Honda HR-V: Fuel Tank Unit Removal and Installation (2WD)

Special Tools Required

Fuel Sender Wrench 07AAAS0XA100

Removal

NOTE: Unless otherwise indicated, illustrations used in the procedure are for USA and Canada models

1. Fuel Pressure - Relieve

2. Center Console - Remove

3. Shift Lever - Remove

NOTE: The shift cable is attached to the shift lever.

• M/T: Remove the shift lever housing
• CVT: Remove the shift lever

4. Access Panel - Remove

1. Remove the access panel (A) from the floor
2. Disconnect the connector (B).

5. Fuel Tank Unit Locknut - Loosen

USA and Canada models

1. Disconnect the quick-connect fittings (A) from the fuel tank unit.
2. Using the fuel sender wrench, loosen the fuel tank unit locknut (B).

Mexico models

1. Disconnect the quick-connect fitting (A) from the fuel tank unit.
2. Disconnect the hoses (B).
3. Using the fuel sender wrench, loosen the fuel tank unit locknut (C).

6. Fuel Tank Unit - Remove

USA and Canada models

Mexico models

1. Remove the locknut (A), then remove the fuel tank unit (B).

   NOTE: Be careful not to bend or twist the fuel level sensor arm (C) excessively.

Installation

1. Fuel Tank Unit - Temporarily Insert

Insert the fuel tank unit (A) partially into the fuel tank with a new base gasket (B).

• Be careful not to damage the new base gasket.
• Be careful not to bend or twist the fuel level sensor arm (C) excessively.
• Do not coat the base gasket with oil.

2. Fuel Tank Unit - Align

USA and Canada models

Mexico models

Align the marks (A) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank.

NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.

3. Fuel Tank Unit - Install

USA and Canada models

1. Tighten a new locknut (A) with a new locknut plate (B) by hand holding the fuel tank unit vertically.

Mexico models

1. Tighten a new locknut (A) by hand holding the fuel tank unit vertically.

4. Fuel Tank Unit Locknut - Tighten

Fig. 7: Fuel Tank Unit Locknut With Torque Specifications (USA and Canada models)

USA and Canada models

1. Using the fuel sender wrench, tighten the locknut to the specified torque.
   NOTE:
   • After tightening, make sure the marks (A) are still aligned.
   • After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
2. Connect the quick-connect fittings to the fuel tank unit.

Fig. 8: Fuel Tank Unit Locknut With Torque Specifications (Mexico models)

Mexico models

1. Using the fuel sender wrench, tighten the locknut to the specified torque.
   NOTE:
   • After tightening, make sure the marks (A) are still aligned.
   • After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
2. Connect the quick-connect fitting to the fuel tank unit.
3. Connect the hoses (B).

5. Fuel Leak - Check

1. Connect the connector (A)
2. 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.

6. Access Panel - Install

1. Install the access panel (A).

7. Shift Lever - Install

• M/T: Install the shift lever housing
• CVT: Install the shift lever

8. Center Console - Install

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