Fuel Tank

Remove and replace the fuel tank on a 2016-2021 Honda Civic 1.5L Turbo, including disconnection of fuel lines, electrical connections, and mounting hardware.

Warnings

Tools required

Parts

• Fuel tank (if replacing) × 1 — 17044-TGG-A00 or equivalent OEM
• Fuel pump module gasket × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification
• Tank strap bolts × 2 — Use OEM specification
• Fuel filler neck clamp × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground outdoors or in extremely well-ventilated area. Remove all ignition sources from work area.
2. Disconnect negative battery terminal and wait 3 minutes to allow fuel pump to fully depressurize.
3. Remove fuel filler cap to relieve any tank pressure.
4. If tank contains more than 1/4 tank of fuel, siphon or drive vehicle until fuel level is low to reduce weight and spill risk.
5. Raise vehicle and secure on jack stands at manufacturer-specified lift points. Ensure vehicle is stable with all four corners supported.
6. Place fire extinguisher within immediate reach of work area.
7. Wear safety glasses and nitrile gloves throughout entire procedure.

Procedure

1. 1

   Relieve fuel system pressure
   With battery already disconnected, locate fuel pump relay in under-hood fuse box (check owner's manual for exact location). Remove the fuel pump relay. Reconnect battery temporarily, start the engine and let it run until it stalls from fuel starvation. Attempt to restart 2-3 times to ensure all pressure is relieved. Turn ignition off and disconnect battery negative terminal again.
2. 2

   Access and disconnect rear fuel lines
   From underneath vehicle, locate the fuel feed and return lines at the front of the fuel tank. Clean the connection areas with a rag to prevent debris entry. Using the appropriate fuel line disconnect tool, press the release tabs on each quick-connect fitting and pull lines straight off. Expect residual fuel spillage. Cap or plug the open lines to prevent contamination.
3. 3

   Disconnect fuel filler neck
   Remove the left rear wheel for improved access to filler neck. Locate the filler neck connection at the tank inlet. Using hose clamp pliers or a flathead screwdriver, loosen the filler neck clamp. Twist and pull the filler neck hose off the tank inlet. There may be fuel spillage; have a drain pan ready.
4. 4

   Disconnect evaporative emission (EVAP) lines
   Locate the EVAP canister lines connected to the top of the fuel tank. These are typically smaller diameter plastic lines with quick-connect fittings. Press the release tabs and disconnect all EVAP lines, noting their positions for reinstallation. Some models may have 2-3 separate EVAP connections.
5. 5

   Disconnect fuel pump electrical connector
   Locate the fuel pump module electrical connector on top of the tank. Press the locking tab and disconnect the harness connector. On some models, you may need to remove a plastic access cover secured with clips. Ensure the connector is moved safely away from the tank.
6. 6

   Support fuel tank with transmission jack
   Position a transmission jack or wide platform jack directly under the center of the fuel tank. Raise the jack until it just contacts the tank bottom. Use ratchet straps or bungee cords to secure the tank to the jack platform to prevent shifting when tank straps are released. The tank should be firmly supported but not under load yet.
   ⚠Ensure jack is centered and stable. Tank will become completely unsupported when straps are removed.
7. 7

   Remove tank strap bolts
   Locate the two fuel tank strap bolts at the rear of the tank straps. These are typically 14mm or 17mm bolts. Support the straps with one hand while removing each bolt completely. Once bolts are removed, carefully swing the straps down and away from the tank. The tank is now supported only by the jack.
   ⚠Tank may shift as straps are released. Keep hands clear of pinch points.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
8. 8

   Lower and remove fuel tank
   With an assistant monitoring the tank position, slowly lower the transmission jack. Watch all connection points to ensure nothing is still attached. Lower the tank approximately 12 inches, then check again for any forgotten hoses or wires. If all connections are clear, continue lowering the tank completely and slide it out from under the vehicle. Be prepared for additional fuel spillage as tank tilts.
   ⚠️Have assistant guide tank and watch for snagged lines. Never work under unsupported tank.
9. 9

