A 1995 Honda Passport fuel pump can be replaced independent of the fuel-sending unit. The upside to this is that it is less expensive than the models with a module. The downside is that the degree of difficulty is greater. Assuming all other possibilities have been eliminated, the pump must be replaced. A few considerations are in order. A heavy tank containing fuel, with open and venting ports, is not easy to work with, especially when it's perched precariously atop a floor jack. This job is much safer if you have a helper.
Relieve the fuel pressure by opening the hood and removing the fuel pump relay located in the fuse relay box on the driver’s side fenderwell. Look on the lid of the box, which contains a diagram indicating position of the relay in the box. Crank the engine over (as to start) for three seconds. Turn the key off and replace the relay.
Raise the rear of the Passport with the floor jack. Place the jack stands under the frame to support the vehicle and lower the jack. This keeps the jack stands from interfering with the removal of the tank. Loosen the hose clamps close to the tank on both the fuel filler hose and the return.
Disconnect the electrical harness connector for the fuel pump at the rear of the tank. Place the floor jack under the center of the fuel tank between the tank straps. Raise the floor jack to the point where it just touches the bottom of the tank.
Remove the two strap-retaining bolts using a 15 mm socket. Pull the straps down and bend them away from the fuel tank so they don’t interfere with its removal. Lower the tank slowly enough to reach the fuel line connectors on the top of the tank. Squeeze the fittings and separate all the connectors.
Lower the fuel tank slowly while pulling the fuel filler hose and vent hose off the tank ports. Pull the tank out from under the vehicle.
Tap the vertical tangs on the fuel pump retaining ring counterclockwise using the screwdriver and hammer to remove it. Lift the fuel pump/sending unit assembly out of the fuel tank, taking care so the sensing unit arm is not damaged. Pull the wire connector off the top of the fuel pump.
Remove the fuel filter screen on the bottom of the pump using the screwdriver to pry it off. Grab the fuel pump and lift it slightly and rotate the bottom of the fuel pump out of the rubber grommet. Hold the top, short hose in one hand and pull the pump out of the hose with the other with a slight twisting motion. Discard the pump.
Install the new pump top by pushing it into the hose and lifting and pushing the bottom of the pump into the lower grommet. Make sure the pump is turned properly so it seats correctly in the shaped grommet. Install the new filter screen on the bottom inlet of the pump by pushing it on with some pressure.
Cut the wires close to the connector that goes on the top of the pump using the crimping tool. The original harness connector is not compatible with the new pump so you need to install the harness pigtail that came with the pump. Use the wire connector terminals to connect the two wires to the new connector and crimp the terminals securely.
Remove the large O-ring at the fuel pump entrance and replace it with a new one. Place the fuel pump/sender assembly into the tank. Align the hose ports properly so they face in the same direction as before.
Place the retaining ring over the fuel pump. Push the horizontal tangs under the tangs on the tank opening and rotate it slightly to engage both the tank and retaining ring tangs. Use the screwdriver and hammer to tap the vertical tangs clockwise to totally engage both tangs.
Place the tank on the floor jack and push the tank under the vehicle. Raise the tank carefully so no fuel is lost. Connect all the fuel lines on the top of the tank by pushing them together. Lay the electrical connector out over the rear of the tank so it can be reached once the tank is in place.
Raise the tank a little at a time so the fuel filler and vent hose can be installed as it goes up. Bring the two tank straps around the bottom of the tank. Insert the strap retainer bolt and tighten with a socket on each strap. Lower the floor jack and remove it.
Tighten the two hose clamps at the filler and vent hose using the screwdriver. Connect the electrical fuel pump connector. Raise the vehicle, remove the jack stands and lower the vehicle.
