Pump HONDA CIVIC 2002 7.G Service Manual

FuelSupply System
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10.
1'].
Fuel Pump Circuit Troubleshooting (cont'dl
Reinstallthe PGM-Fl main relay 2.
Turn the ignition switch ON (ll).
Measure voltage between ECI\4/PCM connector
terminal E1 and body ground.
ECM CONNECTOB E {31P)
ls there battety voltage?
YES Go to step 12.
NO-Replace the PGM-Fl main relay 2.1
Turn the ignition switch OFF.
Reconnecl ECM connector E (31P).
Turn the ignition switch ON (ll), and measure
voltage between ECM connector terminal E1 and
body ground within the first 2 seconds after the
ignition switch was turned ON (ll).
ECM CONNECTOR E (31PI
13.
14.
Wire side of female terminals
Wire side of female terminals
11-142
t5.
to.
11.
18.
ls there battery voltage?
YES U pdate the ECM if it does not have the latest
so{1ware, or substitute a known-good ECM. then
recheck (see page 1 1-6). lf the symptom/indication
goes away with a known-good ECM, replace the
original ECM.I
NO Go to step 15.
Turn the ignition switch OFF.
Remove the rear seat cushion (see page 20-80).
Remove the access panel from the floor.
Measure voltage between fuel pump 5P connector
terminal No. 5 and body ground within the first 2
seconds after the ignition switch was turned ON (ll).
FUEL PUMP 5P CONNECTOR
wire side oI female terminals
ls there battery voltage?
YES Go to step 24.
NO-Go to step 19.
Turn the ignition switch OFF.
Remove the PGM-Fl main relay 2.
19.
20.

21. Connect PGM-Fl main relay 2 5P connector
terminals No. 1 and No. 2 with a iumDer wire.
PGM.FI MAIN RELAY 25P CONNECTOR
FUELPUMP(YEL/GRN)JUMPERWIRE
22.
23.
Wire side of {emale terminals
Turn the ignition switch ON (ll).
Measure voltage between fuel pump 5P connector
terminal No. 5 and body ground.
FUEL PUMP 5P CONNECTOR
Wire side ol female terminals
ls there battery voltage?
YES Replacethe PGM-Fl main relay2.t
NO-Repair open in the wire between the PGM-Fl
main relay 2 and the fuel pump 5P connector.l
Turn the ignition switch OFF.24.
FNI E
tri dffircr fv{YEL/BLK)
A
25. Check for continuity between fuel pump 5P
connector terminal No. 4 and body ground.
FUEL PUMP 5P CONNECTOR
Wire side of female terminals
ls there continuity?
YES Replace the fuel pump.l
NO-Repair open in the wire between the fuel
pump 5P connector and G551.1
11-143

Fuel Pressure Test
Special Tools Required. Fuel pressure gauge 07406-0040004. Fuel pressure gauge sel 07ZAJ-S5A0100
1. Relieve the fuel pressure (see page 1'1-144).
2. Disconnect the quick-connect fitting (A). Aftach the
fuel pressure gauge set and fuel pressure gauge.
Start the engine and let it idle.
. lf the engine starts, goto step 5.. lf the engine does not start, goto step 4.
Check to see if the fuel pump is running: listen to
the fuel fill port with the fuel fill cap removed. The
fuel pump should run for 2 seconds when the
ignition switch is first turned on.
. lf the pump runs, go to step 5.. lf the pump does not run, do the fuel pump circuit
troubleshooting (see page 1 1-1 41 ).
Read the pressure gauge. The pressure should be
320-370 kpa (3.3-3.8 kgf/cm', a7-52 psi)
. lf the pressure is OK, the test is complete.. lf the pressure is out of specification, replace the
fuel pressure regulator and the fuel filter (see
page 11-152), then recheck the fuel pressure.
5.
11-145

Fuel Supply System
Fuel Line/Ouick-Connect Fittings Precaution
The fuel tube/quick-connect fittings connect the fuel rail(A)to fuel feed hose (B), the fuel feed hose (B) to the
fuel line (C), and the fueltube (D) to the fuel pump
assembly (E). When removing or installing the fuelfeed
hose, fuel pump assembly, or fuel tank, it is necessary
to disconnect or connect the quick-connect fittings.
Pay attention to the following:
. The fuel feed hose (B), fuel tube (D), and quick-
connect fittings (F) are not heat-resistanU be careful
not to damage them during welding or other heat-
generalrng proceoures.
. The fuelfeed hose (B), fueltube (D) andquick-
connect fittings (F) are not acid-proof; do not touch
them with a shop towel which was used for wiping
battery electrolyte. Replace them if they came into
contact with electrolyte or something similar.
. When connecting or disconnecting the fuel feed hose(B), fuel tube (D), and quick'connect fittings (F). be
careful not to bend or twist them excessivelv. ReDlace
them it they are damaged.
11-148
A disconnected quick-connect fitting can be
reconnected, but the retainer on the mating line cannot
be reused once it has been removed from the line.
Replace the retainer when
. replacing the fuel rail.. replacing the fuel line.. replacing the fuel pump.
. replacing the fuel filter,. replacing the fuel gauge sending unit.. it has been removed from the line.. it is damaged.
PARTI\4ANUFACTUREBRETAINER
COLOR
E NG INE
COI\4PARTMENT(FUEL FEED
HOSE; FU EL
LINE SIDE)
TOKAIGREEN
EN G INE
COIVIPARTMENT(FUEL FEED
HOSE: FUEL
RAIL SIDE)
TOKAIBLU
FUEL TANK
UNIT
SANOHWHITE
I

