Honda Pilot - 2003-2005

Fuel Level Sending Unit

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Removal & Installation



2003-04 Models

NOTE
This procedure requires the use of Fuel sender wrench 07XAA-001010A, or equivalent wrench.

  1. Turn the ignition switch OFF .
  2.  
  3. Relieve the fuel system pressure, as outlined in the Fuel System Section.
  4.  
  5. Remove the driver's side second row seat.
    WARNING
    Be careful not to cut the wire harness that is under the carpet.

  6.  
  7. Cut the carpet at the dotted line.

    Click image to see an enlarged view

    Fig. Cut the carpet at the dotted line (A)-2003-04 models

  8.  
  9. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B).

    Click image to see an enlarged view

    Fig. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B)-2003-04 models

  10.  
  11. Using the tool, loosen the fuel tank unit locknut (A).

    Click image to see an enlarged view

    Fig. Use a suitable tool to loosen the fuel tank unit locknut (A)-2003-04 models

  12.  
  13. Remove the fuel tank unit.
  14.  
  15. Remove the bracket (A), the fuel filter (B), the fuel gauge sending unit (C), the housing (D), and the wire harness (E).

    Click image to see an enlarged view

    Fig. Exploded view of the fuel gauge sending unit (C) and related components-2003-04 models

  16.  

To install:

  1. When connecting the fuel pump, make sure the connection is secure and the suction filter (F) is firmly connected to the fuel pump (G).
  2.  
  3. Check these items before installing the fuel tank unit:
    1. When connecting the wire harness, make sure the connection is secure and the connector (H) is firmly locked into place.
    2.  
    3. Do not push the lower part of the suction filter.
    4.  
    5. When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.
    6.  

  4.  
  5. Install the parts in the reverse order of removal with a new base gasket. When installing the fuel tank unit, align the marks (J) on the unit (K) and the fuel tank (L).
  6.  

2005 Models

NOTE
This procedure requires the use of Fuel sender wrench 07AAA-S0XA100, or equivalent wrench.

  1. Relieve the fuel system pressure, as outlined in the Fuel System Section.
  2.  
  3. Remove the fuel fill cap.
  4.  
  5. Remove the driver's side second row seat.
    WARNING
    Be careful not to cut the wire harness that is under the carpet.

  6.  
  7. Cut the carpet at the dotted line.

    Click image to see an enlarged view

    Fig. Cut the carpet at the dotted line (A)-2005 models

  8.  
  9. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B).
  10.  
  11. Disconnect the quick-connect fitting from the fuel tank unit.

    Click image to see an enlarged view

    Fig. Remove the access panel (A) and detach the fuel pump connector (B)-2005 models

  12.  
  13. Using the tool, loosen the fuel tank unit locknut (A).

    Click image to see an enlarged view

    Fig. Using the special tool, loosen the fuel tank unit locknut (A)-2005 models

  14.  
  15. Remove the locknut (A) and fuel tank unit (B).
  16.  
  17. Remove the fuel filter (A), the fuel level sensor (fuel gauge sending unit) (B), the case (C), the wire harness (D), and the fuel pressure regulator (E).

    Click image to see an enlarged view

    Fig. View of the fuel filter (A), the fuel level sensor (fuel gauge sending unit) (B), the case (C), the wire harness (D), and the fuel pressure regulator (E). When connecting the fuel pump, make sure the suction filter (F) is firmly connected to the fuel pump (G)-2005 models

  18.  

To install:

  1. When connecting the fuel pump assembly, make sure the connection is secure and the suction filter (F) is firmly connected to the fuel pump (G).
  2.  
  3. Check these items before installing the fuel tank unit:
    1. When connecting the wire harness, make sure the connection is secure and the connectors (H) is firmly locked into place.
    2.  
    3. When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.
    4.  

  4.  
  5. Install the part in the reverse order of removal with new O-rings (I). When installing the fuel tank unit, align the marks on the unit and the fuel tank.
    NOTE
    Coat the O-ring with clean engine oil.

