Recall - Fuel Pump Connector Corrosion: Overview
01-060June 12, 2001
Applies To:
2001 Civic - From VIN 2HGES....1H500001 thru 2HGES....1H556387
Safety Recall: Civic Fuel Pump Connector
BACKGROUND
During inspection and installation of the fuel tank, water may have been left in the fuel pump connector on the top of the fuel filter. Over time, this water could corrode the terminals in the connector, causing the engine not to start or to stall while driving.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be mailed a notification of this recall. An example of the customer notification is shown in this service bulletin.
Some vehicles affected by this recall are still in dealer inventory. According to Federal law, those vehicles cannot be sold or leased until they are repaired.
Not all of the vehicles in the listed VIN range are affected by this campaign. Before beginning work, verify that vehicle is eligible by checking at least one of the following:
^ The customer has a notification letter.
^ The vehicle is shown on your campaign responsibility report.
^ The vehicle is shown as eligible on a VIN Status Inquiry on DCS.
CORRECTIVE ACTION
Inspect the connector for moisture or corrosion. If necessary, replace the fuel filter and any corroded terminals.
PARTS INFORMATION
Fuel Filter Kit: P/N 16010-S5A-999AH, H/C 6821094
REQUIRED SPECIAL TOOLS
Fuel Tank Assembly Wrench: 07XAA-001010A
WARRANTY CLAIM INFORMATION
Failed Part: P/N 16010-S5A-932
H/C 6655831
Defect Code: 927
Contention Code: L27
Skill Level: Repair Technician
INSPECTION PROCEDURE
1. Remove the rear seat cushion.
2. Remove the access panel from the rear floor.
3. Disconnect the fuel pump connector from the top of the fuel filter.
4. Use compressed air to check for moisture in the connector well. Carefully inspect the five terminals in the fuel filter and in the fuel pump connector for any corrosion.
^ If you find corrosion on any of the terminals or moisture in the connector well, go to REPAIR PROCEDURE.
^ If you find no corrosion or moisture, reinstall all removed parts and center-punch the VIN.
REPAIR PROCEDURE
1. Make sure you have the audio system anti-theft code (EX only). Write down the customer's radio station presets.
2. Remove the glove box stops and swing the glove box down.
3. Remove the PGM-FI main relay 2.
4. Start the engine. Let it idle until it stalls. Then turn the ignition switch to LOCK (0).
5. Remove the fuel fill cap.
6. Disconnect the negative cable from the battery.
7. Remove the mounting bracket and the quick disconnect covers from the fuel line quick disconnect on the engine compartment bulkhead.
8. Wrap a shop towel around the quick disconnect so you do not get sprayed with fuel.
9. Squeeze the tabs on the quick disconnect, then pull the halves apart. Use your hands only, do not use tools.
10. Disconnect the fuel line quick disconnect from the fuel filter.
11. Use the special tool to remove the fuel tank locknut.
12. Remove the fuel tank unit from the fuel tank.
13. Disconnect the three electrical connectors from the fuel filter.
14. Slide back the fuel pressure regulator to remove the fuel line connector from the case. Use a small screwdriver to disconnect the fuel line from the fuel pressure regulator.
15. Disconnect the other fuel line from the case.
16. Remove the fuel filter from the case.
17. Install the new fuel filter on the case. Make sure the arms snap into place and that the assembly pivots freely on the case. The arms are spring-loaded. Compressing and suddenly releasing an arm could cause it to come apart and be damaged. Do not compress the arms until the filter is installed on the case.
18. Install the fuel lines to the case and the fuel pressure regulator. Use new 0-rings from the kit.
19. Use a small screwdriver to slightly bend out the tang on the 1 P connector, then snap the connector into the fuel filter. Make sure it is locked in place.
20. Connect the remaining two electrical connectors to the fuel filter. Make sure the wires are routed under the clips on the case.
21. Reinstall the fuel tank unit with a new base gasket from the kit. Align the marks on the fuel tank unit with the marks on the fuel tank, then install the locknut. Torque the locknut to 93 N.m (69 lb-ft). Install the quick disconnect fitting from the kit on the fuel filter outlet tube.
22. Inspect the female terminals in the harness side fuel pump connector for corrosion.
^ If any terminals are corroded, go to step 23.
^ If the terminals are not corroded, go to step 28.
23. Use a small screwdriver to pry the blue plastic end piece off the connector.
24. Use a miniature screwdriver to release the lock tabs on the connector. Separate the halves of the connector.
25. Use the appropriate pin tool to remove the corroded terminal(s) from the connector.
26. Refer to service bulletin 00-099, Terminal Replacement Instructions, for the terminal replacement procedure.
NOTE:
The replacement terminals in the kit are not all the same size. Match the wire color of the terminal you are replacing to the markings on the plastic bags.
27. Reassemble the connector.
28. Reconnect the fuel pump connector and the quick disconnect for the fuel line. Reinstall the access cover.
29. Reconnect the quick disconnect for the fuel line under the hood. Reinstall the quick disconnect fitting covers.
30. Reinstall all other removed parts. Reconnect the battery negative cable.
31. Make sure all electrical items (audio system, heater, lights, etc.) are turned off. Start the engine. After the engine reaches normal operating temperature, let it idle for 10 minutes.
32. Turn off the engine. Enter the customer's radio station presets. Set the clock.
33. Center-punch a completion mark above the tenth character (1) of the engine compartment VIN.
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