Honda CIVIC 10G 2016 Fuel Supply System Page 1

Fuel Supply System Description - Fuel Tank
When the fuel tank is full, there is a fuel tank feature which is the fuel level is higher than the lower end of the opening for the fuel tank
unit at the vehicle horizontal state.
However, even if the same amount of the fuel, this fuel tank has a structure which is the fuel level is lower than the lower end of the
opening at the vehicle inclination state as shown.
Fuel Supply System Description - Fuel Tank 4871 http://techinfo.honda.com/rjanisis/pubs/sm/1/2/Contents/enu/61TBAD/...
1 of 1 1/24/2019 6:06 AM
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Contents Summary of Fuel Supply System

  • Page 1Fuel Supply System Description - Fuel Tank When the fuel tank is full, there is a fuel tank feature which is the fuel level is higher than the lower end of the opening for the fuel tank unit at the vehicle horizontal state. However, even if the same amount of the fuel, this fuel tank has a structure
  • Page 2Fuel Supply System Description - High Pressure Fuel Pump Outline The high pressure fuel pump is driven mechanically by a foursquare cam installed on the camshaft. The pump pressurizes the fuel sent from the fuel tank to high pressure, and supplies the fuel via the fuel joint pipe and the fuel rails
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  • Page 4cardiagn.com Pressure adjustment The piston is pushed up by the cam because of the rotation of the camshaft, and the fuel drawn in is returned from the suction valve. The pulsation damper absorbs and dampens the pulsations caused by the piston displacement, and performs mixing of the fuel sent under
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  • Page 6Fuel Supply System Description - Returnless Fuel System The returnless fuel system incorporates the fuel pressure regulator into the fuel pump to remove the fuel return pipe and other parts. The fuel pressure regulator keeps the fuel pressure constant in the fuel pump. The fuel line is no longer rou
  • Page 7Fuel Fill Pipe Removal and Installation Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1 cardiagn.com Torque: N·m (kgf·m, lbf·ft) 1. Fuel Tank - Drain
  • Page 82. Fuel Fill Door Adapter - Remove cardiagn.com
  • Page 93. Left Rear Inner Fender - Remove 4. Filler Connector Cover - Remove 5. Quick-Connect Fitting - Disconnect 6. Fuel Fill Pipe - Remove 7. All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 10Fuel Gauge Sending Unit Test Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. HDS - Connect 2. Body Electrical System DTC - Check 1. Check for body electrical system DTCs. cardiagn.com If no problem is found, go to th
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  • Page 125. Fuel Tank Unit - Remove 6. Fuel Gauge Sending Unit - Test 1. Measure the resistance between the following terminals with the float at E (EMPTY), LOW (LOW FUEL INDICATOR), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the following readings, replace the fuel gauge sending unit. Test c
  • Page 133. Remove the No. A18 fuse and the No. B7 fuse for at least 10 seconds, then reinstall them. 4. Turn the vehicle to the ON mode. 5. Check that the pointer of the fuel gauge indicates F with the float at F. If the pointer of the fuel gauge does not indicate F, replace the gauge control module. If the
  • Page 14Fuel Gauge Sending Unit Test Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. HDS - Connect 2. Body Electrical System DTC - Check 1. Check for body electrical system DTCs. cardiagn.com If no problem is found, go to th
  • Page 15KX models cardiagn.com 5. Fuel Tank Unit - Remove 6. Fuel Gauge Sending Unit - Test 1. Measure the resistance between the following terminals with the float at E (EMPTY), LOW (LOW FUEL INDICATOR), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the following readings, replace the fuel gau
  • Page 162. Reconnect the fuel tank unit 4P connector. cardiagn.com 3. Remove the No. A18 (10 A) fuse in the under-hood fuse/relay box and the No. B7 (10 A) fuse in the under-dash fuse/relay box for at least 10 seconds, then reinstall them. 4. Turn the vehicle to the ON mode. 5. Check that the pointer of the
  • Page 17Fuel Learn Procedure NOTE: Do this procedure whenever you do any of these actions: Replace the injector. Replace the A/F sensor (Sensor 1). Replace MAF sensor/IAT sensor 1. Update the PCM. Reset the PCM. 1. HDS - Connect 2. PCM - Reset cardiagn.com 3. PCM - Fuel Learn 1. Start the engine. Keep the i
  • Page 18Fuel Line Inspection Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. Fuel may cause flammable gas leaks and may result in fire. Keep sparks, flame and cigarettes away. 1. Fuel Line
  • Page 192.0 L engine cardiagn.com KA/KC models
  • Page 20KX models cardiagn.com
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  • Page 22Fuel Leak Check (1.5 L Engine) cardiagn.com
  • Page 231. Throttle Body - Move NOTE: Do not disconnect the water bypass hoses. Do not bend the water bypass hoses excessively. 2. Intake Manifold Bracket - Remove 1. Remove the intake manifold bracket (A). 2. Move the high pressure fuel pump cover (B). NOTE: Do not disconnect the quick-connect fitting. car
