2009-15 Honda Pilot Body Repair information
Contents
1. HONDA Body Repair News C Applies To 2009 Pilot Model Series ALL December 2014 2009 15 Pilot Body Repair Information DISCLAIMER This publication contains a summary of new body and vehicle technology that may affect collision and other body repairs Always refer to the appropriate service and body repair manuals for complete repair information A subscription may be purchased at techinfo honda com TABLE OF CONTENTS New Model Body Technology Body Repair Information Welding Precautions and Information Page 6 Airbag System Components and Repairs Electrical Repair Information OVERVIEW OF BODY FEATURES 2009 11 models have these body features e Introduction of Advanced Compatibility Engineering ACE crash compatible body structure e Extensive use of high strength steel 52 including 10 in grades 780 and 980 e Aluminum hood panel for weight reduction and improved fuel efficiency not shown in this view For the 2012 model year a minor model change MMC added or upgraded these body features e Reinforced roof and center pillar structure for improved rollover protection e Addition of 1 500 MPa ultra high strength steel UHSS 2014 American Honda Motor Co Inc All Rights Reserved ABN 01129 1412 1 of 10 New Model Body Technology BODY CONSTRUCTION AND HIGH STRENGTH STEEL CONTENT 2009 11 MODELS e Steel parts are color coded based on their tensile strength in megapascals MPa e Hi2. MPa Parts MAG Plug Welding MAG BUTT WELDING GUIDELINES e MAG butt welding may be done only on steel parts with a tensile strength of 780 MPa and lower S B e Welding speed is critical to achieve the correct weld xs strength and minimize the heat affected zone HAZ e Follow the recommendations described in the body repair manual sections Repair Guidelines for a High Strength Steel Parts and MAG Welding BEAD Conditions for High Strength Steel Except 1 500 MPa Parts MAG Butt Welding 2014 American Honda Motor Co Inc All Rights Reserved 7 of 10 Airbag System Components and Repairs AIRBAG SYSTEM COMPONENTS The airbag system in this vehicle includes the following components that may deploy in a collision 1 Driver and front passenger seat belt tensioners may deploy independently from any airbags 2 Driver and front passenger SRS airbags 3 Side airbags mounted in the outer driver and front passenger seat backs 4 Side curtain airbags mounted above the left and right side windows under the headliner AIRBAG SYSTEM INDICATORS There are three indicators used for the airbag system Supplemental Restraint System SRS Indicator When the ignition switch is turned to ON this indicator should come on and then turn off after about 6 seconds e Ifthe SRS indicator does not go off or does not come on at all there is a problem with the system e DTCs must be read and cleared usi
3. 00 MPa Steel MIG BRAZING GUIDELINES FOR 1 500 MPa STEEL PARTS Refer to the body repair manual for complete information e MIG brazed joint locations are specified in the body repair manual e A single or double hole MIG braze may be specified in the body repair manual depending on the tensile strength of the parts being joined e The size and number of holes are critical to achieving adequate joint strength e A pulsed MIG welder MUST be used Refer to the equipment manufacturer s instructions for welder voltage and current setup e The photos at right show the difference in results between pulsed and non pulsed MIG brazing 2014 American Honda Motor Co Inc All Rights Reserved 6 of 10 MAG WELDING SPECIFICATIONS FOR 590 980 MPa HIGH STRENGTH STEEL PARTS NOTE In this publication and the body repair manuals gas metal arc welding GMAW is referred to by its subtypes depending on the welding brazing requirements e MIG welding brazing Metal inert gas welding or brazing where 100 argon Ar shielding gas is used Argon is inert and does not react with the molten weld pool or brazing operation e MAG welding Metal active gas welding where the shielding gas being used contains a mixture of 80 argon Ar and 20 carbon dioxide CO It is considered active because the CO undergoes a limited reaction with the molten weld pool Important Information Parts made of High Strength Steel 590 980 MPa must often
