Safety Recall: 2019 Honda Passport Fuel Pump Motor

Service Bulletin

A21-033
July 30, 2021
Version 3

 

Safety Recall: 2019 Passport Fuel Pump Motor

Supersedes 21-033, dated May 7, 2021, to revise the information highlighted in yellow.

 

AFFECTED VEHICLES

Year Model Trim Level VIN Range
2019 Passport ALL Check the iN VIN status for eligibility.

 

REVISION SUMMARY

Under REPAIR PROCEDURE, steps 20, 29, 30, 31, 32, and 38 were revised.

 

BACKGROUND

Due to swelling of the fuel pump motor impeller, the fuel pump may seize and stop working. If this occurs, the check engine light may be displayed with DTC P0087 (Fuel Rail Pressure Too Low) stored, the engine may not start, or the engine could stall while driving, increasing the risk of a crash.

 

CUSTOMER NOTIFICATION

Owners of affected vehicles will be sent a notification of this campaign.

Do an iN VIN status inquiry to make sure the vehicle is shown as eligible.

Some vehicles affected by this campaign may be in your new or used vehicle inventory.

Failure to repair a vehicle subject to a recall or campaign may subject your dealership to claims or lawsuits from the customer or anyone else harmed as a result of such failure. To see if a vehicle in inventory is affected by this safety recall, do a VIN status inquiry before selling it.

 

CORRECTIVE ACTION

Replace the fuel pump motor.

NOTE: If the vehicle has any of the symptoms listed in BACKGROUND, you must apply this bulletin before attempting any other repairs. If the symptoms remain after the recall repair is complete, only attempt further repairs (such as replacing the high pressure fuel pump) after authorized troubleshooting.

 

PARTS INFORMATION

NOTE: Due to limited supply, this will be a controlled part and will require a valid VIN when ordering.

Part Name Part Number Quantity
Fuel Pump Motor Kit 06170-TG7-305 1

 

For dealers experiencing a strong fuel smell from storing a fuel pump motor replaced under this service bulletin, the fuel pump motor may be disposed of immediately in accordance with local regulations. This only applies to the fuel pump motor replaced under this service bulletin. The published retention policy remains in effect for all other parts.  If you have any questions about this exception or other parts retention issues, contact the WPI Administrative Office at 937-642-2737.

 

TOOL INFORMATION

Tool Name Part Number Quantity
Fuel Sender Wrench 070AA-T0AA100  or 07AAA-T0AA100 1

 

NOTE: 070AA-T0AA100 supersedes 07AAA-T0AA100. If your dealership has 07AAA-T0AA100, it can be used for  this repair.

 

WARRANTY CLAIM INFORMATION

Operation Number Description Flat Rate Time Defect Code Symptom Code Template ID Failed Part Number
3101HK Replace the fuel pump. 1.3 hr 6FE00 UAK00 A21033A 17045-TG7-A10

 

Skill Level: Repair Technician

 

REPAIR PROCEDURE

WARNING

Fuel pump motor removal exposes fuel, which can ignite, causing a fire or explosion.

This can cause serious injury or death.

Always work in a well-ventilated area and keep sparks or open flames away.

 

1. Insert the emergency fuel fill funnel into the fuel filler neck to relieve the pressure in the fuel tank.

 

NOTE: The emergency fuel fill funnel is located in the left rear side trim panel.

 

2. Relieve the fuel pressure. 

With an i-HDS:

  • Connect an i-HDS to the DLC located under the driver’s side of the dashboard.
  • Turn the ignition to ON.
  • Select the PGM-FI system on the i-HDS.
  • Select FUEL PUMP OFF from the Inspection menu.
  • Start the engine and let it idle until it stalls.
  • Turn the ignition to OFF.

 

Without an i-HDS:

  • Remove the PGM-FI main relay 2.

 

  • Start the engine, and let it idle until it stalls.
  • Turn the ignition to OFF.
  • Install the PGM-FI main relay 2.

