Honda Civic/CRX/del Sol 1984-1995 Repair Guide

Electric Fuel Pump

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PRESSURE TESTING



1985-87 MODELS

See Figure 1

  1. With the ignition switch OFF , unplug the main relay connector from behind the fuse box.
  2.  
  3. Connect the Yellow wire to the Black/Yellow wire with a jumper.
  4.  
  5. Relieve fuel pressure, then tighten the service bolt.
  6.  
  7. Disconnect the fuel return hose from the regulator and place the end of the hose in a graduated cylinder, or equivalent, in order to measure fuel flow by volume.
  8.  
  9. Turn the ignition switch ON for exactly 10 seconds, then measure the amount of flow. The correct amount of fuel in the container should be 7.8 oz. (230cc).
  10.  
  11. If the fuel flow is less than specified, or there is no fuel flow, check for the following:

    Clogged fuel filter
     
    Clogged fuel line
     
    Pressure regulator failure
     

  12.  

If you suspect the fuel pump is faulty, check to ensure that it actually runs. When the ignition is turned ON , it should make a noise for about two seconds. If it does not make any noise, check as follows:

  1. Block the front wheels, jack the rear of the car and support it safely with jackstands.
  2.  
  3. Remove the fuel pump cover and disengage the connector.
  4.  


WARNING
Be sure the ignition switch is turned OFF before disconnecting the wires to the fuel pump.

  1. Taking care to not touch the wires together, check that battery voltage is available at the fuel pump wire connector when the ignition switch is turned ON. (Positive probe to the Yellow terminal, negative probe to the Black terminal). If battery voltage is available, replace the pump. If it is not available, check the main relay and wire harness.
  2.  



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Fig. Fig. 1: Electric fuel pump mounting-1985-87

1988-95 MODELS

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Attach a suitable fuel pressure gauge to the fuel filter service port.
  6.  
  7. Connect the negative battery cable and disconnect the vacuum hose at the pressure regulator.
  8.  
  9. Start the engine and allow it to idle. The fuel pressure should be 35-41 psi (240-279 kPa).
  10.  
  11. If the pressure is less than specified, check for the following:

    Clogged fuel filter
     
    Clogged or leaking fuel line(s)
     
    Pressure regulator failure
     

  12.  

  1. If the fuel pressure is higher than specified, inspect for the following:

    Pinched or clogged fuel return hose or pipe
     
    Pressure regulator failure
     

  2.  

If you suspect the fuel pump is faulty, check to ensure that it actually runs. When the ignition is turned ON , it should make a noise for about two seconds. If it does not make any noise, check as follows:

  1. Block the front wheels, jack the rear of the car and support it safely with jackstands.
  2.  
  3. Check if there is battery voltage available at the fuel pump. If there is battery voltage available, replace the fuel pump. If there is no voltage, check the main relay and wire harness.
  4.  



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Fig. Fig. 2: Electric fuel pump assembly, component view-1992-95

REMOVAL & INSTALLATION



1985-87 MODELS

See Figures 3, 4, 5 and 6

The fuel pump is located under the left rear of the vehicle, it is bolted to the chassis and is covered by a 2-piece cover.

Relieve the fuel system pressure before working on any part of the fuel system. Follow all safety precautions.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable and raise and safely support the vehicle.
  4.  
  5. Remove the left rear wheel. Remove the fuel pump cover assembly bolts and remove the cover.
  6.  
  7. Remove the three fuel pump retaining bolts and lower the pump slightly, disconnect the fuel lines from the pump.
  8.  
  9. Disconnect the electrical leads from the pump. Remove the clamp retaining the pump and slide the pump out of the mount. Remove the silencer from the fuel line.
  10.  

To install:
  1. Install the fuel pump on its mount and install the silencer.
  2.  
  3. Install the fuel lines on the pump. Tighten the silencer to 20 ft. lbs. (28 Nm).
  4.  
  5. Install the pump covers and the pump assembly in place.
  6.  
  7. Install the rear wheel. Connect the negative battery cable.
  8.  
  9. Turn the ignition key to the ON position and check the fuel connections for leaks. Lower the vehicle.
  10.  



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Fig. Fig. 3: The rear electric fuel pump as found on 1985-87 models is protected beneath this shroud-1985-87 style CRX shown



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Fig. Fig. 4: Unbolt and remove the shroud for rear fuel pump access-1985-87



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Fig. Fig. 5: Removing the bolts holding the fuel pump bracket-1985-87



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Fig. Fig. 6: Removing the fuel line clamp from the rear fuel pump-1985-87

1988-91 MODELS

The fuel pump is located in the fuel tank.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the fuel tank drain bolt and drain the fuel into a suitable container.
  8.  
  9. On Civic models (except CRX and Wagon) unplug the fuel pump electrical connector in the trunk. On CRX, remove the storage compartment and unplug the fuel pump electrical connector. On Civic Wagon, remove the rear seat and carefully disengage the fuel pump electrical harness.
  10.  
  11. On Civic Wagon with 4WD, remove the driveshaft from the rear differential and the exhaust pipe and muffler.
  12.  
  13. Remove the 2-way valve cover and fuel hose protector.
  14.  
  15. Unbolt the fuel lines.
  16.  
  17. Place a suitable support under the fuel tank.
  18.  
  19. Remove the fuel tank strap nuts and let the straps hang.
  20.  
  21. Remove the fuel tank.
  22.  
  23. Remove the fuel pump mounting nuts and the fuel pump.
  24.  

To install:
  1. Install the pump assembly into the tank and make sure the unit is properly sealed.
  2.  
  3. Install the tank into the vehicle and tighten the strap nuts. Connect the hoses and wiring.
  4.  
  5. On 4WD vehicles, connect the driveshaft and the exhaust system.
  6.  
  7. Put about three gallons of fuel into the tank and test the system.
  8.  

1992-95 Models

The fuel pump is in the fuel tank and is reached through an access panel inside the car in the rear passenger or cargo area.

  1. Relieve the fuel system pressure.
  2.  
  3. Remove the rear seat (if applicable) and remove the access panel.
  4.  
  5. Unbolt the fuel lines and unplug the electrical connector.
  6.  
  7. Remove the mounting nuts and carefully pull out the fuel pump from the fuel tank.
  8.  

To Install:
  1. Place the fuel pump in the tank in the correct position and install the mounting nuts, tightening them to 4 ft. lbs. (6 Nm).
  2.  
  3. Plug in the wire connectors and bolt the banjo line fitting using a new washer. Tighten to 20 ft. lbs. (28 Nm).
  4.  
  5. When properly installed, briefly turn the ignition ON , to ensure proper operation. The pump should make a noise for about two seconds as the system pressurizes.
  6.  
  7. If ok, install the rear seat (if applicable).
  8.  

 
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