2.
Fuel Line/Ouick-Gonnect Fittings Removal
1. Relieve fuel pressure (see page 1'l-144).
Check the fuel quick-connect fiftings for din, and
clean if necessary.
Hold the connector (A) with one hand and squeeze
the retainertabs (B)with the other hand to release
them from the locking paws (C). Pull the connector
off.
NOTE:. Be careful not to damage the line iD) or other
parts. Do not use tools.. lf the connectordoes not move, keep the retainer
tabs pressed down, and alternately pull and push
the connector until it comes off easily.. Do not remove the retainer from the line; once
removed, the retainer must be replaced with a
new one.
4. C heck the contact a rea (A) of the line (B)for dirt and
da mage.
. lf the surface is dirty, clean it.. if the surface is rusty or damaged, replace the
fuel pump, fuelfilter, fuelfeed line.
=k
To prevent damaged and keep foreign matter out,
cover the disconnected connector and line end with
plastic bags (A).
NOTE:. The retainer cannot be reused once it has been
removed from the line.
Replaced the retainer when- replacing the fuel rail.- replacing the fuel feed Iine.
- replacing the fuel pumP.
- replacing the fuel filter.- replacing the fuel gauge sending unit
- it has been removed from the line.
- it is damaged.
11-149

Fuel Supply System
Fuel Line/Ouick-Connect Fittings lnstallation
1. Check the contact a rea (A) of the line (B) for dirt and
damage, and clean if necessary.
Insert a new retainer (A) into the connector (B) if the
retainer is damaged, or after. replacing the fuel rail.. replacing the fuelfeed line.. replacing the fuel pump.. replacing the fuel filter.. replacing the fuel gauge sending unit. removing the retainer from the line.
11-150
3. Before connecting a new fueltube/quick-connect
fitting assembly (A), remove the old retainer from
the matino line,

4. Align the quick-connect fittings with the line (A).
and align the retainer (B) locking pawls with the
connector {C) grooves. Then press the quick-
connect fittings onto the line until both retainer
pawls lock with a clicking sound.
NOTE; lf it is hard to connect, put a small amount of
new engine oil on the line end.
Connection with new retainer:
Reconnection to existing retainer:
5. lvlake sure the connection is secure and that the
pawls are firmly locked into place; check visually
and by pulling the connector.
6. Reconnectthe negative cable to the battery, and
turn the ignition switch ON (ll). The fuel pump will
run for about 2 seconds, and fuel pressure will rise
Repeat 2 or 3 times, and check that there are no
fuel leaks.
11-151

Fuel Supply System
{Fuel Pressure Regulator
Replacement
Remove the fuel pump (see page 1 1-153).
Remove the fuel pressure regulator (A).
Installthe part in the reverse order of removal witha new o-ring (B).
1.
2.
11-152
Fuel Filter Replacement
The fuel filter should be replaced whenever the fuelpressure drops belowthe specified value {270 320 kpa,2.8 3.3 kgf lcm', 40 47 psi), after making sure that thefuel pump and the fuel pressure regulator are OK.
1. Remove the fuel pump(seepagell-'153).
2. Remove the
Install in the reverse order of removalwith a new
base gasket (B) and a new o-ring (C), then check
these items:
' When connecting the wire harness, make sure
the connection is secure and the terminal (D) is
firmly locked into place.. When installing the fuel gauge sending unit iE),make sure the connection is secure and the
connector is firmly locked into place. Be carefulnot to bend or twist it excessively.
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fuel filter (A).
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Fuel Pump/Fuel Gauge Sending Unit Replacement
SpecialTools Required
Fuel sender wrench 07XAA-001010A
1.Relieve the fuel pressure (see page 11-144).
Remove the fuel fill cap.
Remove the seat cushion (see page 20-80).
Remove the access panel (A)from the floor.
5.
7.
Disconnect the fuel pump 5P connector (B).
Disconnect the quick-connect fitting {C) from the
fuel tank unit.
Using the special tool, loosen the fuel tank unit
locknut (A).
93 N.m19.5 kgf.m,69 lbf.ftl
11-153
8. Remove the locknut (A) andthefuel tankunit.
9. Remove the stopper {O). Release the hook (P) and
remove the fuel filter (B), the fuel gauge sending
unit (C). the case (D), the wire harness (E), and the
fuel pressure regulator (F).
10. When connecting the fuel tank unit, make sure the
connection is secure and the suction filter (G) is
firmly connected to the f uel pump (H).
11. Install the fuel tank unit in the reverse order of
removal with a new base gasket (l)and new o-rings
(J), then check these items:
. When connecting the wire harness, make sure
the connection is secure and the connector (K) is
firmly locked into the place.
. When installing the f uel gauge sending unit,
make sure the connection is secure and the
connector is firmly locked into place. Be careful
not to bend or twist the connector excessively.. When installing the fueltank unit, align the marks
(L) on the fuel tank (M) and the fuel tank unit (Ni

Fuel Tank Replacement
Relievethefuel pressure (see page 11-144).
Drain the fuel tank: Remove the fuel pump (see page 1 1-153). Using a hand pump, hose, and container suitable for
gasoline. draw the fuel from the fuel tank.
Jack up the vehicle, and suppon it with safety stands.
Remove the fuel pipe cover (A). Disconnect the fuel vapor hose and quick-connect fittings.
Disconnect the hoses. Slide back the clamps (B), then twist the hoses as you pull to avoid damaging them.
A 38 N.m(3.9 ksf.m,28lbfft)
5. Place a jack or other support under the tank.
6. Removethe strap bolts, and letthestrap (C) hangfree.
7. Remove the fuel tank (D). lf itstickstothe undercoaton its mount, carefully pry itoffthe mount
8. Install the parts in the reverse order of removal.
1.
2.
3.
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11-155