INSTALLATION INSTRUCTIONS
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1 INSTALLATION INSTRUCTIONS Accessory S AND CROSS BARS Application 2009 PILOT Publications No. AII Issue Date MAY 2008 PARTS LIST 4 Roof molding clips Left side roof rack TOOLS AND SUPPLIES REQUIRED Right side roof rack 2 Cross bars 2 Torx screws Phillips screwdriver Flat-tip screwdriver Shop towel Long-nose pliers T-30 Torx driver Air saw: Snap-on AT192A or equivalent Plastic trim tool: T/N SILTRIMTL10 Drill 3 mm, 6 mm, and 10 mm Drill bits Pushpin Eye protection Illustration of the Roof Racks and Cross Bars on the vehicle. S Left front roof rack cover CROSS BARS Right front roof rack cover Left rear roof rack cover Right rear roof rack cover 7D0401AX 8 Torx nuts 2008 American Honda Motor Co., Inc. All Rights Reserved. AII (0805) 08L02-SZA of 6
2 INSTALLATION Customer Information: The information in this installation instruction is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your vehicle. These procedures should not be attempted by do-it-yourselfers. 2. Using a pushpin, pierce two holes at the scribe marks on the roof molding. PUSHPIN NOTE: The weight of the cargo must not exceed the maximum weight capacity of 75 kg (165 lbs). Be extremely careful not to damage the roof and other finished surfaces of the body when installing the roof rack. Installing the Roof Racks 1. Open the tailgate. Using a plastic trim tool, pry up on the rear end of the roof molding left cover. 2 SCRIBE MARKS LEFT COVER TAILGATE 7D0402CX 3. While wearing eye protection drill two holes on the roof molding at the holes made in step 2 with a 3 mm drill bit. DRILL 3 mm 6 mm DRILL BIT PLASTIC TRIM TOOL CX 3 mm 10 mm DRILL BIT HOLE REAR HOLE 4. Widen the front hole with a 10 mm drill bit. 5. Widen the rear hole with a 6 mm bit. 7D1322BB 2 of 6 AII (0805) 2008 American Honda Motor Co., Inc. All Rights Reserved.
3 6. While wearing eye protection, use an air saw to cut off the roof molding to the scribe line as shown. Remove any burrs. Cut off. 8. Remove and discard four vehicle roof molding clips from the roof molding or the stud bolt on the roof. VEHICLE MOLDING S (Remove.) VEHICLE MOLDING S (Remove.) SCRIBE LINE STUD BOLT MOLDING AIR SAW 7D0501CX 7. Remove the roof moldings by carefully lifting it upward from four vehicle roof molding clips AX 9. Remove any excess sealant from the stud bolts. STUD BOLT STUD BOLT SEALANT (Remove the excess.) SEALANT 4 VEHICLE MOLDING S AX AX 2008 American Honda Motor Co., Inc. All Rights Reserved. AII (0805) 3 of 6
4 10. While wearing eye protection, use an air saw to cut off the roof molding as shown. 85 mm 12. Reinstall the roof molding left cover. LEFT COVER TAILGATE 1,110 mm 130 mm Cut off. 893 mm Cut off. AIR SAW CX 11. Install two new roof molding clips to the roof molding. S 13. Reinstall the roof moldings back onto the roof of the vehicle with two new roof molding clips installed on step BD MOLDING MOLDINGS 130 mm AX S AX 4 of 6 AII (0805) 2008 American Honda Motor Co., Inc. All Rights Reserved.
5 14. Install the left side roof rack with four Torx nuts. Make sure the roof rack is installed in the correct position. Torque the Torx nuts to: 12 N m (8.9 lbf ft) TORX BOLT This bolt is located on the rear side. 4 TORX NUTS Installing the Cross Bars 16. Slide two cross bars into the roof racks and align the mark on the cross bars with the mark on the roof racks as shown. Make sure the cross bars are inserted in the correct position and direction. VIEWED FROM THE TOP DIMPLE RACK MARK CROSS BAR Align. Slide. 2 CROSS BARS SIDE TOP VIEW REAR SIDE TOP VIEW CX 15. Repeat steps 1 through 14 for the right side of the vehicle. RIGHT SIDE CX 2008 American Honda Motor Co., Inc. All Rights Reserved. AII (0805) 5 of 6
6 17. Tighten eight thumbwheel screws to secure the cross bars to the roof racks. 19. Install the left front roof rack cover and the left rear roof rack cover to the roof rack with two clips each. 2 THUMBWHEEL SCREWS LEFT REAR COVER LEFT COVER CROSS BAR 2 S 2 S BX 2 CROSS BARS 7D0702AY 18. Install two Torx screws to the roof racks securely. USE AND CARE Check the roof rack mounting bolts frequently, and re-tighten if necessary. Distribute the weight of the cargo evenly, and do not exceed the maximum weight capacity of 75 kg (165 lbs). TORX SCREW TORX SCREW 2 TORX SCREWS 2 S 7D0703AY 6 of 6 AII (0805) 2008 American Honda Motor Co., Inc. All Rights Reserved.
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