SB-00-011

SB-10054948-5359
Service Bulletin
Applies To:
00-011
February 4, 2014
1998–99 Passport – All
MIL Comes On With DTC P1441
(Supersedes 00-011, dated July 26, 2011; see REVISION SUMMARY)
REVISION SUMMARY
The tools needed to diagnose and update the PCM for
this vehicle are no longer supported and have been
deleted from this bulletin. Some generic scan tools may
still work.
SYMPTOM
The MIL comes on and DTC P1441 (EVAP System
Flow During Non-Purge) is set.
POSSIBLE CAUSE
The PCM software does not compensate for signal
variation in the fuel tank pressure sensor when fuel
sloshes in a nearly full fuel tank.
CORRECTIVE ACTION
Replace the 20-to-120-ohm fuel sending unit with an
80-to-290-ohm unit if needed.
WARRANTY CLAIM INFORMATION
None. The customer is responsible for paying for any
repairs.
SOFTWARE UPDATE INFORMATION
AHM no longer supports the tools required to update
the software in the PCM. To update the PCM, you will
have to send it to Par Tech; call 248-276-0213 for
instructions on how to get the vehicle’s PCM updated
and the current cost.
PARTS INFORMATION
Fuel Sending Unit Kit:
P/N 8-25325-073-0, H/C 6258024
Kit contains two 80-to-290-ohm sending units (one
with a small connector, the other with a large
connector), an O-ring, a black locking clip, and a
red locking clip.
You will also need these clips if you break the original
clips while removing or installing the fuel lines:
Fuel Line Retaining Clip, 5/16:
P/N 2-90442-800-0
Fuel Line Retaining Clip, 3/8:
P/N 2-90442-810-0
REQUIRED MATERIALS
ProHonda Non-Chlorinated Brake Cleaner:
P/N 08732-9001
(One container will clean about two vehicles.)
REPAIR PROCEDURE
1. Using a generic scan tool, retrieve any PCM
broadcast codes and compare them to the codes
listed here:
PCM Broadcast Codes (for 20-to-120-ohm fuel
sending units:
BXBB, BXBC, BXBD, BXBF
CKMA, CKMB
CMWZ
CMXA, CMXB, CMXC
CMZA, CMZB, CMZC
• If the code is not listed, the vehicle has the
current 80-to-290-ohm fuel sending unit. Go to
step 32.
• If the code is listed, the vehicle has the original
20-to-120-ohm fuel sending unit. This unit must
be replaced with the 80-to-290-ohm unit. Go to
step 2.
 2014 American Honda Motor Co., Inc. – All Rights Reserved
ATB 21395-50956 REV2 (1402)
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CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment,
and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume
this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an
authorized Honda automobile dealer.
2. Write down your customer’s radio station presets
and mode settings (treble, bass, balance, and
fader).
3. Note the reading on the fuel gauge, then
disconnect the negative cable from the battery.
8. At the front of the tank, disconnect the fuel feed
hose and the fuel return hose where they connect
to the fuel filter and the fuel line. Remove the hoses
from the support clip. Plug the hoses, and cap the
lines to prevent any fuel leakage.
4. Remove the fuel fill cap.
NOTE: Wear proper eye protection through step
28 of this procedure.
5. If the fuel tank is more than 1/2 full, drain or siphon
the fuel into a suitable container.
6. Raise the vehicle on a lift. Support the fuel tank with
a powertrain lift or a commercially available jack as
shown in the illustrations. The powertrain lift, model
No. OTC-1585, is available through the Honda Tool
and Equipment Program.
7. Disconnect the EVAP hose, the fuel filler vent hose,
and the fuel filler hose where they connect to the
fittings at the back of the fuel tank.
FUEL
FILLER FUEL FILLER
VENT OSE
OSE
EVAP OSE
FRONT OF
VE ICLE
FUEL
FILTER
FUEL FEED OSE
(Plug after
disconnecting.)
FUEL RETURN OSE
(Plug after
disconnecting.)
9. Remove the nuts and bolts from the corners of the
tank. Do not remove the bolts from the skid plate.
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00-011
10. Partially lower the tank, then unplug the fuel pump/
sending unit harness and the fuel tank pressure
sensor harness.