  6.  
  7. 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.



    Click image to see an enlarged view

    Fig. View of the locknut (A) and fuel tank unit (B). 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-2005 models

  8.  

Testing



2003-04 Models

NOTE
This procedure requires the use of Fuel sender wrench 07XAA-001010A, or equivalent wrench.

  1. Check the No. 9 BACK UP LIGHT INSTRUMENT LIGHT (10A) fuse in the driver's under-dash fuse/relay box before testing.
  2.  
  3. Turn the ignition switch OFF .
  4.  
  5. Remove the driver's side second row seat.
    WARNING
    Be careful not to cut the wire harness that is under the carpet.

  6.  
  7. Cut the carpet at the dotted line.

    Click image to see an enlarged view

    Fig. Cut the carpet at the dotted line (A)-2003-04 models

  8.  
  9. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B).

    Click image to see an enlarged view

    Fig. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B)

  10.  
  11. Measure voltage between fuel pump 5P connector terminals No. 1 and No. 2 with the ignition switch ON (II). There should be battery voltage:
    1. If the voltage is as specified, go to step 9.
    2.  
    3. If the voltage is not as specified, go to step 7.

      Click image to see an enlarged view

      Fig. Measure voltage between fuel pump 5P connector terminals No. 1 and No. 2 with the ignition switch ON (II). There should be battery voltage-2003-04 models

    4.  

  12.  
  13. Turn the ignition switch OFF. Check for continuity between fuel pump 5P connector terminals No. 1 and body ground. There should be continuity:
    1. If there is continuity, go to step 8.
    2.  
    3. If there no continuity, check for poor ground (G505).

      Click image to see an enlarged view

      Fig. Turn the ignition switch OFF. Check for continuity between fuel pump 5P connector terminals No. 1 and body ground. There should be continuity-2003-04 models

    4.  

  14.  
  15. Measure voltage between gauge assembly connector B (22P) terminals No. 22 and body ground with the ignition switch ON (II). There should be battery voltage:
    1. If the voltage is as specified, check for an open in the YEL/BLU wire.
    2.  
    3. If the voltage is not as specified, replace the gauge assembly.
    4.  

  16.  
  17. Turn the ignition switch OFF. Remove the No. 13 BACK UP (7.5A) fuse from the passenger's under-hood fuse/relay box for at least 10 seconds, then reinstall it.

    Click image to see an enlarged view

    Fig. Measure voltage between gauge assembly connector B (22P) terminals No. 22 and body ground with the ignition switch ON (II). There should be battery voltage-2003-04 models

  18.  
  19. Install a 2 W resistor between fuel pump 5P connector terminals No. 1 and No. 2, then turn the ignition switch ON (II).

    Click image to see an enlarged view

    Fig. Install a 2 W resistor between fuel pump 5P connector terminals No. 1 and No. 2, then turn the ignition switch ON (II) -2003-04 models

  20.  
  21. Check that the pointer of the fuel gauge indicates ''F''.
    1. If the pointer does not indicate ''F'', replace the gauge.
    2.  
    3. If the pointer indicates ''F'', inspect the fuel gauge sending unit, then go to step 12.
      NOTE
      The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is OFF, regardless of the fuel level.

    4.  

  22.  
  23. Relieve the fuel pressure, as outlined in the Fuel System Section.
  24.  
  25. Remove the fuel fill cap.
  26.  
  27. Disconnect the quick-connect fittings from the fuel pump.
  28.  
  29. Using the tool, loosen the fuel tank unit locknut (A).

