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

Special Tools Required

Fuel Nut Wrench 07AAAT0AA100

Removal

1. Fuel Pressure - Relieve

2. Front Seat (Driver's Side) - Remove

3. Rear Heater Duct (Left Side) - Remove

4. Access Panel - Remove

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

5. Fuel Tank Unit Locknut - Loosen

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

6. Fuel Tank Unit - Remove

1. Remove the locknut (A)
2. Disconnect the transfer tube (B), then remove the fuel tank unit (C).
   NOTE: Be careful not to bend or twist the fuel level sensor arm (D) excessively.

Installation

1. Fuel Tank Unit - Temporarily Insert

1. Attach a new base gasket (A) to the fuel tank unit (B), connect the transfer tube (C).
   • Be careful not to damage the new base gasket.
   • Make sure the clamp (D) is positioned as shown.
2. Insert the fuel tank unit partially into the fuel tank with a new base gasket.
   • Be careful not to bend or twist the fuel level sensor arm (E) excessively.
   • Do not coat the base gasket with oil.

2. Fuel Tank Unit - Align

1. 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

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

4. Fuel Tank Unit Locknut - Tighten

Fig. 9: Fuel Tank Unit Locknut With Torque Specifications

1. Using the fuel nut 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 (B) to the fuel tank unit.

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
3. Install the access panel (B).

6. Rear Heater Duct (Left Side) - Install

7. Front Seat (Driver's Side) - Install

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