  • Page 242. Install the intake manifold and the throttle body with the gaskets that had used on them. 3. Turn the vehicle to the ON mode, but do not operate the starter. After the fuel pump runs for about 2 seconds, the low pressure fuel line will be pressurized. Repeat this two or three times, then check fo
  • Page 251. Set the high pressure fuel pump cover (A). 2. Install the intake manifold bracket (B). 7. Throttle Body - Install cardiagn.com
  • Page 26Fuel Line Inspection Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. Fuel may cause flammable gas leaks and may result in fire. Keep sparks, flame and, cigarettes away. 1. Fuel Lin
  • Page 27K20C2 L15BY cardiagn.com
  • Page 28KX '16 KA/KC cardiagn.com
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  • Page 30Fuel Leak Check (L15B7/L15BA/L15BY) cardiagn.com
  • Page 311. Throttle Body - Move NOTE: Do not disconnect the water bypass hoses. Do not bend the water bypass hoses excessively. 2. Intake Manifold Bracket - Remove 1. Remove the intake manifold bracket (A). 2. Move the high pressure fuel pump cover (B). NOTE: Do not disconnect the quick-connect fitting. car
  • Page 322. Install the intake manifold and the throttle body with the gaskets that had used on them. 3. Turn the vehicle to the ON mode, but do not operate the starter. After the fuel pump runs for about 2 seconds, the low pressure fuel line will be pressurized. Repeat this two or three times, then check fo
  • Page 331. Set the high pressure fuel pump cover (A). 2. Install the intake manifold bracket (B). 7. Throttle Body - Install cardiagn.com
  • Page 34Fuel Line Inspection Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. Fuel may cause flammable gas leaks and may result in fire. Keep sparks, flame and, cigarettes away. 1. Fuel Lin
  • Page 35KX models cardiagn.com KX models
  • Page 36cardiagn.com Fuel Leak Check
  • Page 371. Engine Cover - Remove 2. High Pressure Fuel Pump Cover - Remove cardiagn.com 3. Throttle Body - Move NOTE: Do not disconnect the water bypass hoses. Do not bend the water bypass hoses excessively. 4. Intake Manifold - Remove 5. Fuel Rail Insulator - Remove 6. Fuel Leak - Check
  • Page 381. Apply commercially available Met-L-Check D-70 Developer to the joint of the injectors (A), the fuel rail (B), and the high pressure fuel pump (C). Set the probe of the leak detector (Snap-on Combustible Gas Leak Detector) on the joint. 2. Install the intake manifold and the throttle body with the
  • Page 3911. Engine Cover - Install cardiagn.com Non-return Valve Inspection 1. Non-return Valve - Remove Non-return Valve A NOTE: When removing non-return valve A, remove the purge pipe. When removing non-return valve B, remove the engine cover. Non-return Valve B
  • Page 402. Non-return Valve - Inspection 1. Connect the vacuum pump to the non-return valve as shown. Note the direction of the arrow on the valve 2. Apply vacuum to the valve. If it holds vacuum, go to next step. If it doesn’t hold the vacuum, replace the non-return valve. cardiagn.com 3. Connect the vacuu
  • Page 41Fuel Line/Quick-Connect Fitting Precautions Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. Replace the fuel feed hose, fuel line, or the quick-connect fitting to new one if it is damaged. When removing or installing th
  • Page 42cardiagn.com K20C2 L15B7/L15BA/K20C2 (KA/KC/KL)
  • Page 43cardiagn.com L15B7/L15BA/K20C2 (KX) L15BY
  • Page 44cardiagn.com KL and KA/KC except '16 L15BY
  • Page 45cardiagn.com Fuel Line/Quick-Connect Fitting Removal 1. Remove the fuel line/quick-connect fitting cover (If equipped). 2. Check the fuel quick-connect fittings for dirt, and clean it if needed. 3. Place a rag or shop towel over the quick-connect fitting. 4. Hold the connector (A) with one hand, and
  • Page 465. Pull the connector off. NOTE: Be careful not to damage the line (D) or other parts. Do not use tools. If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. Do not remove the retainer from the line; once removed,
  • Page 47Fuel Line/Quick-Connect Fitting Installation 1. Check the contact area (A) of the line (B) for dirt or damage, and clean it if needed. 2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after: cardiagn.com replacing new part which does not pack with the suitable retai
  • Page 48Reconnection to existing retainer cardiagn.com Connection to new fuel line 5. Press the quick-connect fittings onto the line until both retainer tabs lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. 6. When replacing the fuel line with
  • Page 497. Make sure the connection is secure and the tabs are firmly locked into place; check visually and also by pulling the connector. cardiagn.com 8. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat thi
  • Page 50Fuel Line/Quick-Connect Fitting Precautions Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. Replace the fuel feed hose, fuel line, or the quick-connect fitting to new one if it is
  • Page 51cardiagn.com KA/KC models KX models
  • Page 52cardiagn.com KA/KC models Fuel Line/Quick-Connect Fitting Removal 1. Remove the fuel line/quick-connect fitting cover (If equipped).