    Click image to see an enlarged view

    Fig. Use a suitable tool to loosen the fuel tank unit locknut (A) -2003-04 models

  30.  
  31. Measure resistance between the No. 1 and No. 2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the following readings, replace the fuel gauge sending unit:
    1. Float Position: F - Resistance (W): 11-13
    2.  
    3. Float Position: 1 / 2 - Resistance (W): 52.3-58.3
    4.  
    5. Float Position: LOW - Resistance (W): 104.5-118.7
    6.  
    7. Float Position: E - Resistance (W): 130-132
      NOTE
      Remove the No. 13 BACK UP (7.5A) fuse from the passenger's under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level.



      Click image to see an enlarged view

      Fig. Measure resistance between the No. 1 and No. 2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions-2003-04 models

    8.  

  32.  

2005 Models

NOTE
This procedure requires the use of Fuel sender wrench 07AAA-S0XA100, or equivalent tool.

  1. Check the No. 9 BACK UP LIGHT INSTRUMENT LIGHT (10 A) fuse in the driver's under-dash fuse/relay box before testing.
  2.  
  3. Turn the ignition switch OFF.
  4.  
  5. Remove the driver's side second row seat.
  6.  
  7. Cut the carpet (be careful not to cut the wire harness), then remove the access panel from the floor.
  8.  
  9. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B).

    Click image to see an enlarged view

    Fig. Remove the access panel (A) and detach the fuel pump connector (B)-2005 models

  10.  
  11. Measure voltage between fuel pump 5P connector terminals No. 1 and No. 2 with the ignition switch ON (II). There should be battery voltage:
    1. If the voltage is as specified, go to step 7.
    2.  
    3. If the voltage is not as specified, check for:

      an open in the ORN/WHT or BLK/YEL wire
       
      poor ground (G505)
       

    4.  

  12.  
  13. Turn the ignition switch OFF.

    Click image to see an enlarged view

    Fig. Measure voltage between fuel pump 5P connector terminals No. 1 and No. 2 with the ignition switch ON (II)-2005 models

  14.  
  15. Install a 2 ohm resistor between fuel pump 5P connector terminals No. 1 and No. 2.
  16.  
  17. Turn the ignition switch ON (II).
  18.  
  19. Check that the pointer of the fuel gauge indicates ''F'':
    1. If the pointer of the fuel gauge does not indicate ''F'', replace the gauge.
    2.  
    3. If the gauge is OK, inspect the fuel gauge sending unit.
      NOTE
      The pointer of the fuel gauge returns to the bottom on the gauge dial when the ignition switch is OFF, regardless of the fuel level.



      Click image to see an enlarged view

      Fig. Install a 2 ohm resistor between fuel pump 5P connector terminals No. 1 and No. 2

    4.  

  20.  
  21. Turn the ignition switch OFF.
  22.  
  23. Remove the fuel fill cap.
  24.  
  25. Relieve the fuel pressure, as outlined in the Fuel System Section.
  26.  
  27. Disconnect the quick-connect fittings from the fuel tank unit.
  28.  
  29. Using the special tool, loosen the fuel tank unit locknut (A). Remove the fuel tank unit.

    Click image to see an enlarged view

    Fig. Using the special tool, loosen the fuel tank unit locknut (A)-2005 models

  30.  
  31. Measure resistance between the No. 1 and No. 2 terminals with the float at E (EMPTY), L (LOW), 1/2 (HALF FULL), and F (FULL) positions.
  32.  
  33. If you do not get the following readings, replace the fuel gauge sending unit:
    1. Float Position: F / Resistance (W): 19-21
    2.  
    3. Float Position: 1 / 2 / Resistance (W): 185-195
    4.  
    5. Float Position: LOW / Resistance (W): 484-613
    6.  
    7. Float Position: E / Resistance (W): 770-790
    8.  

  34.  
  35. If the resistance is not as specified, replace the fuel gauge sending unit, as outlined in this section.

    Click image to see an enlarged view

    Fig. Measure resistance between the No. 1 and No. 2 terminals with the float at E (EMPTY), L (LOW), 1/2 (HALF FULL), and F (FULL) positions-2005 models

  36.  

 
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