Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Honda Pilot EXFACTORY OEM SERVICE PROCEDURE
Fuel Tank Replacement
- Relieve the fuel pressure (see Fuel Pressure Relieving ).
- Drain the fuel tank: Remove the fuel pump (see Fuel Filter Replacement ). Using a hand pump, hose, and container suitable for gasoline, draw the fuel from the fuel tank.
- Raise the vehicle, and support it with jackstands.
- Remove the propeller shaft (see PROPELLER SHAFT REMOVAL ).
- Remove the fuel tank shield (A).
- Disconnect the fuel vapor hose (B), and quick-connect fittings (C). Disconnect the filler neck hoses (D). Slide back the clamps, then twist the hoses as you pull to avoid damaging them. Remove the bolt (E).
- Place a jack or other support under the fuel tank (F).
- Remove the strap bolts (G).
- Remove the fuel tank. If it sticks to the undercoat on its mount, carefully pry it off the mount.
- Install the parts in the reverse order of removal.
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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