  • Page 532. Check the fuel quick-connect fittings for dirt, and clean it if needed. 3. Place a rag or shop towel over the quick-connect fitting. cardiagn.com 4. Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). 5. Pull the c
  • Page 547. To prevent damage and keep foreign matter out, cover the disconnected connector and line ends with plastic bags (A). NOTE: The retainer cannot be reused once it has been removed from the line. Replace the retainer when: - replacing a new part that does not include the retainer. (a fuel line, a fu
  • Page 55replacing new part which does not pack with the suitable retainer. (a fuel line, a fuel tank unit etc.) removing the retainer from the line. NOTE: Use the same manufacturer retainer and the same size retainer when the replacing the retainer. 3. Before connecting a new fuel line/quick-connect fitting
  • Page 565. Press the quick-connect fittings onto the line until both retainer tabs lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. 6. When replacing the fuel line with a new retainer as a set, make sure you remove the ring pull upwards after
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  • Page 58Fuel Pressure Relieving Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. Before disconnecting fuel lines or hoses, relieve pressure from the system by disabling the fuel pump and disconnecting the fuel line/quick connect
  • Page 593. 12 volt Battery Terminal - Disconnect cardiagn.com
  • Page 60Fuel Pressure Test Special Tool Required Image Description/Tool Number Fuel Pressure Gauge 07406-004000B cardiagn.com Fuel Pressure Gauge Attachment Set 07AAJ-S6MA150 Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emissions Systems Service Precautions b
  • Page 61cardiagn.com 3. Fuel Line - Disconnect 1. Remove the quick-connect fitting cover (A). 2. Check the fuel quick-connect fitting (B) for dirt, and clean it if needed. 3. Place a rag or shop towel over the quick-connect fitting, then disconnect the quick-connect fitting. 4. Fuel Pressure - Test NOTE: If
  • Page 62cardiagn.com 2. Start the engine, and let it idle. If the engine starts, go to step 3 and read the fuel pressure gauge. If the pump does not run, do the fuel pump circuit troubleshooting. 3. Read the fuel pressure gauge. The pressure should be: Grade name Standard value Except Si 390-440 kPa (3.98-4
  • Page 63Fuel Pressure Test Special Tool Required Image Description/Tool Number Fuel Pressure Gauge 07406-004000B cardiagn.com Fuel Pressure Gauge Attachment Set 07AAJ-S6MA150 Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. F
  • Page 641. Remove the quick-connect fitting cover (A). 2. Check the fuel quick-connect fitting (B) for dirt, and clean it if needed. 3. Place a rag or shop towel over the quick-connect fitting, then disconnect the quick-connect fitting. 3. Fuel Pressure - Test cardiagn.com NOTE: If you were referred to this
  • Page 65Fuel Pulsation Damper Removal and Installation Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. Fuel Rail - Remove 2. Fuel Pulsation Damper - Remove 1. Place a wrench (A) on the fuel rail (B). cardiagn.com 2. Place a
  • Page 66Fuel Pump Circuit Troubleshooting cardiagn.com
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  • Page 68Fuel Pump Circuit Troubleshooting If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is on, you will hear some noise if you listen to the fuel fill port. The fuel pump should run for 2 seconds when the vehicle is turned to ON mode. If the fuel pump does not
  • Page 69cardiagn.com Is there continuity? YES Remove and test the relay circuit board, and replace it if needed.■ NO Repair an open in the FI MAIN RLY OUT wire between the relay circuit board and PGM-FI main relay 2.■ 3. Open wire check (IG1 FUEL PUMP line): ‐1. Measure the voltage between test points 1 and
  • Page 70‐3. Disconnect the following connector. PCM connector No. 2 (58P) ‐4. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PGM-FI main relay 2: disconnected PCM connector No. 2 (58P): disconnected Test point 1 PGM-FI main relay 2 4P socket (female terminals) No. 4
  • Page 71‐3. Remove the jumper wire from PCM connector No. 2 (58P). ‐4. Reconnect PCM connector No. 2 (58P). ‐5. Exit the SCS mode with the HDS. ‐6. Turn the vehicle to the ON mode, and measure the voltage between test points 1 and 2. Test condition Within 2 seconds after turning vehicle to ON mode PGM-FI ma
  • Page 72Is there battery voltage? YES Go to step 9. NO Go to step 8. 8. Open wire check (FUEL PUMP RLY OUT line): ‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Remove PGM-FI main relay 2. ‐3. Connect terminals A and B with a jumper wire. Terminal A PGM-FI main relay 2 4P socket (female terminals) No. 1:
  • Page 73Fuel tank unit 4P connector: disconnected Test point 1 Fuel tank unit 4P connector (female terminals) No. 3: Test point 2 Body ground Is there continuity? YES The GND wire is OK. Replace the fuel tank unit.■ NO Repair an open in the GND wire between the fuel tank unit and G601.■ cardiagn.com
