Honda Pilot: Fuel Tank Unit Removal and Installation

Removal

1. Fuel Pressure - Relieve

2. Second Row Seat (Left Side) - Remove

3. Access Panel - Remove

1. Remove the access panel (A) from the floor.
2. Disconnect the connector (B).

4. Fuel Line Quick-Connect Fitting - Disconnect

1. Place a rag or shop towel (A) over the quick-connect fitting.
2. Disconnect the quick-connect fitting from the fuel tank unit.

5. Fuel Tank Unit Locknut - Loosen

1. Using the fuel nut wrench, loosen the fuel tank unit locknut (A).

6. Fuel Tank Unit - Remove

1. Remove the locknut (A), then remove the fuel tank unit (B).

   NOTE: Be careful not to bend or twist the fuel level sensor arm (C) excessively.

Installation

1. Fuel Tank Unit - Temporarily Insert

1. Insert the fuel tank unit (A) partially into the fuel tank with a new O-ring (B).

• Be careful not to damage the new O-ring.
• Be careful not to bend or twist the fuel level sensor arm (C) excessively.
• Do not coat the base gasket with oil.

2. Fuel Tank Unit - Align

1. Align the marks (A) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank.

NOTE: To avoid a fuel leak, check the O-ring, visually or by hand, to make sure it is not pinched.

3. Fuel Tank Unit - Install

1. Tighten a new locknut (A) by hand holding the fuel tank unit vertically.

NOTE: Before tightening, align the mark (B) on the locknut to the start of the thread (C).

2. Using the fuel nut wrench, tighten the locknut to the specified torque.

NOTE:

• After tightening, make sure the marks (A) are still aligned.
• After installation, check the O-ring, visually or by hand, to make sure it is not pinched.

4. Fuel Line Quick-Connect Fitting - Connect

5. Fuel Leak - Check

1. Connect the fuel tank unit connector (A).
2. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then check for fuel leakage.

6. Access Panel - Install

1. Install the access panel (A) to the floor.

7. Second Row Seat (Left Side) - Install

Special Tool Required

• Fuel Nut Wrench 07AAA-T0AA100

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