🔧 Pilot - Fuel Pump Replacement

Replacing the in-tank fuel pump on your Pilot means removing the fuel pump module from the top of the fuel tank and installing a new module with a fresh seal. The fuel system is pressurized, so the pressure must be relieved before disconnecting any fuel lines.

Difficulty Level: Advanced | Estimated Time: 3-5 hours

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⚠️ Safety & Precautions

• ⚠️ Work outside or in a very well-ventilated area. Gasoline fumes are flammable and harmful to breathe.
• ⚠️ Do not smoke, weld, grind, or use any open flame near the vehicle.
• ⚠️ Disconnect the negative battery cable before opening the fuel system.
• ⚠️ Keep a Class B/C fire extinguisher nearby. This type is rated for flammable liquids and electrical fires.
• ⚠️ Wear safety glasses and fuel-resistant gloves.
• ⚠️ Clean dirt from the fuel pump area before removal so debris does not enter the tank.
• ⚠️ Fuel may spill when lines are disconnected. Use shop towels and a drain pan.
• ⚠️ Support the fuel tank securely with a transmission jack or wide floor jack pad before removing tank straps.

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🔧 Required Tools

You'll need the following tools for this repair:

• 10mm socket
• 12mm socket
• 14mm socket
• 3/8-inch ratchet
• 3/8-inch extension set
• Torque wrench rated 5-80 ft-lbs
• Flat-blade screwdriver
• Plastic trim removal tool
• Fuel line disconnect tool set (specialty)
• Fuel pump lock ring tool (specialty)
• Brass drift punch
• Dead-blow hammer
• Floor jack rated 3-ton minimum
• Jack stands rated 3-ton minimum
• Transmission jack or wide fuel tank support adapter (specialty)
• Wheel chocks
• Drain pan
• Shop towels
• Nitrile gloves
• Safety glasses
• Class B/C fire extinguisher

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel pump module assembly - Qty: 1
• Fuel pump tank seal/O-ring - Qty: 1
• Fuel pump lock ring - Qty: 1
• Fuel line retaining clips - Qty: As needed
• Fresh gasoline - Qty: As needed

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📋 Before You Begin

• 🅿️ Park your Pilot on level ground, shift to Park, and set the parking brake.
• ⛽ Run the fuel level as low as safely possible before starting. A lighter tank is much easier and safer to lower.
• 🧯 Keep the fire extinguisher within arm’s reach before opening the fuel system.
• 🔋 Disconnect the negative battery cable using a 10mm socket.
• 🧰 A fuel line disconnect tool releases quick-connect fuel fittings. Quick-connect fittings are plastic locking connectors that hold fuel lines to the pump module.
• 🧰 A fuel pump lock ring tool turns the large retaining ring that clamps the pump module into the tank.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve Fuel System Pressure

• Open the hood and locate the under-hood fuse/relay box.
• Use your fingers or a plastic trim removal tool to remove the fuel pump fuse or relay cover access as needed.
• Remove the fuel pump fuse or relay using the fuse puller from the fuse box.
• Start the engine and let it run until it stalls.
• Crank the engine for 3-5 seconds after it stalls to release remaining pressure.
• Turn the ignition OFF.
• Do not skip pressure relief.

Step 2: Disconnect the Battery

• Use a 10mm socket to loosen the negative battery terminal clamp.
• Lift the negative cable off the battery post and move it aside so it cannot spring back.
• Wait at least 3 minutes before working around fuel connectors.

Step 3: Raise and Support the Vehicle

• Place wheel chocks in front of the front wheels.
• Use a floor jack rated 3-ton minimum to lift the rear of your Pilot at the rear center jacking point.
• Place jack stands rated 3-ton minimum under the rear side support points.
• Lower the vehicle gently onto the jack stands.
• Keep the floor jack lightly in place as a backup, but do not rely on it alone.

Step 4: Remove Rear Underbody Covers If Equipped

• Use a 10mm socket and plastic trim removal tool to remove any rear underbody splash shields blocking the fuel tank.
• Set bolts and clips aside in order so reassembly is easier.
• Take a photo before removal.

Step 5: Disconnect Filler Neck and Vent Hoses

• Locate the fuel filler hose and smaller vent hose at the side of the tank.
• Use a flat-blade screwdriver or 10mm socket to loosen the hose clamps, depending on clamp style.
• Twist the hoses gently by hand to break them loose, then slide them off the tank fittings.
• Use shop towels to catch any fuel drips.

Step 6: Support the Fuel Tank

• Place a transmission jack or wide fuel tank support adapter under the fuel tank.
• If using a floor jack, use a wide wood board between the jack and tank to spread the load.
• Raise the jack until it just contacts the tank. Do not crush the tank.

Step 7: Lower the Tank Slightly

• Use a 14mm socket, 3/8-inch ratchet, and 3/8-inch extension to remove the fuel tank strap bolts.
• Lower the tank only a few inches at first using the jack.
• Stop as soon as you can reach the top connectors and hoses.