  • Page 74Fuel Pump Circuit Troubleshooting cardiagn.com
  • Page 75Fuel Pump Circuit Troubleshooting cardiagn.com
  • Page 76If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is on, you will hear some noise if you listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the vehicle is turned to ON mode. If the fuel pump does not mak
  • Page 77Is there continuity? cardiagn.com YES Remove and test the relay circuit board, and replace it if needed.■ NO Repair an open in the FI MAIN RLY OUT wire between the relay circuit board and PGM-FI main relay 2.■ 3. Open wire check (IG1 FUEL PUMP line): ‐1. Measure the voltage between test points 1 and
  • Page 78‐2. Jump the SCS line with the HDS, and wait more than 1 minute. ‐3. Disconnect the following connector. PCM connector A (50P) ‐4. Check for continuity between test points 1 and 2. Test condition Vehicle OFF (LOCK) mode PGM-FI main relay 2: disconnected PCM connector A (50P): disconnected Test point
  • Page 79‐2. Remove PGM-FI main relay 2. ‐3. Remove the jumper wire from PCM connector A (50P). ‐4. Reconnect PCM connector A (50P). ‐5. Exit the SCS mode with the HDS. ‐6. Turn the vehicle to the ON mode, and measure the voltage between test points 1 and 2. Test condition Within 2 seconds after turning vehi
  • Page 80Is there battery voltage? YES Go to step 9. NO Go to step 8. 8. Open wire check (FUEL PUMP RLY OUT line): ‐1. Turn the vehicle to the OFF (LOCK) mode. cardiagn.com ‐2. Remove PGM-FI main relay 2. ‐3. Connect terminals A and B with a jumper wire. Terminal A PGM-FI main relay 2 4P socket No. 1 Termina
  • Page 81Is there battery voltage? YES The FUEL PUMP RLY OUT wire is OK. Replace PGM-FI main relay 2.■ NO Repair an open in the FUEL PUMP RLY OUT wire between PGM-FI main relay 2 and the fuel tank unit.■ 9. Open wire check (GND line): ‐1. Turn the vehicle to the OFF (LOCK) mode. cardiagn.com ‐2. Check for co
  • Page 82Fuel Pump Circuit Troubleshooting cardiagn.com
  • Page 83Fuel Pump Circuit Troubleshooting cardiagn.com
  • Page 84If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is on, you will hear some noise if you listen to the fuel fill port. The fuel pump should run for 2 seconds when the vehicle is turned to ON mode. If the fuel pump does not make noise, check as follows: 1. D
  • Page 85Is there continuity? YES Remove and test the relay circuit board, and replace it if needed.■ NO Repair an open in the FI MAIN RLY OUT wire between the relay circuit board and PGM-FI main relay 2.■ 3. Open wire check (IG1 FUEL PUMP line): ‐1. Measure the voltage between test points 1 and 2. Test cond
  • Page 86PCM connector A (50P): disconnected Test point 1 PGM-FI main relay 2 4P socket No. 4 Test point 2 PCM connector A (50P) No. 11 Is there continuity? YES The FUEL PUMP RLY CL- wire is OK. Go to step 5. NO Repair an open in the FUEL PUMP RLY CL- wire between the PCM (A11) and PGM-FI main relay 2.■ 5. D
  • Page 87‐6. Turn the vehicle to the ON mode, and measure the voltage between test points 1 and 2. Test condition Within 2 seconds after turning vehicle to ON mode PGM-FI main relay 2: disconnected Test point 1 PGM-FI main relay 2 4P socket No. 3 Test point 2 Body ground Is there battery voltage? YES Check f
  • Page 88‐2. Remove PGM-FI main relay 2. ‐3. Connect terminals A and B with a jumper wire. Terminal A PGM-FI main relay 2 4P socket No. 1 Terminal B PGM-FI main relay 2 4P socket No. 2 ‐4. Turn the vehicle to the ON mode. ‐5. Measure the voltage between test points 1 and 2. Test condition Vehicle ON mode Fue
  • Page 89Is there continuity? YES The GND wire is OK. Replace the fuel pump.■ NO Repair an open in the GND wire between the fuel tank unit and G601.■ cardiagn.com
  • Page 90Fuel Tank Draining Flammable - Keep Fire Away 1. Fuel Tank Unit - Remove 2. Fuel Tank - Drain 1. Using a hand pump, a hose, and a container suitable for fuel, draw the fuel from the fuel tank. cardiagn.com 3. Fuel Tank Unit - Install
  • Page 91Fuel Tank Removal and Installation Special Tool Required Image Description/Tool Number Wrench, Fuel Sender 07AAA-TBAA100 cardiagn.com Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. Fuel Pressure - Relieve 2. Fuel Ta
  • Page 921. Drain the fuel tank, then reinstall the fuel tank unit and the fuel tank unit cam lock ring without connecting the fuel tank unit connector, and the quick-connect fitting. NOTE: When installing the fuel tank unit cam lock ring (A) using the fuel sender wrench, temporarily set the positioning edge
  • Page 936. Fuel Tank Heat Baffle - Remove cardiagn.com 7. Rear Wheel - Remove 8. Left Rear Inner Fender - Remove 9. Fuel Fill Pipe - Disconnect
  • Page 941. Remove the filler connector cover (A). 2. Disconnect the quick-connect fittings (B). cardiagn.com 10.Rear Brake Caliper Assembly, Rear Subframe, and Rear Trailing Arm - Remove NOTE: Do not disconnect the brake lines and the brake hoses. Do not twist the brake hose excessively. 1. Remove the rear
