Honda - HR-V - Workshop Manual - 2019 - 2019

Service Bulletin July 30, 2021 21-024 Version 2 Safety Recall: 2019 HR-V (2WD) Fuel Pump Motor Supersedes 20-024, dated May 11, 2021, to revise the information highlighted in yellow AFFECTED VEHICLES Year Model Trim Level VIN Range 2019 HR-V (2WD) ALL Check the iN VIN status for eligibility. REVISION SUMMARY Under REPAIR PROCEDURE, steps 26, 36, 37, 38, 39, and 45 were revised. BACKGROUND Due to swelling of the fuel pump motor impeller, the fuel pump may seize and stop working. If this occurs, the check engine light may be displayed with DTC P0087 (Fuel Rail Pressure Too Low) stored, the engine may not start, or the engine could stall while driving, increasing the risk of a crash. This service bulletin is only for the HRV-2WD. If working on an HR-V AWD, go to service bulletin 21-025, Safety Recall: 2019 HR-V (AWD) Fuel Pump Motor. CUSTOMER NOTIFICATION Owners of affected vehicles will be sent a notification of this campaign. Do an iN VIN status inquiry to make sure the vehicle is shown as eligible. Failure to repair a vehicle subject to a recall or campaign may subject your dealership to claims or lawsuits from the customer or anyone else harmed as a result of such failure. To see if a vehicle in inventory is affected by this safety recall, do a VIN status inquiry before selling it. CORRECTIVE ACTION Replace the fuel pump motor. NOTE: If the vehicle has any of the symptoms listed in BACKGROUND, you must apply this bulletin before attempting any other repairs. If the symptoms remain after the recall repair is complete, only attempt further repairs (such as replacing the high pressure fuel pump) after authorized troubleshooting. CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Honda automobile dealer. © 2021 American Honda Motor Co., Inc. – All Rights Reserved Page 1 of 28 PARTS INFORMATION NOTE: Due to limited supply, this is a controlled part and will require a valid VIN when ordering. Part Name Part Number Quantity Fuel Pump Motor Kit 06170-TRN-305 1 Shift Knob Screws (CVT Only) 54903-SYA-981 2 For dealers experiencing a strong fuel smell from storing a fuel pump motor replaced under this service bulletin, the fuel pump motor may be disposed of immediately in accordance with local regulations. This only applies to the fuel pump motor replaced under this service bulletin. The published retention policy remains in effect for all other parts. If you have any questions about this exception or other parts retention issues, contact the WPI Administrative Office at 937-642-2737. TOOL INFORMATION Tool Name Part Number Quantity Fuel Nut Wrench (Fuel Sender Wrench) 07AAA-S0XA100 1 Fuel Module Separator Set 07AAF-T5RA100 1 WARRANTY CLAIM INFORMATION Operation Number Description Flat Rate Time Defect Code Symptom Code Template ID Failed Part Number 3101HK Replace the fuel pump motor. 1.7 hr 6FE00 YAB00 A21024A 17045-T7W-A00 Skill Level: Repair Technician REPAIR PROCEDURE ⚠ WARNING Fuel pump motor removal exposes fuel, which can ignite, causing a fire or explosion. This can cause serious injury or death. Always work in a well-ventilated area, and keep sparks or open flames away. 1. Remove the fuel fill cap to relieve the pressure in the fuel tank. 2. Remove the PGM-FI main relay 2 from the under-dash fuse/relay box. Page 2 of 28 3. Start the engine, and let it idle until it stalls. 4. Turn the ignition to OFF. 5. Install the PGM-FI main relay 2. 6. Disconnect both 12-volt battery terminals. NOTICE To protect the terminal connector from damage, do not hold it when removing the negative terminal. NOTE: • Always disconnect the negative terminal first. • Do not disconnect the 12-volt battery sensor from the cable. 7. Remove the passenger’s dashboard undercover. Page 3 of 28 8. Remove the shift lever knob. CVT Models NOTICE Do not remove the special grease applied to the end of the shift lever. M/T Models Lower the shift lever boot to release the hooks from the boot. Then, remove the shift lever knob. Page 4 of 28 9. Remove the center console switch trim, and disconnect the connector. 10. Remove the center console panel. 