FUEL TAN PRESSURE
SENSOR ARNESS
12. Carefully remove the fuel feed hose and the fuel
return hose from the fuel pump. Do not use too
much force on the fuel line retaining clips or you
may break them. Make sure you replace any
broken clips. Remove the tank from the vehicle.
FUEL PUMP
SENDIN UNIT
ARNESS
Squeeze the
ends of the 1
retaining clip.
Pull off the
connector.
11. Use brake cleaner and compressed air to
thoroughly clean the fuel pump and surrounding
area.
2
13. Use snap ring pliers to remove the fuel pump snap
ring. Before you remove the pump, use brake
cleaner and compressed air to clean the area
around it.
FUEL PUMP
SNAP RIN
00-011
SNAP
RIN
PLIERS
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14. Remove the fuel pump assembly. To prevent
damage to the float arm, lift the assembly straight
up, and rotate it to the right.
FUEL PUMP
ASSEMBLY
16. Remove the sending unit from the fuel pump
assembly:
Unplug
this connector
from the fuel
1
pump.
2
Remove the red
locking clip,
then unplug
the connector.
FLOAT ARM
15. Insert a small screwdriver under the float arm at the
brass bushing, and carefully pry the float arm out of
the sending unit. Do not bend the arm.
SENDIN
UNIT
3
Remove the black locking clip,
then remove the sending
unit from the housing.
Pry at the
pivot of the
float arm.
17. Remove the O-ring from the top of the pump
assembly, and clean the O-ring seat. Lubricate the
new O-ring with engine oil, and install the O-ring on
the pump.
NEW O-RIN
18. Of the two sending units in the kit, select the one
with the connector that matches the connector from
the original sending unit.
TWO STYLES OF FUEL
PUMP CONNECTOR
(Choose the connector
that matches the original.)
NEW SENDIN UNIT
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00-011
19. Install the new sending unit:
21. Move the float arm to its lowest position, then
connect a DVOM to the sending unit, and measure
the resistance. Resistance should be about 290
ohms. If the resistance is about 120 ohms, you
have reinstalled the original sending unit.
Plug this connector into
the top plate, and install
the new (red) locking clip.
4
Clip the two
wires into
the wire
holders.
2
Measure resistance
with the float arm
at its lowest position.
3
Plug this
connector into
the fuel pump.
Ω
Connect the sending unit
1 to the fuel pump assembly,
and install the new (black)
locking clip.
20. Reinstall the original float arm by pushing on its
pivot point to snap it into place. After installation,
make sure the arm moves freely under its own
weight. If it does not, the pivot arm is bent, and the
sending unit will not show the correct fuel level. To
repair a bent pivot point, remove the arm, bend the
pivot point back to its original 90-degree position,
and reinstall the arm.
22. Discard the original sending unit and the unused
unit from the kit.
23. Make sure the fuel pump opening on the tank is
clean, then reinstall the pump assembly and its
snap ring.
24. Reconnect the fuel feed hose and the fuel return
hose to the fuel pump.
25. Raise the tank close to its installed level with the
powertrain lift or jack, then plug in the fuel pump/
sending unit harness and the fuel tank pressure
sensor harness.
26. Raise the tank all the way, then reinstall its nuts
and bolts. Torque the nuts and bolts to 68 N•m
(50 lb-ft).
27. Reconnect the fuel feed hose and the fuel return
hose to the fuel filter and the fuel line at the front of
the tank. Attach the hoses to the support clip.
RETAINER
CLIPS
PIVOT POINT
28. Reconnect the EVAP hose, the fuel filler vent hose,
and the fuel filler hose to the fittings on the back of
the tank. Make sure the hoses are not kinked or
crushed, then lower the vehicle.
29. Refill the tank with the fuel you drained, and
reinstall the fuel fill cap.
30. Reconnect the negative cable to the battery.
90o
31. Enter your customer’s radio station presets and
mode settings. Reset the clock.
32. The PCM needs to be updated. Contact Par Tech
Inc. at 248-276-0123 to have the PCM updated.
33. Clear any remaining DTCs with an appropriate
scan tool.
34. Recheck the broadcast code with the generic scan
tool. The code must not match any of the codes
listed in step 1.
00-011
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