  • Page 95cardiagn.com 11. Fuel Tank Assembly - Remove
  • Page 961. Place a transmission jack or other support under the fuel tank (A). 2. Remove the strap (B) and the fuel tank carefully. 3. If needed, remove the fuel tank unit. cardiagn.com Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emissions Systems Service Pr
  • Page 971. If needed, Install the fuel tank unit with the O-ring that had used on them. NOTE: When installing the fuel tank unit cam lock ring (A) using the fuel sender wrench, temporarily set the positioning edge (B) of the fuel tank at the fuel tank unit cam lock ring tabs (C) on the fuel tank unit cam lo
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  • Page 993. Rear Subframe, Rear Trailing Arm and Rear Brake Caliper Assembly - Install 1. Install the rear subframe with the rear trailing arms, do the following procedures while installing the indicated part(s) from both sides. The rear subframe bolts (A) and the rear trailing arm bolts (B). NOTE: Place a t
  • Page 100cardiagn.com 4. Fuel Fill Pipe - Connect
  • Page 1011. Connect the quick-connect fittings (A). 2. Install the filler connector cover (B). cardiagn.com 5. Left Rear Inner Fender - Install 6. Rear Wheel - Install 7. Fuel Tank Heat Baffle - Install
  • Page 1028. Fuel Vent Tube - Connect cardiagn.com
  • Page 103cardiagn.com 9. Front Floor Undercover - Install 10.Muffler - Install 11. Fuel Tank Unit - Install NOTE: Remove the fuel tank unit cam lock ring, then replace the new O-ring. 12.Fuel Leak - Check
  • Page 1041. Connect the quick-connect fitting (A). 2. Connect the connector (B). 3. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then check for fuel leakage. 4. Install the access
  • Page 105Fuel Tank Removal and Installation Special Tool Required Image Description/Tool Number Wrench, Fuel Sender 07AAA-TBAA100 cardiagn.com *Available through the Honda Tool and Equipment Program 888-424-6857 Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emi
  • Page 1061. Drain the fuel tank, then reinstall the fuel tank unit and the fuel tank unit cam lock ring without connecting the fuel tank unit connector, the quick-connect fitting, the fuel vent tube, and fuel tank vapor recirculation tube. NOTE: When installing the fuel tank unit cam lock ring (A) using the
  • Page 107cardiagn.com 6. Fuel Vent Tube B - Disconnect (KX models) 7. Rear Wheel - Remove 8. Left Rear Inner Fender - Remove
  • Page 1089. Fuel Fill Door Adapter - Remove 10.Connector (Adaptive Damper System) - Disconnect (If Equipped) 11. Rear Brake Caliper Assembly, Rear Subframe, and Rear Trailing Arm - Remove NOTE: Do not disconnect the brake lines and the brake hoses. Do not twist the brake hose excessively. 1. Remove the rear
  • Page 109cardiagn.com 12.Fuel Tank Assembly - Remove
  • Page 1101. Remove the fuel fill pipe bracket (A), the fuel fill pipe mounting bolt (B), and the ground cable terminal bolt (C). cardiagn.com 2. Place a transmission jack or other support under the fuel tank (A). 3. Remove the strap (B) and the fuel tank carefully. 4. If needed, remove the fuel tank unit. Fl
  • Page 1111. If needed, Install the fuel tank unit with the O-ring that had used on them. NOTE: When installing the fuel tank unit cam lock ring (A) using the fuel sender wrench, temporarily set the positioning edge (B) of the fuel tank at the fuel tank unit cam lock ring tabs (C) on the fuel tank unit cam lo
  • Page 1121. KA/KC/KL models: Tape the fuel tank vapor recirculation tube (A) as shown. 2. Place a transmission jack under the fuel tank (B) and carefully raise the fuel tank into position. 3. Tighten the fuel tank mounting bolts (C) in the numbered sequence shown. 4. Install the strap (D). cardiagn.com 5. In
  • Page 1131. Tape the fuel tank vapor recirculation tube (A) as shown. 2. Place a transmission jack under the fuel tank (B) and carefully raise the fuel tank into position. 3. Install the fuel tank and the strap (C). NOTE: Tighten the fuel tank mounting bolts and the strap mounting bolts in the following proc
  • Page 114The rear subframe bolts (A) and the rear trailing arm bolts (B). NOTE: Place a transmission jack or other support under the rear subframe. Pay attention to prevent damage to the connector (C). Connect the connector(s). The bracket(s) (D). The rear damper upper bolts (E). The rear brake caliper brack
  • Page 115cardiagn.com 5. Connector (Adaptive Damper System) - Connect (If Equipped) 6. Fuel Fill Door Adapter - Install 7. Left Rear Inner Fender - Install
  • Page 1168. Rear Wheel - Install 9. Fuel Vent Tube B - Connect (KX models) NOTE: Make sure the hose clamps are properly positioned and tightened. 10.Fuel Tank Heat Baffle - Install cardiagn.com
  • Page 11711. Front Floor Undercover - Install 12.Muffler - Install 13.Fuel Tank Unit - Install 1. Remove the fuel tank unit cam lock ring (A), then replace the new O-ring (B), do the following procedures. Refer to the "Fuel Tank Unit Cam Lock Ring - Unlock" on the Fuel Tank Unit Removal and Installation. 2.