11. For some models: Disconnect the connectors. Page 5 of 28 12. Remove the center console pad by removing bolts A, and loosening bolts B. 13. Disconnect the connector and remove the harness clip. NOTE: Make sure not to drop the bolts when loosening them. 14. Remove the center console pad, and disengage the brackets from the bolts. Page 6 of 28 15. Remove the center console rear trim, and disconnect the connector. 16. Remove the console front mat. 17. Remove the console middle cover. Page 7 of 28 18. Remove the console box mat. 19. Remove the bolts, clips, and the harness clip. 20. Remove the center console. Page 8 of 28 21. M/T Models Only: Remove the shift lever housing. NOTE: The shift cable is attached to the shift lever. • • Remove the spring pin and washer. Do not lose them, they will be reused for installation. Remove the shift lever housing bolts. • Unlock the retainer lock. • Rotate the socket holder retainer counterclockwise until it stops, then push the retainer lock into the socket holder retainer to lock the retainer. Slide the socket holder and change wire out of the shift lever housing. • NOTE: o Do not remove the change wire by pulling the change wire guide. o Do not bend the change wire excessively. Page 9 of 28 • Remove the clip. • Disconnect the shift cable from the shift lever. 22. CVT Models Only: Remove the shift lever. NOTE: The shift cable is attached to the shift lever. • Shift to Reverse by pushing down the shift lock release, then moving the shift lever to R. Page 10 of 28 • Insert a 6 mm (0.236 in) pin with no burrs into the positioning holes. • Remove the shift cable end nut. • Expand the lock tab. Page 11 of 28 • Rotate the socket holder retainer counterclockwise until it stops, then remove the shift cable. NOTE: Do not remove the shift cable by pulling the shift cable guide. • Remove the shift cable end. • Disconnect the connectors. Page 12 of 28 • Remove the harness clamps. • Remove the shift lever assembly. Page 13 of 28 23. Remove the fuel tank unit access panel, and disconnect the connector. 24. Place a rag or shop towel over the quick-connect fitting and hoses, and disconnect them. 25. Loosen the fuel tank unit locknut using the Fuel Sender Wrench (T/N 07AAA-S0XA100). Page 14 of 28 26. Remove the fuel tank unit locknut, then remove the fuel tank unit. NOTE: • After unlocking the fuel tank unit cam lock ring, clean the top of the fuel pump flange and adjacent areas to make sure it's free of dirt, dust, and debris. • Do not bend or twist the fuel level sensor arm excessively. This may damage the fuel level sensor or cause it to send inaccurate readings. 27. Prepare the fuel tank unit and parts to be replaced. NOTE: Take a photo of the fuel tube and wire harness, and note their routing for assembly. There are various types of routing. Page 15 of 28 28. Spread the wire harness clamps, and remove the wire harness. Make sure not to damage the wire harness. NOTICE Do not spread the clamps too wide. Spreading them too wide may damage them. 29. Press the tab on the fuel level sensor to release the lock. Then, push up on the fuel level sensor. 30. Remove the fuel level sensor from the fuel tank unit. Page 16 of 28 31. Remove the E-rings and discard them. 32. Disconnect the joint at the bottom of the reservoir. Page 17 of 28 33. Remove the fuel filter assembly from the reservoir by releasing the three clips. NOTICE Do not spread the clips too wide. Spreading them too wide may damage them. NOTE: • Use the fuel module separator on two of the clips. • The spring may slide off the sliding shaft. Retain this spring. It will be used during assembly. Page 18 of 28 34. Release the three clips at the base of the fuel pump assembly. 35. Pull the fuel pump assembly out of the fuel filter. 36. Install the new spacer on the new fuel pump motor. Page 19 of 28 37. Install the new O-ring, then lubricate the outside edge of it, using only clean engine oil. NOTE: Do not pinch the O-ring during installation. 38. Install the new harness and make sure the connection is secure and the connectors are firmly locked into place. 