Honda Pilot - 2003-2005

Fuel Pressure Regulator

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Removal & Installation



2003-04 Models
  1. Place a shop towel under the fuel pressure regulator, then relieve fuel pressure, as outlined earlier in this section.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Disconnect the vacuum hose (A) and fuel return hose (B).
  6.  
  7. Loosen the locking nut (C), and remove the fuel pressure regulator (D).

    Click image to see an enlarged view

    Fig. View of the vacuum hose (A), fuel return hose (B), locking nut (C), fuel pressure regulator (D) and O-ring (E)

  8.  

To install:

  1. Apply clean engine oil to a new O-ring (E), and carefully install it into its proper position.
  2.  
  3. Install the fuel pressure regulator in the fuel joint. Turn it by hand until it stops.
  4.  
  5. Turn the fuel pressure regulator (A) counterclockwise to set the angle as shown.

    Click image to see an enlarged view

    Fig. Turn the fuel pressure regulator (A) counterclockwise to set the angle as shown

  6.  
  7. Tighten the locking nut to 22 ft. lbs. (29 Nm).
  8.  
  9. When assembling the fuel pressure regulator, apply clean engine oil to the O-ring and assemble it into its proper position, taking care not to damage the O-ring.
  10.  
  11. Reconnect the vacuum hose and fuel return hose.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel pressure in the fuel line rises. Repeat this two or three times, then check for any fuel leakage.
  16.  

2005 Models
  1. Relieve the fuel system pressure, as outlined earlier in this section.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Remove the fuel tank unit, as follows:
    1. Remove the driver-s side second row seat and cut the carpet along the dotted line. Be careful not to cut the wiring harness under the carpet.
    2.  
    3. Remove the access panel.
    4.  
    5. Detach the fuel pump module wiring connector.
    6.  
    7. Disconnect the fuel supply and return lines.
    8.  
    9. Remove the fuel pump locknut.
    10.  
    11. Remove the fuel pump module
    12.  

  6.  
  7. Remove the clip (A).
  8.  
  9. Remove the fuel pressure regulator (B).

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pressure regulator (B) and related components

  10.  

To install:

  1. Install the fuel tank unit, in the reverse of the removal procedure.
  2.  
  3. Install the regulator in the reverse order of removal with new O-rings (C).
    NOTE
    Coat the O-ring with clean engine oil.

  4.  
  5. Apply the engine oil to the O-ring, and install the pressure regulator with care hot to pinch the O-ring.
    WARNING
    Never apply the brake fluid, vegetable oil or alcohol-based oil to the O-ring.

  6.  
  7. Install the fuel tank unit.
  8.  

 
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