Honda HR-V: Secondary Fuel Gauge Sending Unit Removal and Installation (AWD)

Special Tools Required

Fuel Nut Wrench 07AAAT0AA100

Removal

1. Fuel Pressure - Relieve

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

3. Rear Heater Duct (Right Side) - Remove

4. Access Panel - Remove

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

5. Secondary Fuel Gauge Sending Unit - Remove

1. Using the fuel nut wrench, loosen the secondary fuel gauge sending unit lock nut (A).

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

Installation

1. Secondary Fuel Gauge Sending Unit - Temporarily Insert

1. Attach a new base gasket (A) to the secondary fuel gauge sending 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 secondary fuel gauge sending 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. Secondary Fuel Gauge Sending Unit - Align

1. Align the marks (A) on the fuel tank and secondary fuel gauge sending unit, then insert the secondary fuel gauge sending 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. Secondary Fuel Gauge Sending Unit - Install

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

4. Secondary Fuel Gauge Sending Unit Locknut - Tighten

Fig. 10: Secondary Fuel Gauge Sending 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.

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 (Right Side) - Install

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

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