  • Page 118KX models cardiagn.com 15.Rear Seat-Back and Rear Seat-Cushion - Install 16.Wheel Alignment - Adjustment
  • Page 119Fuel Tank Unit Disassembly and Reassembly Flammable - Keep Fire Away NOTE: Where icon is shown, click for further information. Coat the O-rings with clean engine oil; do not use any other oil or fluid. Do not pinch the O-rings during installation. When connecting the wire harness, make sure the conn
  • Page 120Note for installation Make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively. 2. Reservoir - Remove 1. Separate the fuel filter by disconnecting the hose. 3. Fuel Pressure Regulator - Remove 4. Fuel Pump - Remove 5. All Remove
  • Page 121Fuel Tank Unit Disassembly and Reassembly Flammable - Keep Fire Away NOTE: Where icon is shown, click for further information. 1 KA/KC/KL models cardiagn.com Detailed information, notes and precautions Replace 2 KX models
  • Page 122cardiagn.com Detailed information, notes and precautions Replace 1. Fuel Level Sensor (Fuel Gauge Sending Unit) - Remove NOTE: Be careful not to bend or twist the fuel level sensor arm excessively. 2. Reservoir - Remove 1. Separate the fuel filter by disconnecting the hose. 3. Fuel Pressure Regulato
  • Page 123When connecting the wire harness, make sure the connection is secure and the connectors are firmly locked into place. When installing the fuel level sensor, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively. Use all the n
  • Page 124Fuel Tank Unit Removal and Installation Special Tool Required Image Description/Tool Number Wrench, Fuel Sender 07AAA-TBAA100 cardiagn.com Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. Fuel Pressure - Relieve 2. Re
  • Page 1251. Remove the access panel (A) from the floor. 2. Disconnect the connector (B). 3. Disconnect the quick-connect fitting (C) from the fuel tank unit. cardiagn.com 4. Fuel Tank Unit Cam Lock Ring - Unlock 1. Set the fuel sender wrench as shown. 2. Turn the fuel tank unit cam lock ring (A) counterclock
  • Page 1266. Fuel Tank Unit - Remove cardiagn.com 1. Remove the fuel tank unit (A) with the O-ring (B). NOTE: Be careful not to bend or twist the fuel level sensor arm (C) excessively. Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel li
  • Page 127NOTE: Be careful not to bend or twist the fuel level sensor arm (A) excessively. 1. Insert the fuel tank unit (B) partially into the fuel tank with a new O-ring (C). NOTE: Be careful not to damage the new O-ring. Do not coat the O-ring with oil. cardiagn.com 2. Align the tab (A) of the fuel tank uni
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  • Page 1292. Fuel Tank Unit Cam Lock Ring - Lock 1. Rotate the fuel tank unit cam lock ring (A) and slide the fuel tank unit cam lock tabs (B) into the positioning edge (C) slightly as shown by hand. NOTE: Confirm the fuel cam lock ring is not floating. cardiagn.com
  • Page 1302. Using the fuel sender wrench, turn the fuel tank unit cam lock ring (A) clockwise. NOTE: Try to keep the fuel sender wrench from floating. Securely set the positioning edge (B) of the fuel tank at the fuel tank unit cam lock ring tabs (C) on the fuel tank unit cam lock ring as shown. cardiagn.com
  • Page 1311. Connect the fuel line quick-connect fitting (A). 2. Connect the connector (B). 3. Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then check for fuel leakage. 4. Install
  • Page 1324. Rear Seat-Back and Rear Seat-Cushion - Install cardiagn.com
  • Page 133Fuel Tank Unit Removal and Installation Special Tool Required Image Description/Tool Number Wrench, Fuel Sender 07AAA-TBAA100 cardiagn.com ORVR Service Plug 07AAK-TBAA100 *Available through the Honda Tool and Equipment Program 888-424-6857. ORVR Service Plug (07AAK-TBAA100) is used only for KA, KC,
  • Page 134If the front of the vehicle is not raised with the fuel level more than 90 %, fuel in the fuel tank will spill. 1. When the fuel indicator points at F segment or more, or you cannot confirm the fuel level, apply the parking brake, block the rear wheels, use the jack to raise the front of the vehicle
  • Page 135KX models cardiagn.com 5. Fuel Tank Unit Cam Lock Ring - Unlock KA/KC/KL models 1. Set the fuel sender wrench as shown. 2. Turn the fuel tank unit cam lock ring (A) counterclockwise. NOTE: Try to keep the fuel sender wrench from floating.
  • Page 136KX models cardiagn.com 6. Fuel Vent Tube and Fuel Tank Vapor Recirculation Tube - Disconnect (KA/KC/KL Models) NOTE: Do not bend the fuel vent tube (A) and fuel tank vapor recirculation tube (B) excessively. 1. Disconnect the fuel vent tube by doing the following procedure. Hold the fuel vent tube w
  • Page 1378. Fuel Tank Unit - Remove (KA/KC/KL Models) cardiagn.com 1. Hook the plug’s lanyard (A) on the child safety seat hook (B) as shown. Set the ORVR service plug near the fuel tank unit opening. NOTE: Do not damage any part of the ORVR service plug’s surface. Damage to the ORVR service plug may cause f
  • Page 138cardiagn.com 3. Install the ORVR service plug onto the inner fuel vent tube. Make sure the ORVR service plug is fully seated by holding the inner fuel vent tube and gently pulling on the plug’s lanyard. NOTE: The ORVR service plug should not come off. 4. Carefully lower the inner fuel vent tube (A)