39. Place the fuel pump on a bench, then install the filter to the fuel pump. NOTE: If the fuel pump does not engage into the fuel filter and re-insertion is necessary, confirm that the O-ring is seated on the fuel pump before repeating installation. Page 20 of 28 40. Install the fuel filter assembly to the reservoir. NOTE: • Install the spring onto the sliding shaft, and make sure it is lined up when installing the fuel filter. • Make sure the fuel tube is routed exactly as shown in the photo taken before disassembly. • Make sure the three clips are fully engaged. 41. Install the new E-rings. NOTE: After installation, make sure the E-rings can be rotated with your finger. If they cannot be rotated, the E-rings may not be fully seated or may be incorrectly installed. 42. Install the fuel level sensor to the reservoir. Make sure the lock is engaged and the connection is secure. NOTICE Do not bend or twist the fuel level sensor arm excessively. This may damage the fuel level sensor or cause it to send inaccurate readings. Page 21 of 28 43. Install the wiring harness to the clamps. NOTICE Do not spread the clamps too wide. Spreading them too wide may damage them. NOTE: • Clip in the smaller harness wires followed by the larger wires. • Make sure not to damage the wire harness. • Make sure to route the wire harness exactly as shown in the photo taken before disassembly. Page 22 of 28 44. While compressing the fuel tank unit, make sure the movement is smooth and the fuel tube and wiring harness do not stretch, pinch, or bind. 45. Partially insert the fuel tank unit into the fuel tank with a new base gasket. NOTICE Do not bend or twist the fuel level sensor arm excessively. This may damage the fuel level sensor or cause it to send inaccurate readings. NOTE: • Before installing the new O-ring, clean the fuel tank around the fuel pump opening where the O-ring will seat. The tank opening must be free of dirt, dust, and debris. • Be careful not to damage the O-ring. • Do not coat the O-ring with any oil. Page 23 of 28 46. Line up the marks on the fuel tank and fuel tank unit as shown, then insert the fuel tank unit. NOTE: To avoid a fuel leak, make sure the base gasket is not pinched. 47. Hold the fuel tank unit vertically, and tighten the new fuel tank unit locknut with a new locknut plate by hand. 48. Tighten the fuel tank unit locknut to the specified torque using the fuel sender wrench. NOTICE If the locknut is not properly installed, the fuel tank can be damaged and will require replacement. NOTE: • After tightening, make sure the marks are still lined up. • To avoid a fuel leak, make sure the base gasket is not pinched. Page 24 of 28 49. If the marks do not line up, friction between the fuel tank unit and the locknut may cause the fuel tank unit to turn while tightening. Observe the difference (shaded area), and loosen the locknut until the fuel tank unit can be rotated. Rotate the fuel tank unit counter-clockwise by the same amount, and repeat the tightening process. NOTE: Repeat this step as necessary until the marks are lined up when the locknut is tightened to the specified torque. 50. Remove the quick-connect fitting retainers on the fuel tank unit, then install the new retainers to the quick-connect fittings as shown. 51. Connect the quick-connect fittings to the fuel tank unit. Page 25 of 28 52. Connect the fuel tank unit connector. 53. Connect the 12-volt battery terminals. 54. Check for fuel leaks by turning the ignition to ON, but do not turn the engine on. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then make sure there is no fuel leakage. 55. Install the fuel tank unit access panel. Page 26 of 28 56. Install the remaining parts in the reverse order of removal. NOTE: • CVT Models Only: Replace the two screws when installing the shift knob. • M/T Models Only: Inspect the spring pin that secures the shift wire to the shifter. If the spring pin is damaged or does not secure the shift wire, replace it. 57. Clear all DTCs using an i-HDS. Page 27 of 28 58. California residents only: Fill out a Vehicle Emissions Recall – Proof of Correction certificate, and use YAB as the recall number. Have the service advisor give the certificate to your customer, and advise him or her to keep it as proof that the recall was completed. Your customer will need to submit this certificate to the DMV only if the DMV requests it. If you need more certificates, use reorder number Y0657. END Page 28 of 28