4. L PARTS 2012 15 Models Observe these precautions when repairing 1 500 MPa steel parts e NEVER attempt to straighten damaged 1 500 MPa steel parts because they may crack e 1 500 MPa steel parts MUST be replaced at factory seams using squeeze type resistance spot welding STRSW DO NOT SECTION these parts e MIG brazed joints should be used ONLY in locations not accessible by a spot welder e To assure adequate weld tensile strength always set the spot welder to the specifications provided in the body repair manual Important Information Parts made of Ultra High Strength Steel UHSS 1 500MPa USIBOR must be installed as a complete part No sectioning allowed Ultra High Strength Steel requires special welding equipment procedures and settings See the welding section of the appropriate body repair manual Failure to use the proper equipment or follow the proper procedures can result in an unsafe repair e NEVER perform MAG welding on 1 500 MPa steel The heat generated during MAG welding will significantly reduce the strength and structural integrity of 1 500 MPa steel parts e This photo shows tensile strength test results of MAG welded 1 500 MPa steel The 1 500 MPa steel fractured first because the welding heat reduced 7 its strength to far below 590 MPa j i z e For more information refer to Repair Guidelines for p High Strength Steel Parts in the body repair manual Tensile Test Results of MAG Welded 1 5
5. YSTEM REPAIRS REQUIRED AFTER DEPLOYMENT To restore proper function and allow DTCs to be cleared the airbag system MUST be repaired as specified in the service manual Refer to Component Replacement Inspection After Deployment for complete information DO NOT install used refurbished or modified airbag system parts When making airbag system repairs only use new genuine replacement parts which are manufactured to the same standards and quality as the original parts To ensure the correct replacement airbag system parts are installed provide the vehicle s VIN when ordering parts Compare the part numbers on the new and removed parts to make sure they match AIRBAG SYSTEM ELECTRICAL REPAIRS Except when doing electrical inspections that require battery power always turn the ignition to OFF disconnect the negative battery cable then wait at least 3 minutes before starting work NOTE Refer to the service manual for complete restraint system operation diagnostic and repair information For easier identification electrical connectors that contain only airbag system wiring are yellow in color Many harnesses that contain primarily airbag wiring are also wrapped in yellow tape Airbag system wiring that runs in a common harness such as a floor harness is generally not marked NEVER attempt to modify splice or repair airbag system wiring If airbag system wiring is damaged replace the wiring harness es Airbag System E am
6. ation Lower View 590 MPa N N Steel Tensile Strength Legend 2014 American Honda Motor Co Inc All Rights Reserved 3 of 10 1 500 MPa HOT STAMP STEEL LOCATIONS 2012 15 MODELS 1 500 MPa steel is stronger than ordinary steel so it can help protect vehicle occupants while reducing overall vehicle weight to improve fuel efficiency The numbered parts in the diagram below are constructed of 1 500 MPa steel NOTE 1 500 MPa steel is not used in 2009 11 models 2012 15 Models 1 Roof arch B w o sunroof Sunroof Rear Stiffener w sunroof 2 Center Pillar Inner Reinforcement ALUMINUM PARTS amp REPAIRABILITY The hood panel is constructed of aluminum alloy Repairability Issues e The aluminum hood may be repaired by body shops that have a dedicated aluminum repair facility and separate tools e To prevent galvanic corrosion some fasteners for aluminum parts are considered one time use and must be replaced if removed Refer to the service or body repair manual for more information Aluminum Hood Panel TOWING AND LIFTING PRECAUTIONS e AWD models must be towed using only flat bed towing equipment to prevent VIM 4 system damage e 2WD models may be towed using front wheel lift or flat bed towing equipment e AWD models do not have a manual switch to disable the VIM 4 system Whenever service work requires spinning the front or rear wheels with the engine always lift and sup
7. be installed as a complete part Section only according to published repair information and guidelines This high strength steel requires special welding equipment procedures and settings See the welding section of the appropriate body repair manual Failure to use the proper equipment or follow the proper procedures can result in an unsafe repair The body repair manual specifies the weld types and Steel Tensile MPa Wire Tensile ksi locations for each body panel e The welding wire used must have a tensile strength equal to or greater than the lowest tensile strength of the parts being welded This conversion chart shows the relationship of steel tensile strength MPa to the minimum welding wire tensile strength ksi e Typical ER70S 6 MIG wire has a minimum tensile strength of 70 ksi 483 MPa It can be used when welding up to 440 MPa steel parts Refer to the diagrams shown below 1 000 psi 1 ksi MAG Plug Welds MAG Butt Welds 980 MPa Steel 590 MPa Steel 590 MPa Steel 590 MPa Steel Welding Wire Tensile Strength Must Be Welding Wire Tensile Strength Must Be 2590 MPa 286 ksi 2590 MPa 286 ksi MAG PLUG WELDING GUIDELINES e MAG plug welding may be done when joining body components to 590 980 MPa steel parts e Follow the recommendations described in the body repair manual sections Repair Guidelines for High Strength Steel Parts and MAG Welding Conditions for High Strength Steel Except 1 500