   Drain remaining fuel and remove fuel pump module (if servicing tank)
   If replacing or servicing the tank, drain all remaining fuel into approved fuel-safe containers. To remove the fuel pump module, turn the large locking ring counterclockwise using a brass punch and hammer (do not use steel tools that could spark). Lift the fuel pump module out carefully, tilting as needed to clear the tank opening. Remove and discard the old pump module gasket.
10. 10

    Install fuel pump module in new/serviced tank
    Install new fuel pump module gasket on tank opening, ensuring proper seating in the groove. Carefully lower fuel pump module into tank, aligning the tabs. Press down firmly and install locking ring, turning clockwise until tight. The locking ring should be firmly seated with alignment marks matching.
11. 11

    Position tank on jack and raise into position
    Place the tank (new or serviced) onto the transmission jack and secure with straps. Raise the jack slowly, guiding the tank up into position. Align the tank with the mounting points and tank strap locations. Raise until tank is firmly against the vehicle underbody but do not apply excessive upward force.
    ⚠Guide all lines and connectors through their proper routing paths as tank rises.
12. 12

    Install tank straps and bolts
    Swing the tank straps up and over the tank, aligning the bolt holes. Install both tank strap bolts and hand-tighten initially. Once both bolts are started, torque them to specification in an alternating pattern to ensure even loading. Verify straps are properly seated and not twisted.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
13. 13

    Reconnect fuel pump electrical connector
    Reconnect the fuel pump module electrical connector, pressing firmly until the locking tab clicks into place. Reinstall any access covers that were removed. Tug gently on connector to verify it is locked.
14. 14

    Reconnect EVAP lines
    Reconnect all EVAP lines to their respective ports on top of the tank, referencing your notes or photos from disassembly. Push each line firmly until you hear or feel a click, then tug to verify connection. Ensure lines are routed properly without kinks or tension.
15. 15

    Reconnect fuel filler neck
    Push the fuel filler neck hose onto the tank inlet, ensuring it is fully seated. Install a new filler neck clamp and position it properly over the connection. Tighten the clamp to specification. Verify the connection is secure with no gaps.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
16. 16

    Reconnect fuel feed and return lines
    Remove caps or plugs from fuel lines. Install new O-rings on all fuel line fittings (do not reuse old O-rings). Push each fuel line onto its corresponding connection until you hear a distinct click. Tug firmly on each line to verify it is locked. Visually inspect that the locking tabs are properly engaged.
    ⚠New O-rings are CRITICAL for proper sealing. Reusing old O-rings can cause fuel leaks.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
17. 17

    Lower vehicle and reinstall wheel
    Carefully lower the transmission jack and remove it from under the vehicle. Reinstall the left rear wheel if removed and torque lug nuts to Honda specification (108 Nm / 80 lb-ft). Lower vehicle from jack stands to ground level.
18. 18

    Reconnect battery and reinstall fuel pump relay
    Reconnect the negative battery terminal and tighten securely. Reinstall the fuel pump relay in the under-hood fuse box. Turn the ignition to ON position (do not start) for 2 seconds, then OFF. Repeat this cycle 3-4 times to allow fuel pump to prime the system and build pressure.

Reassembly

1. Double-check that all fuel line connections are secure and properly locked before starting engine
2. Verify all EVAP lines, electrical connectors, and filler neck are properly connected
3. Ensure tank straps are torqued to specification and not twisted or binding
4. Confirm transmission jack and all tools are removed from under vehicle

Verification

• With vehicle outdoors and well-ventilated, start the engine and let it idle for 5 minutes while monitoring for fuel odors
• Inspect all fuel line connections, filler neck, and tank straps for any signs of fuel seepage or leakage
• Check under vehicle with a flashlight for any fuel drips or wet spots on tank or lines
• Turn engine off and check fuel system pressure holds (engine should restart immediately without extended cranking)
• Add fuel if tank was drained and verify no leaks at filler neck during and after refueling
• Test drive vehicle and recheck all connections after 50 miles of driving
• If ANY fuel odor or leakage is detected, do not drive vehicle. Shut off engine immediately and diagnose the leak source

More procedures for this vehicle