 

3. Remove the front bulkhead cover.

 

4. Remove the air intake tube.

 

5. Open the positive battery terminal cover.

 

6. Disconnect both 12-volt battery terminals.

 

NOTICE

To protect the terminal connector from damage, do not hold it when removing the negative terminal.

 

NOTE:

  • Always disconnect the negative terminal first.

 

7. Remove the left side second row seat front foot covers.

 

8. Remove the left side second row front seat bolts.

 

9. Remove the left side rear sill upper trim.

 

10. Remove the left side rear sill middle trim.

 

11. Remove the left side rear sill lower trim.

 

12. Remove the second row seat rear foot cover.

 

13. Remove the left side second row rear seat bolts.

 

14. Lift up the left side second row seat, and then remove the harness clip and disconnect the connector.

 

15. Remove the left side second row seat.

16. Remove the fuel tank unit access panel and disconnect the fuel tank unit connector.

 

17. Place a rag or shop towel over the quick-connect fitting.

 

18. Disconnect the quick-connect fitting from the fuel tank unit.

 

19. Remove the fuel tank unit locknut using the fuel sender wrench (T/N 070AA-T0AA100) as shown.

 

NOTE: Keep the fuel sender wrench from floating.

 

20. Remove the fuel tank unit locknut, then remove the fuel tank unit.

 

NOTICE

Do not bend or twist the fuel level sensor arm excessively. This may damage the fuel level sensor or cause it to send inaccurate readings.

 

NOTE: After unlocking the fuel tank unit cam lock ring, clean the top of the fuel pump flange and adjacent areas to make sure it’s free of dirt, dust, and debris.

 

21. Prepare the fuel tank unit and parts to be replaced.

 

NOTE: Take a photo of the fuel tube and wire harness, and note their routing for assembly. There are various types  of routing.

 

22. Spread the wire harness clamps, and remove the wire harness. Make sure not to damage the wire harness.

 

NOTICE

Do not spread the clamps too wide. Spreading them too wide may damage them.

 

23. Press the tab on the fuel level sensor to release the lock. Then, push up on the fuel level sensor.

 

24. Remove the E-rings and discard them.

 

25. Disconnect the joint at the bottom of the reservoir.

26. Remove the fuel filter assembly from the reservoir by releasing the three clips.

 

NOTICE

Do not spread the clips too wide. Spreading them too wide may damage them.

 

NOTE: The spring may slide off the sliding shaft. Retain this spring. It will be used during assembly.

 

27. Release the three clips at the base of the fuel pump assembly and remove it from the fuel filter.

 

28. Pull the fuel pump assembly out of the fuel filter.

 

NOTE: If the O-ring remains on the fuel filter, use a flat-tip screwdriver wrapped in protective tape to remove it. Make sure not to damage the O-ring seat section.

 

29. Install the new spacer on the new fuel pump motor.

 

30. Install the new O-ring, then lubricate the outside edge of it, using only clean engine oil.

 

NOTE: Do not pinch the O-ring during installation.

 

31. Install the new harness and make sure the connection is secure and the connectors are firmly locked into place.

 

32. Place the fuel pump on a bench, then install the filter to the fuel pump.

 

NOTE: If the fuel pump does not engage into the fuel filter and re-insertion is necessary, confirm that the O-ring is seated on the fuel pump before repeating installation.

 

33. Install the fuel filter assembly to the reservoir.

 

NOTE:

  • Coat the O-ring with clean engine oil; do not use any other oil or fluid.
  • Do not pinch the O-ring during installation.
  • Insert the spring into the sliding shaft, and make sure it is lined up when installing the fuel filter.
  • Make sure the fuel tube is routed exactly as shown in the photo taken before disassembly.
  • Make sure the three clips are fully engaged.