8. ensor system The sensors send out ultrasonic waves and receive waves reflected by an obstacle to determine the distance from the vehicle The system uses multiple devices to inform the driver that an obstacle is near e There are six body colored sensors in the front and rear bumpers One at each corner and two center sensors in the rear bumper e The sensors must be free of debris snow and ice to work correctly e When the ignition is turned to ON a system check is performed each time the parking and back up sensor switch is turned ON e When a failure occurs the parking and back up sensor control unit stores DTCs and the multi information display shows CHECK PARKING SENSOR SYSTEM e The HDS or equivalent scan tool is required to read DTCs Contact a Honda dealer for assistance if necessary Rear Parking and Back up Sensors 2014 American Honda Motor Co Inc All Rights Reserved 10 of 10
9. gh strength steel is defined as any steel with a tensile strength of 340 MPa or higher e Steel repair and welding procedures vary depending on the tensile strength of the parts involved 2009 11 Body Construction Upper View 590 MPa HUGE Steel Tensile Strength Legend Important Information These illustrations are for general reference only Some body parts are constructed from multiple layers of different tensile strength steels Always refer to the body repair manual body construction section for specific steel tensile strength information Lower View 270 MPa 590 MPa LL Steel Tensile Strength Legend 2014 American Honda Motor Co Inc All Rights Reserved 2 of 10 BODY CONSTRUCTION AND HIGH STRENGTH STEEL CONTENT 2012 15 MODELS e Steel parts are color coded based on their tensile strength in megapascals MPa e High strength steel is defined as any steel with a tensile strength of 340 MPa or higher e Steel repair and welding procedures vary depending on the tensile strength of the parts involved 2012 15 Body Construction Upper View Note 1 500 MPa Steel Reinforcement Inside Both Upper Center Pillars Important Information These illustrations are for general reference only Some body parts are constructed from multiple layers of different tensile strength steels Always refer to the body repair manual body construction section for specific steel tensile strength inform
10. lding or electrical repairs Refer to 12 Volt Battery Terminal Disconnection and Reconnection in the service or body repair manuals for more information e Certain front and rear electrical connectors subject to collision damage may be repaired using pigtails and connectors listed in the ELECTRICAL CONNECTORS illustrations in the parts catalog example shown here e Pigtails attach to the vehicle wiring using special crimp and seal terminal joints After crimping the joints are heated using a heat gun to seal out the environment e Repair pigtails come in a limited range of colors that usually do not match the vehicle s wiring Pay close attention during repairs to ensure correct locations e Vehicle wiring schematics service information can be found in the Electrical Wiring Diagrams EWD e If wiring is damaged and a repair pigtail or connector is not available replace the affected harness e NEVER attempt to modify splice or repair airbag system wiring ELECTRICAL GROUND WIRE PROTECTION e Painting over electrical ground locations may cause electrical systems such as Vehicle Stability Assist VSA to malfunction and set DTCs that may be difficult to diagnose e Protect the ground wire and the ground wire mounting hole threads with a bolt or silicone plug when priming or painting GROUND IFE MOUNTING MOLE PARKING AND BACK UP SENSOR SYSTEM Touring grade models are equipped with a parking and back up s
11. ng the HDS or equivalent scan tool Contact a Honda dealer for assistance if necessary e Ifa vehicle is sent to the dealer for airbag system repair or troubleshooting include a copy of the repair estimate with part numbers and the source for any replaced airbag system parts SRS Indicator PASSEBGER AIRBAG OFF Indicator The indicator comes on to alert you that the passenger s front airbag has been turned off e This occurs when the front passenger s weight sensors detect 65 Ib 29 kg or less the weight of an infant or small child PASSENGER on the seat AIRBAG Passenger Airbag e If the indicator comes on with no front passenger and no objects OFF Indicator on the seat or with an adult occupying the seat something may be interfering with the seat weight sensors or there may be a problem with the system Refer to SRS Symptom Troubleshooting in the service manual or contact a Honda dealer for assistance if necessary SIDE AIRBAG OFF Indicator This indicator comes on when the OPDS sensor detects that the front passenger side airbag needs to be shut off for safety e This may occur because the passenger is too small to be sitting in the front seat is slouching or not sitting upright or has leaned into the airbag s deployment path e This light is not used to indicate problems with the OPDS or airbag system Side Airbag OFF Indicator 2014 American Honda Motor Co Inc All Rights Reserved 8 of 10 AIRBAG S
