Service Bulletin 11-068
Applies To: 2006–11 Civic Hybrid – Check the iN VIN status for eligibility November 4, 2011
Warranty Extension: Fuel Tank
BACKGROUND DIAGNOSIS
On some 2006–11 Civic Hybrids, small cracks may Raise the vehicle on a lift, and check if there is any
develop where the fuel filler pipe joins the fuel tank. evidence of fuel leaks in the area where the fuel tank
Customers may smell the gasoline vapors or, in rare meets the fuel filler pipe.
cases, may see a small amount of gas spilled on the • If there is any evidence of fuel leaks, go to the
ground. To increase customer confidence, American REPAIR PROCEDURE.
Honda is extending the warranty on the fuel tank in
affected vehicles to 10 years from the original date of • If there is no evidence of fuel leaks, continue with
purchase or 120,000 miles, whichever comes first. normal troubleshooting.
CUSTOMER NOTIFICATION REPAIR PROCEDURE
Owners of affected vehicles will receive a notification of NOTE: This procedure is in an outline form that you
this warranty extension. An example of the customer can also use as a checklist for the repair. If you need
notification is included at the end of this service more details on the procedures listed below, bookmark
bulletin. them in the appropriate service manual, or view them
online:
Before doing work on a vehicle, verify its eligibility by • 12 Volt Battery Terminal Disconnection and
doing an iN VIN status inquiry.
Reconnection
• Air Cleaner Removal/Installation
CORRECTIVE ACTION
• Fuel Line/Quick-Connect Fitting Installation
Do the diagnosis and, if needed, replace the fuel tank.
• Fuel Tank Unit Removal and Installation
PARTS INFORMATION 1. Remove the fuel cap to relieve the pressure in the
fuel tank.
Fuel Tank Kit: P/N 06171-SNC-305
(Includes fuel tank, fuel tank unit locknut, locknut 2. Connect the HDS to the DLC.
plate, base gasket, two circlips, two fender clips, and 3. Turn the ignition switch to ON (II).
five various fuel pipe retainers)
4. From the INSPECTION MENU of the HDS, select
Fuel Pump OFF, then start the engine, and let it idle
TOOL INFORMATION until it stalls.
Fuel Pump/Fuel Gauge Sending Unit Lock Nut
NOTE:
Wrench: T/N 07AAA-SNAA100
• Do not allow the engine to idle above 1,000 RPM
or the PCM will continue to operate the fuel
WARRANTY CLAIM INFORMATION pump.
Operation Number: 3101Q4 • Pending and Confirmed DTCs may be set during
Flat Rate Time: 1.3 hours this procedure. Check for DTCs, and clear them
as needed.
Failed Part: P/N 17044-SNC-L00
5. Turn the ignition switch to LOCK (0).
Defect Code: 5T100
Symptom Code: R9700 6. Do the battery terminal disconnection procedure.
Skill Level: Repair Technician
© 2011 American Honda Motor Co., Inc. – All Rights Reserved ATB 47282 (1111) 1 of 5
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.
7. 2006 Models: Place a rag or shop towel over the 9. 2007–11 Models: Disconnect the fuel pipe.
fuel pipe, then loosen the bolt. • Check the fuel quick connect fitting for dirt, and
clean it if needed.
• Place a rag or shop towel over the quick-connect
fitting.
FUEL PIPE
BOLT
12.8 N.m (9.4 lb-ft)
8. 2007–11 Models: Remove the air cleaner, then
remove the cover and the quick-connect fitting
cover. QUICK-CONNECT
FITTING
• Disconnect the quick-connect fitting:
QUICK-CONNECT
FITTING COVER - Hold the connector with one hand, and
squeeze the retainer tabs with the other hand
to release them from the locking tabs.
9.8 N·m - Pull the connector off. If the connector does
(7.2 lb·ft) 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.
COVER
LOCKING TABS
RETAINER
TABS
QUICK-CONNECT FUEL
FITTING LINE
CONNECTOR
10. Raise the vehicle on a lift.
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11. Remove the fuel tank cover and the EVAP canister 12. Disconnect the fuel tank unit subharness 4P
guard pipe. connector and the quick-connect fittings.
