Honda Accord/Prelude 1984-1995 Repair Guide

Tank Assembly

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Although draining the tank is part of each procedure, it is unlikely that you can safely store large amounts of fuel during the repair. For this reason, the tank should be as empty as possible before removal is begun. The remaining few gallons must be drained and stored in approved fuel containers. The containers must be tightly capped.


CAUTION
Fuel and its vapors are extremely explosive. Take great care to eliminate all sources of heat, flame and sparks from the work area before beginning. This must include shutting off heaters or furnaces and shutting off electric motors in machinery, fans, etc. Keep a dry powder (Class B-C) fire extinguisher within arm's reach at all times.

REMOVAL & INSTALLATION



1984-89 Accord and 1984-85 Prelude

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Block the front wheels. Elevate the rear of the car and support it safely on stands.
  6.  
  7. Remove the drain bolt from the tank and drain the remaining fuel into an approved fuel container.
  8.  
  9. Unplug the sending unit connectors.
  10.  
  11. Label and disconnect the hoses from the pipes mounted to the body (over the suspension control arm). Slide the hose clamps back on the hose, then twist the hose while pulling it off the fitting.
  12.  
  13. Use a floor jack and a broad piece of wood under the tank. Adjust the position as necessary to allow the tank to be evenly supported.
  14.  



Click image to see an enlarged view

Fig. Fig. 1: Fuel tank assembly used on 1984-85 Accords

  1. Remove the nuts securing the tank straps; let the straps fall free.
  2.  
  3. Lower the jack and remove the tank from under the vehicle.
  4.  

To install:
  1. Place the tank on the jack and position it under the car. Lift the tank into position.
  2.  
  3. Install the tank straps and tighten the retaining nuts to 16 ft. lbs. (22 Nm). Make certain the opposite ends of the straps are still firmly mounted in their slots
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Fuel tank assembly used on 1986-89 Accords

  1. Connect the hoses and engage the wiring connectors.
  2.  
  3. Install the drain bolt in the tank; tighten it to 36 ft. lbs. (50 Nm).
  4.  
  5. Lower the vehicle to the ground.
  6.  
  7. Refill the tank with fuel.
  8.  
  9. When starting, the engine may crank longer than usual due to lack of fuel in the lines.
  10.  

1986-95 Prelude

See Figures 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Block the front wheels. Elevate the rear of the car and support it safely on stands.
  6.  
  7. Remove the drain bolt from the tank and drain the remaining fuel into an approved fuel container.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: Fuel tank assembly used on 1986-87 Preludes

  1. On 1986-87 vehicles, unplug the sending unit connectors.
  2.  
  3. On 1988-95 vehicles, lift the carpet in the luggage area. Remove both access panels. Unplug the wiring to the fuel pump and fuel sender. Disconnect the fuel lines.
  4.  
  5. On 1986-87 Preludes, remove the muffler.
  6.  
  7. Label and disconnect the hoses. Slide the hose clamps back on the hose, then twist the hose while pulling it off the fitting.
  8.  



Click image to see an enlarged view

Fig. Fig. 4: Fuel tank assembly used on 1988-91 Preludes

  1. Use a floor jack and a broad piece of wood under the tank. Adjust the position as necessary to allow the tank to be evenly supported.
  2.  
  3. Remove the nuts securing the tank straps and free them.
  4.  
  5. Lower the jack and remove the tank.
  6.  

To install:
  1. Place the tank on the jack and position it under the car. Lift the tank into position.
  2.  
  3. Install the tank straps and tighten the retaining nuts to 16 ft. lbs. (22 Nm). Make certain the opposite ends of the straps are still firmly mounted in their slots.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Fuel tank assembly on 1992-95 Preludes

  1. Connect the hoses and engage the wiring connectors. Reinstall the access covers if they were removed. Reposition the carpeting in the cargo area as needed.
  2.  
  3. If removed, insall the muffler (use new nuts and gaskets).
  4.  
  5. Install the drain bolt in the tank; tighten it to 36 ft. lbs. (50 Nm).
  6.  
  7. Lower the vehicle to the ground. Refill the tank with fuel.
  8.  
  9. When starting, the engine may crank longer than usual due to lack of fuel in the lines.
  10.  

1990-95 Accord

See Figures 6 and 7

  1. Block the front wheels. Elevate the rear of the car and support it safely on stands.
  2.  
  3. Remove the drain bolt from the tank and drain the remaining fuel into an approved fuel container.
  4.  
  5. Remove the cover from the fuel hoses on the side of the tank.
  6.  
  7. Label and disconnect the hoses. Slide the clamps back, then twist and pull the hoses off the fittings.
  8.  
  9. Use a floor jack and a broad piece of wood under the tank. Adjust the position as necessary to allow the tank to be evenly supported.
  10.  



Click image to see an enlarged view

Fig. Fig. 6: Fuel tank assembly used on 1990-93 Accords

  1. Remove the nuts holding the tank straps; let the straps fall free.
  2.  
  3. Lower the jack and remove the tank from under the vehicle. The tank may be stuck by the undercoating on the body; use a piece of wood to gently pry it loose.
  4.  

To install:
  1. Place the tank on the jack and position it under the car. Lift the tank into position.
  2.  
  3. Install the tank straps and tighten the retaining nuts to 27 ft. lbs. (38 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Fuel tank assembly used on 1994-95 Accords

  1. Connect the hoses and wiring connectors. Tighten the threaded fuel line fitting to 26 ft. lbs. (37 Nm).
  2.  
  3. Install the cover for the fuel lines.
  4.  
  5. Install the drain bolt in the tank with a new washer; tighten it to 36 ft. lbs. (50 Nm).
  6.  
  7. Lower the vehicle to the ground.
  8.  
  9. Reuse the fuel drained from the tank unless it is heavily polluted with rust, water, etc. Use a funnel at the fuel filler and pour the fuel slowly.
  10.  
  11. When starting, the engine may crank longer than usual due to lack of fuel in the lines.
  12.  

SENDING UNIT REPLACEMENT



See Figure 8

1985 Accord and 1985-87 Prelude
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel tank from the vehicle.
  4.  
  5. Disengage the retaining collar using a fuel sending unit removal tool. This tool is available at Honda dealers and many auto parts stores.
  6.  
  7. Remove the sending unit from the vehicle.
  8.  
  9. Installation is the reverse of removal.
  10.  



Click image to see an enlarged view

Fig. Fig. 8: A special tool is used to disengage the retaining collar of the sending unit

1986-95 Accord and 1988-95 Prelude
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the access panels in the luggage area.
  4.  
  5. Unplug the electrical connector from the sending unit.
  6.  
  7. Disengage the retaining collar using a fuel sending unit removal tool. This tool is available at Honda dealers and many auto parts stores.
  8.  
  9. Remove the sending unit from the vehicle.
  10.  
  11. Installation is the reverse of removal.
  12.  

 
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