but I the camera's I bought (I've bought multiple not learning my lesson) all embed the 'parking' lines on the image. I was planning on putting one of the really subtle ones on the rear door latch but the combination of it being on the far right of the car and being on the door changed my mind. It is a pain feeding RCA connectors through the rubber electrical sock. Long story short I don't have the right camera and gave up haha.

I'm also adding in additional lighting in the headliner and rear interior panels (almost like pot lamps) which I will post later... I'm planning to do a large tour in it shortly so it will be my home for a while!

Just as a tip, be cautious removing your headliner, because it does have to be gently bent to remove it from the vehicle and reinstall. Make sure you fold down everything you can (including the front seats) so you can get as much room as possible and get a paint which will handle the flex.