Campaign - Fuel Tank Warranty Extension
11-068December 7, 2011
Applies To:
2006-11 Civic Hybrid - Check the iN VIN status for eligibility
Warranty Extension: Fuel Tank
(Supersedes 11-068, dated November 4, 2011, to revise the information marked by the asterisks)
*REVISION SUMMARY
^ Under BACKGROUND, PARTS INFORMATION, and WARRANTY CLAIM INFORMATION, notes were added.
^ Under REPAIR PROCEDURE, the 2006 model steps were revised to make the procedures common across all model years.*
BACKGROUND
On some 2006-11 Civic Hybrids, small cracks may develop where the fuel filler pipe joins the fuel tank. Customers may smell the gasoline vapors or, in rare cases, may see a small amount of gas spilled on the ground. To increase customer confidence, American Honda is extending the warranty on the fuel tank in affected vehicles to 10 years from the original date of purchase or 120,000 miles, whichever comes first.
*NOTE:
Do not do the diagnosis or replace the fuel tank unless the customer has seen or smelled a fuel leak.*
CUSTOMER NOTIFICATION
Owners of affected vehicles will receive a notification of this warranty extension. An example of the customer notification is included at the end of this service bulletin.
Before doing work on a vehicle, verify its eligibility by doing an iN VIN status inquiry.
CORRECTIVE ACTION
Do the diagnosis and, if needed, replace the fuel tank.
PARTS INFORMATION Fuel Tank Kit: P/N 06171-SNC-305
(Includes fuel tank, fuel tank unit locknut, locknut plate, base gasket, two circlips, two fender clips, and five various fuel pipe retainers)
*NOTE:
For collision damage, use Fuel Tank Set, P/N 17044-SNC-L01. It has the same updated fuel tank as the kit above.*
TOOL INFORMATION
Fuel Pump/Fuel Gauge Sending Unit Lock Nut
Wrench: T/N 07AAA-SNAA100
WARRANTY CLAIM INFORMATION
Operation Number: 3101Q4
Flat Rate Time: 1.3 hours
Failed Part: P/N 17044-SNC-L00
Defect Code: 6T100
Symptom Code: R9700
Skill Level: Repair Technician
*NOTE:
Do not submit a warranty claim for this campaign unless a leaking fuel tank has been confirmed and replaced.*
DIAGNOSIS
Raise the vehicle on a lift, and check if there is any evidence of fuel leaks in the area where the fuel tank meets the fuel filler pipe.
^ If there is any evidence of fuel leaks, go to the REPAIR PROCEDURE.
^ If there is no evidence of fuel leaks, continue with normal troubleshooting.
REPAIR PROCEDURE
NOTE:
This procedure is in an outline form that you can also use as a checklist for the repair. If you need more details on the procedures listed below, bookmark them in the appropriate service manual, or view them online:
^ 12 Volt Battery Terminal Disconnection and Reconnection
^ Air Cleaner Removal/Installation
^ Fuel Line/Quick-Connect Fitting Installation
^ Fuel Tank Unit Removal and Installation
1. Remove the fuel cap to relieve the pressure in the fuel tank.
2. Connect the HDS to the DLC.
3. Turn the ignition switch to ON (II).
4. From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.
NOTE:
Do not allow the engine to idle above 1,000 RPM or the PCM will continue to operate the fuel pump.
^ Pending and Confirmed DTCs may be set during this procedure. Check for DTCs, and clear them as needed.
5. Turn the ignition switch to LOCK (0).
6. Do the battery terminal disconnection procedure.
7. Remove the air cleaner, then remove the cover and the quick connect fitting cover.
8. Disconnect the fuel pipe.
Check the fuel quick connect fitting for dirt, and clean it if needed.
Place a rag or shop towel over the quick-connect fitting.
^ Disconnect the quick-connect fitting:
- Hold the connector with one hand, and squeeze the retainer tabs with the other hand to release them from the locking tabs.
- Pull the connector off. If the connector does not release, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.
- After disconnecting the quick-connect fitting, check it for dirt or damage.
9. Raise the vehicle on a lift.
10. Remove the fuel tank cover and the EVAP canister guard pipe.
11. Disconnect the fuel tank unit subharness 4P connector and the quick-connect fittings.
12. Remove the fuel tank:
^ Support the fuel tank by placing a jack or a similar support under it, and secure the tank to the jack with a winch strap.
^ Remove the strap bolts and the fuel tank straps.
^ Remove the fuel tank.
13. Transfer the fuel tank unit to the replacement tank:
^ Remove the fuel feed pipe and the fuel vent pipe from the fuel tank unit.
^ Remove the fuel tank unit.
^ Install the fuel tank unit in the replacement fuel tank with a new base gasket, a new locknut, and a new locknut plate. Torque the locknut to 120 N.m (88 lb-ft).
NOTE:
To prevent a fuel leak, check the base gasket, visually or with your hand, to make sure it is not pinched.
Reinstall the fuel feed pipe and the fuel vent pipe on the fuel tank unit with new retainers.
14. Lift the tank into position, and reinstall the straps and strap bolts. Torque the strap bolts to 38 N.m (28 lb-ft).
15. Reconnect the fuel tank unit subharness, and reconnect the quick-disconnect fittings with new retainers.
16. Reinstall the EVAP canister guard pipe, and torque the bolts to 22 N.m (16 lb-ft).
17. Reinstall the fuel tank cover with the new circlips supplied in the kit.
18. Lower the vehicle.
19. Reinstall the fuel cap.
20. Reconnect the quick-connect fittings using a new retainer, then reinstall the quick-connect fitting cover, the cover [torque bolts to 9.8 N.m (7.2 lb-ft)], and the air cleaner.
21. Do the battery terminal reconnection procedure.
22. Fill the fuel tank with the fuel from the old tank.
23. From the INSPECTION MENU of the HDS, select fuel pump ON.
24. Check for, and clear any DTCs that set when you relieved the fuel pressure.
25. Start the engine, and check for any fuel leaks.
Disclaimer