FUEL FILL CAP
FUEL TANK WINCH STRAP
WINCH
STRAP JACK
FUEL TANK UNIT
SUBHARNESS
4P CONNECTOR
BOLT
22 N.m
(16 lb-ft)
EVAP CANISTER
GUARD PIPE
QUICK-
CONNECT
FITTINGS
FUEL TANK
COVER
CLIPS
FUEL TANK
38 N.m
(28 lb-ft)
FUEL TANK STRAPS
13. 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.
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14. Transfer the fuel tank unit to the replacement tank: 21. 2006 Models: Torque the fuel pressure release bolt
• Remove the fuel feed pipe and the fuel vent pipe to 12.8 N.m (9.4 lb-ft).
from the fuel tank unit. 22. 2007–11 Models: Reconnect the quick-connect
• Remove the fuel tank unit. fittings using a new retainer, then reinstall the
quick-connect fitting cover, the cover [torque bolts
• Install the fuel tank unit in the replacement fuel
to 9.8 N.m (7.2 lb-ft)], and the air cleaner.
tank with a new base gasket, a new locknut, and
a new locknut plate. Torque the locknut to 23. Do the battery terminal reconnection procedure.
120 N.m (88 lb-ft).
24. Fill the fuel tank with the fuel from the old tank.
NOTE: To prevent a fuel leak, check the base
gasket, visually or with your hand, to make sure it is 25. From the INSPECTION MENU of the HDS, select
not pinched. fuel pump ON.
26. Check for, and clear any DTCs that set when you
relieved the fuel pressure.
LOCKNUT 27. Start the engine, and check for any fuel leaks.
(Replace.)
LOCKNUT PLATE
(Replace.) Example of Customer Letter
November 2011
BASE GASKET Warranty Extension: Fuel Tank
(Replace.)
Dear Civic Hybrid Owner:
This letter is to notify you of a warranty extension on
FUEL TANK UNIT your Civic Hybrid.
What is the reason for this notice?
On some 2006–11 Civic Hybrids, small cracks may
develop where the fuel filler pipe joins the fuel tank.
You may smell 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. This warranty
extension provides coverage for the original owner and
any subsequent owners. No action is required on your
part unless you experience a problem.
What should you do?
If you believe your fuel tank is leaking, call any
• Reinstall the fuel feed pipe and the fuel vent pipe authorized Honda dealer and make an appointment to
have your vehicle inspected. If the fuel leak is from the
on the fuel tank unit with new retainers. fuel tank, the fuel tank will be replaced at no cost.
15. Lift the tank into position, and reinstall the straps Please plan to leave your vehicle for a day to allow the
and strap bolts. Torque the strap bolts to dealer flexibility in scheduling.
38 N.m (28 lb-ft). What to do if you feel this notice is in error.
Our records show that you are the current owner or
16. Reconnect the fuel tank unit subharness, and lessee of a 2006–11 Civic Hybrid involved in this
reconnect the quick-disconnect fittings with new warranty extension. If this is not the case, or the name/
retainers. address information is not correct, please complete
and sign the Information Change Card, and return it in
17. Reinstall the EVAP canister guard pipe, and torque the enclosed postage-paid envelope. We will then
the bolts to 22 N.m (16 lb-ft). update our records.
18. Reinstall the fuel tank cover with the new circlips If you previously paid to have the fuel tank replaced
supplied in the kit. because of a leak, you may be eligible for
reimbursement, even if you no longer own the vehicle.
19. Lower the vehicle. Refer to the attached Instructions for Reimbursement
20. Reinstall the fuel cap. form for eligibility requirements and the reimbursement
procedure.
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Lessor Information
If you are the vehicle lessor receiving this warranty
extension notice, please forward a copy of this notice
to the lessee.
If you have questions
If you have any questions about this notice, or need
assistance with locating a Honda dealer, please call
Honda Automobile Customer Relations at
800-999-1009, and select option 4.
Sincerely,
American Honda Motor Co., Inc.
Honda Automobile Division
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