Bulletins & Advisories Safety recall :FR-V Diesel Fuel strainer failure (KE type only)

Discussion in '1st Generation (2004-2011)' started by Service News, Thursday 16th Mar, 2006.

  1. Service News Staff Managed Dealer Information

    UK
    202
    33
    Honda have issued the following TSB#HUK000000000755 dated 16-03-06 for all BE6 for MY06

    KE* models have a look at In-Depth - Honda Model Area Code Listing • Honda Karma

    Symptom
    Hesitation and stalling followed by the MIL coming on because of low fuel pressure.

    Cause
    Air is separated from the fuel in the strainer and forms an air bubble in the top of the strainer. Under certain conditions, this air bubble can be sucked into the high pressure pump, leading to intermittent fuel supply to the engine.

    Countermeasure
    A spacer has been added to the strainer which reduces air build up.

    Application to Production Line
    JHMBE5***6S210483
    Affected VIN Range
    JHMBE5***6S000001 - JHMBE5***6S208875
    Note : Cars from VIN JHMBE5***6S208876 to VIN
    JHMBE5***6S210483 have been repaired before delivery.

    Please remember to use the "Campaign for a VIN/PIN" to identify if a vehicle requires this Recall.If this does not appear in the search, the Recall has been carried out or is not affected.

    Affected VIN list
    Cyprus 6 units
    JHMBE57406S208762
    JHMBE57406S208763
    JHMBE57406S208764
    JHMBE57406S208765
    JHMBE57406S208809
    JHMBE57406S208810

    Malta 1 unit JHMBE57406S203796
    Germany 1 unit JHMBE57406S204915
    U.K. 1296 units

    Market Treatment
    Call in the affected units and replace the fuel strainer. For related repair information refer to bulletin No HUK000000756

    Repair Method
    1. Make sure you have the anti-theft codes for the radio, then write down the frequencies for the radio's preset buttons.

    2. Remove the battery and the battery box (unplug the wiring harness clip on the side of the battery box).

    3. Remove the air cleaner bolt (A).

    4. Remove the four bolts (C), then remove the battery base (B).
    Fuel FRV Diesel.
    5. Loosen the air cleaner hose band (A), then disconnect the MAF sensor / IAT sensor connector (B).

    6. Remove the air cleaner (C).
    Fuel FRV Diesel1.
    7. Disconnect the three connectors (A) from fuel filter.
    - Fuel Temperature Sensor connector
    - Fuel Heater connector
    - Fuel Filter Water Level Switch connector

    8. Release the hose clips (B), then remove the fuel outlet hose (C) and the fuel feed hose (D).
    NOTE: Be careful not spill fuel in engine compartment.

    9. Unscrew the two nuts (E) and remove the fuel filter assembly from the body.
    Fuel FRV Diesel3.
    10. Remove the two bolts (A) and the cover (B).

    11. Remove the two bolts (C) and the fuel filter (D) from the fuel bracket (E).
    Fuel FRV Diesel4.
    12. Connect the tube (B) to the water screw (A) on the fuel filter, then loosen water screw (A) to drain fuel in the filter. When fuel has been completely drained, tighten the water screw and the disconnect the tube.
    NOTE: Prepare a container for the fuel drained from the filter. Be careful not to spill fuel from the container.
    Fuel FRV Diesel5.

    13. Set the fuel filter (A) on a vise(B).

    14. Using the water sensor wrench (D), remove the water sensor level switch (C).
    Fuel FRV Diesel6.
    15. Using the fuel filter wrench (B), remove the fuel filter (A).
    Fuel FRV Diesel7.
    16. Install a new fuel filter (A) with a new O-ring (B) then tighten it to the specified torque with fuel filter wrench (C).
    NOTE: When using the special tool in conjunction with a torque wrench, the tightening torque for the fuel filter varies depending on the length of the torque wrench (D). The table below will allow for the variation and should be used when tightening the fuel strainer to the specified torque.
    Fuel FRV Diesel8.

    Fuel FRV Diesel9. Fuel FRV Diesel10.PNG


    17. Install the water sensor level switch (A) with a new O-ring (B) to the fuel filter (D), then tighten it to the specified torque with the water sensor wrench (C).
    Fuel FRV Diesel11.
    NOTE: When using the special tool in conjunction with a torque wrench, the tightening torque for the fuel filter varies depending on the length of the torque wrench (D). The table below will allow for the variation and should be used when tightening the fuel strainer to the specified torque.
    Fuel FRV Diesel12. Fuel FRV Diesel13.PNG


    18. Remove the fuel filter from the vise. Install the fuel filter bracket and cover in the reverse order of removal.

    19. Install a new bracket kit. Refer to bulletin

    20. Install all parts in reverse order of removal.

    21. Squeeze the fuel hand primer (A) until it becomes hard. When it becomes hard, stop bleeding.
    Fuel FRV Diesel14.

    22. Turn the ignition switch ON, then check that the glow plug indicator goes off, then start the engine.

    23. Depress the accelerator pedal about 3 times, then check that idle speed is stable. If the engine dose not start, operate the hand primer again until it becomes hard.
    NOTE:
    - Make sure that continuous cranking time of engine is 30 seconds or less. Cranking engine for longer than 30 seconds can cause damage to the starter and the fuel pump.

    24. Enter the anti-theft codes for the radio and navigation system, then enter the customer's radio station presets and reset the clock.

    25. After finishing the work, stamp a center punch mar kabove the 1st digit of the engine compartment VIN :

    Tool information
    All tools are supplied through the Honda Special Tool Programme.
    Tool Number Description
    070AA-RMA0101 Fuel Filter Wrench
    070AA-RMAC200 Water Sensor Wrench Parts Information
    Fuel strainer kit : 06160-RJL-305