Step 8: Disconnect Fuel Pump Electrical Connector and Fuel Lines

• Use your hand to press the locking tab and disconnect the fuel pump electrical connector.
• Use a fuel line disconnect tool set to release the quick-connect fuel lines from the pump module.
• Wrap the connection with shop towels before disconnecting to catch fuel spray or drips.
• Inspect plastic retaining clips. Replace any broken or loose clips.

Step 9: Lower and Remove the Fuel Tank

• Slowly lower the tank with the transmission jack or floor jack.
• Watch carefully for any remaining hoses or wiring.
• Once free, slide the tank out from under your Pilot.

Step 10: Clean Around the Fuel Pump Module

• Use shop towels to wipe dirt and dust from the top of the fuel tank.
• Clean especially around the fuel pump lock ring.
• Do not blow debris into the tank opening.
• Cleanliness prevents repeat failures.

Step 11: Remove the Fuel Pump Lock Ring

• Install the fuel pump lock ring tool onto the lock ring.
• Use a 3/8-inch ratchet to turn the lock ring counterclockwise until it releases.
• If using the backup method, tap the lock ring tabs gently with a brass drift punch and dead-blow hammer.
• Do not use a steel punch. Steel can create sparks.

Step 12: Remove the Old Fuel Pump Module

• Lift the fuel pump module straight up by hand.
• Angle it carefully to avoid bending the fuel level float arm. The float arm measures fuel level in the tank.
• Let fuel drain from the module into the tank before moving it away.
• Remove the old tank seal/O-ring by hand and discard it.

Step 13: Install the New Fuel Pump Module

• Place the new fuel pump tank seal/O-ring into the tank groove by hand.
• Lower the new fuel pump module assembly into the tank carefully.
• Make sure the alignment marks on the pump module and tank line up.
• Keep the seal flat. A twisted seal can cause a fuel vapor leak.

Step 14: Install the Lock Ring

• Install the new fuel pump lock ring by hand first.
• Use the fuel pump lock ring tool and 3/8-inch ratchet to rotate it clockwise until fully seated against the tank stops.
• If using the backup method, use the brass drift punch and dead-blow hammer to tap it clockwise until seated.
• Torque to manufacturer lock-ring stop position; do not overtighten beyond the stops.

Step 15: Reinstall the Fuel Tank

• Slide the tank back under your Pilot.
• Raise it slowly with the transmission jack or floor jack.
• Reconnect the fuel pump electrical connector by hand until it clicks.
• Reconnect the fuel lines by hand until each connector clicks into place.
• Pull gently on each line to confirm it is locked.

Step 16: Reinstall Tank Straps

• Raise the tank fully into position with the jack.
• Install the tank strap bolts by hand first to avoid cross-threading.
• Use a 14mm socket and torque wrench rated 5-80 ft-lbs to tighten the tank strap bolts.
• Torque to 39 Nm (29 ft-lbs).

Step 17: Reconnect Filler and Vent Hoses

• Slide the filler hose and vent hose fully onto the tank fittings by hand.
• Use a flat-blade screwdriver or 10mm socket to tighten the hose clamps snugly.
• Make sure hoses are not twisted or kinked.

Step 18: Reinstall Underbody Covers

• Use a 10mm socket and plastic trim removal tool to reinstall any underbody shields and clips.
• Make sure no shield touches the exhaust or fuel tank.

Step 19: Lower the Vehicle

• Use the floor jack rated 3-ton minimum to lift the rear slightly off the jack stands.
• Remove the jack stands rated 3-ton minimum.
• Lower your Pilot slowly to the ground.

Step 20: Reconnect Battery and Prime the Fuel System

• Reinstall the fuel pump fuse or relay by hand.
• Use a 10mm socket to reconnect the negative battery cable.
• Turn the ignition ON for 2 seconds, then OFF for 10 seconds.
• Repeat this ON/OFF cycle 3 times to prime the fuel system.
• Do not crank the engine during the first priming cycles.

Step 21: Start and Leak Check

• Start the engine and let it idle.
• Use safety glasses and visually inspect under the vehicle for leaks.
• Do not touch fuel lines while the engine is running.
• If you smell raw fuel or see a leak, shut the engine OFF immediately.

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✅ After Repair

• ✅ Let the engine idle for 3-5 minutes and confirm it runs smoothly.
• ✅ Check that the fuel gauge reads normally.
• ✅ Drive gently for 5-10 minutes, then recheck for fuel smell or leaks.
• ✅ If the check engine light comes on, scan for codes before continuing to drive.
• ✅ Dispose of fuel-soaked towels safely according to local hazardous-waste rules.

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💰 DIY vs Shop Cost

Shop Cost: $850-$1,400 (parts + labor)

DIY Cost: $250-$650 (parts only)

You Save: $600-$750 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 3-4 hours.

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