  • Page 1399. Fuel Tank Unit - Remove (KX Models) 1. Remove the fuel tank unit (A) with the O-ring (B). NOTE: Be careful not to bend or twist the fuel level sensor arm (C) excessively. Flammable - Keep Fire Away cardiagn.com NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting
  • Page 1402. Grab the plug lanyard (B) and pull the inner fuel vent tube (C) up until it is close to the fuel tank unit opening. cardiagn.com 3. Move the fuel tank unit (D) aside, allowing space to remove the ORVR service plug from the inner fuel vent tube. NOTE: Do not allow the inner fuel vent tube to fall
  • Page 1416. Remove the ORVR service plug from the child safety seat hook (D) and install the provided protective cap (E). 7. Align the tab (A) of the fuel tank unit as shown, and temporarily insert the fuel tank unit cam lock ring (B). cardiagn.com 2. Fuel Tank Unit - Install (KX Models)
  • Page 142NOTE: Be careful not to bend or twist the fuel level sensor arm (A) excessively. 1. Insert the fuel tank unit (B) partially into the fuel tank with a new O-ring (C). NOTE: Be careful not to damage the new O-ring. Do not coat the O-ring with oil. cardiagn.com 2. Align the tab (A) of the fuel tank uni
  • Page 1431. Connect the fuel vent tube (A) and fuel tank vapor recirculation tube (B) by rotating the fuel tank unit (C) counterclockwise slightly. NOTE: Do not bend the fuel vent tube and fuel tank vapor recirculation tube excessively. 4. Fuel Tank Unit Cam Lock Ring - Lock 1. Rotate the fuel tank unit cam
  • Page 1442. Using the fuel sender wrench, turn the fuel tank unit cam lock ring (A) clockwise. NOTE: Try to keep the fuel sender wrench from floating. Securely set the positioning edge (B) of the fuel tank at the fuel tank unit cam lock ring tabs (C) on the fuel tank unit cam lock ring as shown. cardiagn.com
  • Page 145cardiagn.com KX models 6. Rear Seat-Back and Rear Seat-Cushion - Install
  • Page 146High Pressure Fuel Pump Removal and Installation Flammable - Keep Fire Away NOTE: Where icon is shown, click for further information. Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. The fuel joint pipe cannot be reused once it has been removed or loose
  • Page 147cardiagn.co
  • Page 148cardiagn.com Detailed information, notes and precautions Replace 1. Fuel Pressure - Relieve 2. EVAP Canister Purge Valve and Purge Joint - Remove 3. Throttle Body - Move NOTE: Do not disconnect the water bypass hoses. Do not bend the water bypass hoses excessively. 4. Intake Manifold - Remove 5. Joi
  • Page 1496. High Pressure Fuel Pump Cover - Remove 7. Harness Holder - Move 8. Quick-Connect Fitting - Disconnect 9. Fuel Joint Pipe - Remove 10.High Pressure Fuel Pump and Pump Lifter - Remove 1. Loosen the bolts alternately, and remove the high pressure cardiagn.com fuel pump and the pump lifter. 11. Fuel
  • Page 1502. Install the pump lifter (A) to the high pressure fuel pump cam. 3. Set the gauge (B) on the pump lifter and hold it. 4. Rotate the crankshaft 720 ° and measure the four cam lobes height. If the cam lobes are excessively worn, replace the exhaust camshaft. NOTE: The high pressure fuel pump cam has
  • Page 151cardiagn.com Detailed information, notes and precautions Torque: N·m (kgf·m, lbf·ft) Replace 2
  • Page 152Replace cardiagn.com 1. Camshaft Timing - Set
  • Page 1531. Check the position of the cam (A) that drives high pressure fuel pump as shown. If the cam position angle is wrong as shown, rotate the crankshaft to set it. cardiagn.com 2. Fuel Feed Pipe - Install (If Necessary) 3. High Pressure Fuel Pump and Pump Lifter - Temporarily Install 1. Coat the pump l
  • Page 1544. Fuel Joint Pipe - Install NOTE: Before you install the fuel joint pipe (A), loosen the high pressure fuel pump mounting bolts (B). 1. Lubricate the top of the new fuel joint pipe (C) and the threaded area (D) of the fuel rail and the high pressure fuel pump with polyethylene glycol of a new fuel
  • Page 1555. Quick-Connect Fitting - Connect 6. Harness Holder - Install 7. Fuel Leak - Check 8. Joint Pipe Bracket - Install 9. Intake Manifold - Install 10.Throttle Body - Install cardiagn.com 11. EVAP Canister Purge Valve and Purge Joint - Install 12.High Pressure Fuel Pump Cover - Install
  • Page 156High Pressure Fuel Pump Removal and Installation Flammable - Keep Fire Away NOTE: How to read the torque specifications. Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. Fuel Pressure - Relieve 2. Throttle Body - Move cardiagn.com NOTE: Do not discon
  • Page 1574. Intake Manifold - Remove 5. High Pressure Fuel Pump Cover - Remove Except Si 1. Disconnect the quick-connect fitting (A). 2. Remove the high pressure fuel pump cover (B). cardiagn.com
  • Page 158Si cardiagn.com 6. Fuel Joint Pipe - Remove Except Si 1. Remove the fuel joint pipe (A).
  • Page 159Si cardiagn.com 7. High Pressure Fuel Pump - Remove Except Si 1. Disconnect the connector (A). 2. Loosen the bolts (B) alternately, and remove the high pressure fuel pump (C) with the O-ring (D), and the pump lifter (E).
  • Page 160Si cardiagn.com Except Si 3. Remove the fuel feed pipe (A) with the sealing washers (B) from the high pressure fuel pump (C).
  • Page 161Si 8. High Pressure Fuel Pump Cam - Check cardiagn.com 1. Rotate the crankshaft and check the high pressure fuel pump cam (A) for pits, scores, or excessively wear. If needed, replace the intake camshaft.
