Honda Civic Service Manual: Fuel Tank Removal and Installation (K24Z7)

1.

Remove the fuel fill cap to relieve the pressure in the fuel tank.

NOTE: For specific operations, refer to the user's manual that came with the Honda Diagnostic System (HDS). Make sure the HDS is loaded with the latest software.

1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.

2.

Turn the ignition switch to ON (II).

3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.

1.

Turn the ignition switch to ON (II).

2.

From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.

NOTE:

3.

Turn the ignition switch to LOCK (0).

1.

Remove the engine cover.

1.

Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode.

2.

Disconnect and isolate the negative cable with the battery sensor (A) from the battery.

NOTE:

3.

Disconnect the positive cable (D) from the battery.

1.

Remove the bracket (A).

2.

Remove the quick-connect fitting cover (A).

3.

Check the fuel quick-connect fitting for dirt, and clean it if needed.

4.

Place a rag or shop towel over the quick-connect fitting (A).

5.

Disconnect the quick-connect fitting: 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). Pull the connector off.

NOTE:

1.

Remove the bolt (A) securing the rear seat cushion (B).

2.

While pushing down the rear seat cushion (A), pull the seat hook handles (B) to release the hooks (C).

3.

Remove the rear seat cushion.

1.

Fold down the seat-back(s).

2.

Remove the front area of the trunk floor cover (A).

3.

Remove the trunk floor cover (A).

1.

Remove the right rear seat-back (A).

1.

Remove the center pivot bracket (A).

2.

If necessary, remove the bushing (B).

1.

Remove the bolt (A) securing the left rear seat-back (B).

2.

Extend the center seat belt (A), then remove the left rear seat-back (B).

1.

Remove the rear floor upper cross-member (A).

1.

Remove the access panel (A) from the floor.

2.

Disconnect the connector (B).

1.

Using the special tool, loosen the locknut (A).

2.

Remove the locknut (A).

3.

Remove the fuel tank unit (B).

1.

Using a hand pump, a hose, and a container suitable for fuel, drain the fuel from the fuel tank.

1.

Raise the vehicle on a lift, and make sure it is securely supported.

1.

Remove the left rear wheel.

1.

Remove the left floor undercover (A).

1.

Remove the bolts (A) securing the fuel tank baffle (B).

2.

Remove the rear floor under bar (A).

1.

Remove the fuel tank baffle plate (A).

2.

Remove the fuel tank protector (A).

New fuel tanks have a ring pull (A) at the fuel vapor hose connector (B). When you connect the hose and confirm that the connection is secure, remove the ring pull by pulling it down.

Before connecting the fuel fill pipe and the quick-connect fitting, check for dirt, and clean them if needed. Take care not to damage the fuel fill pipe or other parts.

5.

Install the fuel tank protector (A).

6.

Install the fuel tank baffle plate (A).

1.

Install the rear floor under bar (A).

2.

Install the bolts (A) securing the fuel tank baffle (B).

1.

Install the left floor undercover (A).

1.

Install the left rear wheel.

NOTE: Before installing the wheel, clean the mating surfaces between the brake disc or the brake drum and the inside of the wheel.

1.

Insert the fuel tank unit (A) into the fuel tank with a new O-ring (B).

2.

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

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

3.

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

NOTE: Before tightening, align the mark (B) on the locknut to the start of the thread (C).

NOTE: If the battery performs abnormally, test the battery.

1.

Clean the battery terminals.

2.

Connect the positive cable (A) to the battery.

NOTE: Always connect the positive side first.

3.

Connect the negative cable and the battery sensor (B) to the battery.

NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal.

4.

Apply multipurpose grease to the terminals to prevent corrosion.

1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.

2.

Turn the ignition switch to ON (II).

3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.

1.

From the INSPECTION MENU of the HDS, select Fuel Pump ON.

NOTE: Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.

2.

Turn the ignition switch to LOCK (0).

1.

Connect the connector (A).

2.

Install the access panel (B) to the floor.

1.

Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.

1.

Install the rear floor upper cross-member (A).

1.

Extend the center seat belt (A), then install the pivot shaft (B) to the center pivot bracket (C).

2.

Install the left rear seat-back (A).

1.

If necessary, install the bushing (A).

2.

Install the center pivot bracket (B).

1.

Install the right rear seat-back (A).

1.

Install the fuel fill cap.

1.

Install the trunk floor cover (A).

2.

Install the front area of the trunk floor cover (A).

3.

Raise the seat-back(s).

1.

Install the hooks (A) to the rear seat cushion clips (B).

2.

Install the bolt (A) securing the rear seat cushion (B).

1.

Install the engine cover.