Interior - Headliner Rattles Near The Moonroof
10-018September 13, 2010
Applies To:
2009 Pilot EX-L, EX-L RES, Touring - ALL
2010 Pilot EX-L, EX-L RES, Touring 2WD - See VEHICLES AFFECTED
2010 Pilot EX-L, EX-L RES, Touring 4WD - See VEHICLES AFFECTED
Headliner Rattles
(Supersedes 10-018, dated April 6, 2010, to revise the information marked by the asterisks)
REVISION SUMMARY
*Under TOOL INFORMATION, the adhesive applicator was changed.*
SYMPTOM
There is a rattling coming from the headliner, near the moonroof.
VEHICLES AFFECTED
PROBABLE CAUSE
The headliner stiffener is not attached to the headliner, or the stiffener is contacting the roof ribs.
CORRECTIVE ACTION
Re-glue the stiffeners to the headliner, and install EPT sealer between the stiffeners and the roof ribs.
REQUIRED MATERIALS
3M Scotch-Weld DP-100 NS Adhesive:
3M P/N 62-3265-1435-3
(one container repairs one vehicle)
EPT Sealer ST: P/N 06991-5A5-000
(one roll repairs about 20 vehicles)
PARTS INFORMATION
Pillar Clip (two required):
P/N 91561-SJD-003
TOOL INFORMATION
*3M Scotch-Weld EPX Plus II Applicator 50004:
3M T/N 62-9170-9930-1*
3M Scotch-Weld EPX Mixer Nozzles 9742:
3M T/N 62-9742-9935-6
KTC Trim Tool Set: T/N SOJATP2O14
(Use the appropriate tool from the KTC trim tool set to remove components)
WARRANTY CLAIM INFORMATION
The normal warranty applies.
Failed Part: P/N 83201-SZA-A51ZA
Defect Code: 02502
Symptom Code: 04201
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
^ SRS components are located in this area. Make sure you are familiar with the SRS component locations, precautions, and procedures in the service manual before doing repairs or service.
^ If any clips are damaged, replace them.
This procedure is in an outline form that you can also use as a checklist for the repair. If you need more details, bookmark the following procedures in the 2OO~2O1 1 Pilot Service Manual, or view them online:
Interior Trim Removal/Installation - Pillar Areas
^ Sunvisor Removal/Installation (NOTE: Important procedure - see ISIS or the service manual)
^ Grab Handle Removal/Installation
^ Rear Individual Map Light Test/Replacement
^ Rear Controller and Screen Removal/Installation
^ Headliner Removal/Installation
1. Disconnect or remove these items:
^ A-pillar trim - remove both
^ B-pillar lower trim - unhook the top of both
^ B-pillar upper trim - remove both
^ Sunvisors - remove both, (IMPORTANT: see ISIS or the service manual for the specific procedure. Possibility for damage if not removed correctly)
^ Grab handles - remove all four
^ Second row seat map lights - remove
^ On vehicles with a rear entertainment system:
Remove the wireless remote control and the display cover, then disconnect the rear entertainment system connector.
2. Remove the roof console:
^ Remove the map light lenses.
^ Remove the map light screws, then pull out the front map light.
^ Disconnect the front map light connector.
^ Disconnect the moonroof switch connector.
^ Remove the four roof console screws.
^ Pull out the front side of the console, and release the front hooks.
^ Disconnect the microphone connector.
^ Disconnect the HomeLink connector.
3. Remove the ground bolt.
4. Lower the headliner:
^ Adjust the steering column all the way down, and inward.
^ Move both front seats all the way back, and recline the seat-back about 45 degrees.
^ Pull down to detach, but do not remove completely, the front and rear door opening seals from each roof portion.
^ Release the hook and loop fasteners and the front clips by lowering the headliner.
^ Detach the magnets around the moonroof opening by carefully pulling down on the headliner.
^ Disconnect the DVD connector.
^ Detach the clips attaching the wire harness to both side stiffeners. Release the wire harness from the EPT sealer along the front portion of the headliner.
5. Mark the headliner along the front and side of the stiffener.
6. Remove the old glue from the detached portion of the stiffener and the headliner. If the loose stiffener is still partially attached, do not remove it from the headliner.
7. For vehicles with a rear entertainment system, add six pieces of EPT sealer 51 (25 mm x 60 mm) to the left and right stiffeners, as shown, to insulate the stiffeners from the roof ribs. On vehicles without the rear entertainment system, use four pieces in the front four positions.
8. Attach the stiffener to the headliner using 3M DP100 epoxy, making sure the epoxy wraps around the top edge of the stiffener as shown.
NOTE:
The working time for the epoxy is 5 minutes.
9. If both stiffeners were loose, repeat steps 6 thru 8 on the other side.
10. Move both front seats fully forward, and return the seatbacks to the fully upright position. Allow the headliner to rest on the head rests while the adhesive dries. It may be necessary to raise the headrests. Make sure the stiffener does not separate from the headliner while the adhesive is drying. Allow the adhesive to dry a minimum of 1 hour before reassembling the headliner.
11. To prevent the side curtain airbags from deploying improperly and possibly causing injury, inspect the headliner and all removed trim. Replace any pieces that show the following damage:
^ Crease or tears on the headliner
^ Cracks or breakage on the four grab handles
^ Damage around the grab handle holes or the sunvisor holes on the headliner
^ Cracks on the sunvisor bracket cover
^ Bends or cracks on the sunvisor stay shaft
^ Cracks on the sunvisor base
^ Cracks or breakage on the vanity mirror base
^ Fasteners, clip bases, or magnet bases that came off the headliner
12. Raise the headliner:
^ Reattach the clips attaching the wire harness to both side stiffeners.
^ Reattach the wire harness and the washer tubes along the front of the headliner using EPT sealer.
^ Reconnect the DVD connector.
^ Reattach the magnets around the moonroof opening by carefully pushing up on the headliner.
^ Reconnect the hook and loop fasteners and the front clips by raising the headliner.
^ Reattach the front and rear door opening seals to each roof portion.
13. Reinstall the ground bolt.
14. Reinstall the roof console.
^ Reconnect the HomeLink connector.
^ Reconnect the microphone connector.
^ Reconnect the console front hooks, and push the front of the console into place.
^ Reinstall the four console screws.
^ Reconnect the moonroof switch connector.
^ Reconnect the front map light connector.
^ Install the two map light screws, then push in the front map light.
^ Install the map light lenses.
15. Reconnect or reinstall these parts:
^ On vehicles with a rear entertainment system:
^ Reinstall the wireless remote control, and the display cover, then reconnect the rear entertainment system connector.
^ Reinstall the second row seat map lights.
^ Reinstall the grab handles by pushing the handle against the bracket until the clips securely snap into place - four places.
^ Reinstall the sunvisors (IMPORTANT: see ISIS or the service manual for the specific procedure).
^ B-pillar upper trims - Replace the one time use clip on each B-pillar.
^ B-pillar lower trims - Re-hook the top.
^ Reinstall the A-pillar trims.
16. Test-drive the vehicle, and make sure the rattle is gone.
Disclaimer