12. p Harness Yellow Electrical Repair Information TIRE PRESSURE MONITORING SYSTEM TPMS This vehicle is equipped with an initiator type TPMS The low tire pressure indicator comes on if the air pressure is too low in one or more tires The TPMS indicator will stay on and the system will set DTCs if all four tire pressure sensor IDs aren t memorized by the TPMS control unit after you replace a wheel and or tire pressure sensor Refer to Memorizing a Tire Pressure Sensor ID in the service manual for complete information The HDS or equivalent scan tool may be required to perform this memorization Contact a Honda dealer for assistance if necessary Low Tire Pressure Indicator TPMS Indicator POWER TAILGATE INFORMATION _ 2009 15 Touring and 2012 15 EX L grade models vl r Power Tailgate include a power tailgate k Actuator The power tailgate will not be able to open or close automatically until it is reset when e The battery is disconnected or the No 23 10 A fuse in the under hood fuse relay box is removed while the power tailgate is operating e Certain power tailgate components have been replaced Refer to Resetting the Power Tailgate Control Unit in the service manual for complete information View Inside Left Rear Pillar Area 2014 American Honda Motor Co Inc All Rights Reserved 9 of 10 ELECTRICAL PIGTAIL AND CONNECTOR REPAIR e Disconnect the vehicle s battery before doing any we
13. port the vehicle so all four wheels are off the ground For more information refer to Emergency Towing in the owner s manual e Lift or jack only at the specified points to avoid damaging the vehicle e Do not lift or tow this vehicle by its bumpers or serious damage will result For more information refer to Lift and Support Points in the appropriate service or body repair manual 2014 American Honda Motor Co Inc All Rights Reserved 4 of 10 Body Repair Information NOTE The following content is intended only to highlight new special concerns No body repairs should be attempted without first referencing the appropriate body repair manual for complete information USE OF HEAT DURING BODY STRAIGHTENING AND REPAIR Heating Unacceptable When you are doing body straightening and repair procedures Pan raw e DO NOT apply heat to any body part during straightening g E This may compromise the internal structure and strength of high strength steel parts e Any part that has heat applied to it during straightening MUST be replaced with new parts e Ignoring these instructions may significantly reduce occupant protection in any subsequent collision SECTIONING CUT AND JOINT GUIDELINES Various high strength steel materials with different sheet thicknesses and strengths are applied in many places that vary by body design in order to increase collision safety STIFFENER performance body stiffness and weight red
14. uction Stiffening members inside each part patch stiffener etc are also specified in detail Follow these guidelines to avoid an unsafe repair e Sectioning cut and joint should usually be avoided except for mild steel outer panels and floor panels unless a specific procedure is provided in the body repair manual e However depending on the type of vehicle damage steel parts with a tensile strength lt 780 MPa may be Single layer area of Multi layer area of sectioned provided ALL of the following conditions are met a ee Sectioning must be done in a single layer area of the part OK NOT OK Multi layer internal steel reinforcements and stiffeners must not be cut The repair is not in a load bearing area such as engine transmission or suspension mounting points REINFORCEMENT Sectioning Area Examples e Replace body structural components such as Welding Method stiffeners reinforcements and other multi layered dit aenblle MAG Welding steel parts as assemblies that match the replacement parts configuration e Approved welding methods are listed in the table e Refer to the body repair manual section Parts Sectioning Cut and Joint Guidelines for complete information Spot SEC Weld Plug Butt Welding Methods For Steel Parts O Approved X Not Approved 2014 American Honda Motor Co Inc All Rights Reserved 5 of 10 Welding Precautions and Information REPAIRING 1 500 MPa STEE
Download Pdf Manuals
Related Search