 

34. Install the new E-rings.

 

NOTE:

After installation, make sure the E-rings can be rotated with your finger. If they cannot be rotated, the E-rings may not be fully seated or may be incorrectly installed.

 

35. Install the fuel level sensor to the reservoir. Make sure the lock is engaged and the connection is secure.

 

NOTICE

Do not bend or twist the fuel level sensor arm excessively. This may damage the fuel level sensor or cause it to send inaccurate readings.

 

36. Install the wiring harness to the clamps.

 

NOTICE

Do not spread the clamps too wide. Spreading them too wide may damage them.

 

NOTE:

  • Clip in the smaller harness wires followed by the larger wires.
  • Make sure not to damage the wire harness.
  • Make sure to route the wire harness exactly as shown in the photo taken before disassembly.

 

37. While compressing the fuel tank unit, make sure the movement is smooth and the fuel tube and wiring harness do not stretch, pinch, or bind.

 

38. Insert the fuel tank unit partially into the fuel tank with a new O-ring.

 

NOTICE

Do not bend or twist the fuel level sensor arm excessively. This may damage the fuel level sensor or cause it to send inaccurate readings.

 

NOTE:

  • Before installing the new O-ring, clean the fuel tank around the fuel pump opening where the O-ring will seat. The tank opening must be free of dirt, dust, and debris.
  • Be careful not to damage the O-ring.
  • Do not coat the O-ring with any oil.

 

39. Line up the mark on the fuel tank unit to the marks on the fuel tank, then insert the fuel tank unit into the fuel tank.

 

NOTE: To avoid any leaks, check the O-ring, either visually or by hand, to make sure it is not pinched.

 

40. Align the mark on the new locknut to the start of the thread on the fuel tank.

 

41. Press down on the fuel tank unit while turning the locknut clockwise by hand.

42. Using the fuel nut wrench, tighten the locknut to 100 N·m (74 lb-ft).

 

NOTE:

  • During installation, check the O-ring, either visually or by hand, to make sure it is not pinched.
  • After tightening, make sure the mark on the fuel tank unit is still lined up with the marks on the fuel tank.

 

43.  If the marks do not line up, friction between the fuel tank unit and the locknut may cause the fuel tank unit to turn while tightening. Observe the difference (shaded area), and loosen the locknut until the fuel tank unit can be rotated. Rotate the fuel tank unit counter-clockwise by the same amount, and repeat the tightening process.

 

NOTE: Repeat this step as necessary until the marks are lined up when the locknut is tightened to the specified torque.

 

44. Remove the quick-connect fitting retainer from the fuel tank unit, then install a new retainer onto the quick-connect fitting.

 

45. Connect the 12-volt battery terminals.

 

46. Connect the fuel tank unit connector.

 

47. Connect the 12-volt battery terminals.

 

48. Turn the ignition to ON, but do not turn the engine on. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then make sure there is no fuel leakage.

 

49. Install the fuel tank unit access panel.

 

50. Install the remaining parts in the reverse order of removal.

 

51. Clear all DTCs using an i-HDS.

 

52. California residents only: Fill out a Vehicle Emissions Recall – Proof of Correction certificate, and use UAK as the recall number. Have the service advisor give the certificate to your customer, and advise him or her to keep it as proof that the recall was completed. Your customer will need to submit this certificate to the DMV only if the DMV requests it. If you need more certificates, use reorder number Y0657.

 

END


 

 


Remedy Instructions and TSB

RCRIT-21V215-2400.pdf 1987.452KB

RCRIT-21V215-2400

 


Remedy Instructions and TSB

RCRIT-21V215-5020.pdf 1965.412KB

RCRIT-21V215-5020

 


Remedy Instructions and TSB

RCRIT-21V215-9298.pdf 1988.659KB

RCRIT-21V215-9298

 


ISSUED Owner Notification Letter(Part 577)- 2019 Passport

RCONL-21V215-4390.pdf 60.859KB

RCONL-21V215-4390

 


 

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