2005 Honda Pilot EXFACTORY OEM SERVICE PROCEDURE

Fuel Tank Unit Removal/Installation

Special Tools Required 

Fuel sender wrench 07AAA-S0XA100

  1. Relieve fuel pressure (see FUEL PRESSURE RELIEVING  ).
  2. Remove the fuel fill cap.
  3. Remove the driver's side second row seat (see SECOND ROW SEAT REMOVAL/INSTALLATION ).
  4. Cut the carpet at the dotted line (A). Be careful not to cut the wire harness under the carpet.
    Fig 1: Cutting Carpet
    G04546184Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B).
    Fig 2: Removing Access Panel From Floor
    G04546185Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Disconnect the quick-connect fitting from the fuel tank unit.
  7. Using the tool, loosen the fuel tank unit locknut (A).
    Fig 3: Loosening Fuel Tank Unit Locknut Using Tool
    G04546186Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Remove the locknut (A) and fuel tank unit (B).
    Fig 4: Removing Locknut And Fuel Tank Unit
    G04546187Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Align the marks (C) on the fuel tank (D) and the fuel tank unit, then install the fuel tank unit in the reverse order of removal with a new base gasket (E) and new locknut.
    NOTE: After installation, check circumference of the base gasket visually or by hand and be sure that the gasket is not pinched.
Factory Service Tools

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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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