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HOMESERVICE MANUALSHONDA2006PILOT EX, 3.5 YF2, J35A9REPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMFUEL SUPPLY SYSTEMFUEL TANK UNIT REMOVAL/INSTALLATIONINSTALLATION
2006 Honda Pilot EX, 3.5 YF2, J35A9

Fuel Tank Unit Removal/Installation: Installation

2006 Honda Pilot EX, 3.5 YF2, J35A9SECTION Installation
  1. Temporarily attach a new base gasket (A) to the fuel tank unit (B), then insert the fuel tank unit partially into the fuel tank.
    NOTE:
    • Be careful not to damage the new base gasket.
    • Be careful not to bend the fuel gauge sending unit.
    • Do not coat the base gasket with oil.
    2. Fig 1: Attaching New Base Gasket To Fuel Tank Unit And Inserting Fuel Tank Unit Partially Into Fuel Tank
    G00465073Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Transfer the base gasket (A) from the fuel tank unit to the fuel tank.
    3. Fig 2: Transfering Base Gasket From Fuel Tank Unit To Fuel Tank
    G00465074Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Algin the marks (B) on the fuel tank and the fuel tank unit, then insert the fuel tank unit into the fuel tank until the fuel tank unit rest on top of the base gasket.
    NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
  4. Using the special tool, tighten a new locknut (A).
    NOTE:
    • After tightening, make sure the marks are still aligned.
    • After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
    5. Fig 3: Using Special Tool To Tighten New Locknut
    G04245502Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Connect the fuel tank unit 5P connector, then connect the quick-connect fitting.
  6. Reconnect the negative cable to the battery, and turn the ignition switch ON (II) (but do not operate the starter motor). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat this two or three times, then check that there is no leakage in the fuel supply system.
  7. Install the access panel.
  8. Install the driver's side second row seat (see SECOND ROW SEAT REMOVAL/INSTALLATION )
  9. Install the fuel fill cap.
RENDER: 1.0x

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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.