This procedure covers removal and replacement of the fuel level sensor located in the fuel tank on 2016-2021 Honda Civic 1.5L Turbo models.

Warnings

Tools required

Parts

• Fuel level sensor assembly × 1 — Use OEM Honda part number
• Fuel pump module gasket/seal × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure fuel tank is no more than 1/4 full (drain if necessary)
3. Disconnect negative battery terminal and wait 3 minutes for system discharge
4. Remove rear seat cushion by pulling forward on front edge to release clips
5. Clean area around fuel pump access cover to prevent debris from entering tank

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay in the under-hood fuse box (relay #38). Remove the relay and attempt to start the engine. Allow it to run until it stalls, then crank for an additional 3 seconds. Turn ignition off. This relieves residual pressure in the fuel lines.
   ⚠️Do not skip this step. Fuel system operates at high pressure and can spray fuel causing injury or fire.
2. 2

   Remove fuel pump access cover
   Locate the rectangular access cover under the rear seat. Remove the screws securing the cover using a Phillips screwdriver or appropriate socket. Carefully lift the cover to expose the fuel pump module and fuel lines.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
3. 3

   Disconnect electrical connector
   Press the locking tab on the fuel pump module electrical connector and carefully pull straight up to disconnect. Ensure the connector is positioned away from the work area to prevent damage.
4. 4

   Disconnect fuel lines
   Using the appropriate fuel line disconnect tool, depress the tabs on the quick-connect fittings for both the supply and return lines. Pull the lines straight off the module. Have shop towels ready to catch residual fuel. Cap or plug the lines to prevent contamination.
   ⚠Residual fuel will drain from lines. Keep towels and fuel-safe container ready.
5. 5

   Remove fuel pump module locking ring
   The fuel pump module is secured by a large locking ring with tabs. Using a flathead screwdriver and hammer (or locking ring tool if available), tap the ring counterclockwise to loosen. Once loose, carefully unscrew by hand and remove the locking ring.
6. 6

   Remove fuel pump module assembly
   Carefully lift the fuel pump module straight up and out of the tank. Tilt the module to drain residual fuel back into the tank. Be mindful of the fuel level sensor arm and float - do not bend or damage these components. Place the module on clean shop towels.
   ⚠Fuel level sensor arm and float are fragile. Handle with care to avoid bending.
7. 7

   Remove old gasket and inspect tank opening
   Remove and discard the old fuel pump module gasket from the tank opening. Clean the sealing surface on the tank thoroughly with a clean shop towel. Inspect for damage, debris, or corrosion. The surface must be clean and smooth for proper seal.
8. 8

   Replace fuel level sensor
   With the fuel pump module removed, locate the fuel level sensor on the side of the module assembly. Disconnect the internal electrical connector. Release the locking tab or clip securing the sensor and slide it out of the module housing. Install the new fuel level sensor by reversing the removal process, ensuring the float arm moves freely through its full range of motion.
   ℹ️Verify the float arm moves smoothly without binding before installation.
9. 9

   Install new gasket and reinstall module
   Position the new fuel pump module gasket on the tank opening, ensuring proper alignment. Carefully lower the fuel pump module assembly into the tank, guiding the fuel level sensor arm and float to prevent damage. Rotate the module to align the tabs with the grooves in the tank.
10. 10

    Install locking ring
    Position the locking ring over the module and engage the threads. Turn clockwise by hand until snug, then use a screwdriver and hammer (or locking ring tool) to tighten securely. The ring should be firmly seated with no gaps between the ring and tank.
11. 11

    Reconnect fuel lines
    Install new O-rings on the fuel line quick-connect fittings, lightly lubricating with clean gasoline. Push each fuel line straight onto the module ports until you hear and feel a positive click. Pull gently on each line to verify secure connection.
    ℹ️Always use new O-rings on fuel line connections to prevent leaks.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
12. 12

    Reconnect electrical connector
    Align the fuel pump module electrical connector and press firmly until the locking tab clicks into place. Verify the connection is secure by gently pulling on the connector.
13. 13

    Reinstall access cover and rear seat
    Position the fuel pump access cover over the opening and install the screws. Tighten to specification. Reinstall the rear seat cushion by aligning the hooks at the rear and pressing down at the front until the clips engage.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)
14. 14

    Reconnect battery and test system
    Reconnect the negative battery terminal. Reinstall the fuel pump relay. Turn the ignition to ON position (without starting) for 2 seconds, then OFF. Repeat this 3 times to prime the fuel system. Check for fuel leaks around the access area and all connections.
    ⚠️Inspect thoroughly for fuel leaks before starting engine. Any fuel smell or visible leak must be corrected immediately.

Reassembly

1. Ensure all fuel line connections are secure and properly locked
2. Verify electrical connector is fully seated with locking tab engaged
3. Confirm access cover is properly sealed and all screws are tightened to specification
4. Double-check rear seat is securely clipped in place

Verification

• Turn ignition to ON position and listen for fuel pump operation (should run for 2 seconds)
• Check for fuel odor or visible leaks at pump module, fuel lines, and access cover
• Start engine and verify it runs normally without hesitation or fuel delivery issues
• Drive vehicle and monitor fuel gauge operation through multiple fuel levels to confirm accurate readings
• Scan for diagnostic trouble codes related to fuel system or fuel level sensor - there should be none
• After initial test drive, re-inspect fuel pump access area for any signs of fuel seepage

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