  • Page 1622. Install the pump lifter (A) to the high pressure fuel pump cam. 3. Set the gauge (B) on the pump lifter and hold it. 4. Rotate the crankshaft 720 ° and measure the four cam lobes height. If the cam lobes are excessively worn, replace the intake camshaft. NOTE: The high pressure fuel pump cam has
  • Page 1631. Check the position of the cam (A) that drives high pressure fuel pump as shown. If the cam position angle is wrong as shown, rotate the crankshaft to set it. cardiagn.com 2. High Pressure Fuel Pump - Install
  • Page 164Except Si 1. Install the fuel feed pipe (A) to the high pressure fuel pump (B) with new sealing washers (C). Si cardiagn.com
  • Page 165Except Si 2. Coat the pump lifter (A), the cam (B), a new O-ring (C), and around the bore of the lifter insert with clean engine oil. 3. Install the pump lifter and the high pressure fuel pump (D) with the O-ring. 4. Temporarily tighten the bolts (E) in an alternate pattern until the high pressure f
  • Page 166Si 3. Fuel Joint Pipe - Install cardiagn.com
  • Page 167Except Si NOTE: Before you install the fuel joint pipe (A), loosen the high pressure fuel pump mounting bolts (B). 1. Lubricate the top of the new fuel joint pipe (C) and the threaded area (D) of the fuel rail and the high pressure fuel pump with polyethylene glycol of a new fuel joint pipe kit. NOT
  • Page 168Except Si 4. Tighten the high pressure fuel pump mounting bolts (A) to the specified torque. 5. Tighten the fuel joint pipe bracket mounting bolt (B) to the specified torque. 6. Tighten the fuel joint pipe nut (C) to the specified torque in the numbered sequence shown. NOTE: A crowfoot-type special
  • Page 169Except Si 1. Install the high pressure fuel pump cover (A). NOTE: The high pressure fuel pump cover will be reinstalled after the fuel leak check. 2. Connect the quick-connect fitting (B). cardiagn.com Si
  • Page 1705. Fuel Leak - Check cardiagn.com
  • Page 171Low Fuel Indicator Test 1. Low Fuel Indicator - Test 1. Do the gauge control module self-diagnostic function. If the low fuel indicator flashes, go to step 2. If the low fuel indicator does not flash, replace the gauge control module. 2. Check for body electrical system DTCs. If any DTCs are indicat
  • Page 172Mis-Fuel Inhibit Device Removal and Installation Special Tool Required Image Description/Tool Number Capless Wrench 07AAF-TBAA100 Capless Flapper Retainer 07AAF-TBAA200 cardiagn.com Capless Pick 07AAF-TBAA300 Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precaution
  • Page 1731. Break the six lock tabs (A). 2. Pry up the lock tab (B), then remove the mis-fuel inhibit device (C). NOTE: Never reuse the mis-fuel inhibit device. cardiagn.com 3. Main Flap Unit/Flow Guide Assembly - Remove (If Necessary) 1. Set the capless wrench and slightly turn the main flap unit/flow guide
  • Page 174cardiagn.com 2. Remove the capless wrench and install the capless flapper retainer onto the main flap unit/flow guide assembly (A) as shown to keep the flap open. 3. Insert the capless pick under the lock tab (A) and release the lock by turning the pick counterclockwise. NOTE: The lock tab is unlock
  • Page 175cardiagn.com 4. Set the capless wrench onto the main flap unit/flow guide assembly (A) as shown. NOTE: It may be necessary to move the flapper retainer slightly to install the capless wrench. 5. Turn the capless wrench clockwise until it stops, then remove it. NOTE: If the lock tab was disengaged pr
  • Page 176cardiagn.co
  • Page 177Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. Main Flap Unit/Flow Guide Assembly - Install (If Necessary) 1. Position the new main flap unit/flow guide assembly (A) onto the filler neck (B) with the top arrow (C) a
  • Page 178cardiagn.com 2. Mis-Fuel Inhibit Device - Install 1. Install the new mis-fuel inhibit device (A). NOTE: Confirm the lock tabs (B) are engaged. 3. Fuel Fill Door Adapter - Install
  • Page 179Mis-Fuel Inhibit Device Removal and Installation Special Tool Required Image Description/Tool Number Capless Wrench 07AAF-TBAA100 Capless Flapper Retainer 07AAF-TBAA200 cardiagn.com Capless Pick 07AAF-TBAA300 Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precaution
  • Page 1801. Break the six lock tabs (A). 2. Pry up the lock tab (B), then remove the mis-fuel inhibit device (C). NOTE: Never reuse the mis-fuel inhibit device. cardiagn.com 3. Main Flap Unit - Remove (If necessary) 1. Set the capless wrench and slightly turn the main flap unit (A) counterclockwise. NOTE: Th
  • Page 181cardiagn.com 2. Remove the capless wrench and install the flapper retainer onto the main flap unit (A) as shown to keep the flap open. 3. Insert the capless pick under the lock tab (A) and release the lock by turning the pick counterclockwise. NOTE: The lock tab is unlocked when it folds inside the
  • Page 182cardiagn.com 4. Set the capless wrench onto the main flap unit (A) as shown. NOTE: It may be necessary to move the flapper retainer slightly to install the capless wrench. 5. Turn the main flap unit clockwise until it stops, then remove it. NOTE: If the lock tab was disengaged properly, the main fla
  • Page 183cardiagn.co
  • Page 184Flammable - Keep Fire Away NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line. 1. Main Flap Unit - Install (If necessary) 1. Position the new main flap unit (A) onto the filler neck (B) with the top arrow (C) at the 1 o'clock position. cardiagn.com 2
  • Page 1852. Mis-Fuel Inhibit Device - Install cardiagn.com 1. Install the new mis-fuel inhibit device (A). 3. Fuel Fill Door Adapter - Install