Body - Fuel Filler Door Detaches From Body
09-023June 10, 2009
Applies To:
2009 TSX - ALL
Fuel Fill Door Detaches From the Body
SYMPTOM
The fuel fill door detaches from the body if you lift it or push down when you swing it open.
PROBABLE CAUSE
The hinge on the fuel fill door adapter is faulty.
CORRECTIVE ACTION
Replace the fuel fill door adapter.
PARTS INFORMATION
Fuel Fill Door Adapter:
P/N 74480-TL0-G01
REQUIRED MATERIALS
Hondalock 2 Thread lock:
P/N 08713-0002
(One container repairs about 50 vehicles.)
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Operation Number: 3101D3
Flat Rate Time: 0.3 hour
Failed Part: P/N 74480-TL0-G00
Defect Code: 01801
Symptom Code: 07902
Template ID: 09-023A
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Remove the left rear wheel.
2. Remove the three fuel pipe protector clips, then remove the fuel pipe protector.
3. Remove the fuel fill cap, then remove the cap tether from the hinge arm. Remove the screw from the fuel fill door adapter.
4. Remove the two bolts from the fuel fill pipe, then lower the pipe to detach it from the fuel fill door adapter.
5. Close the fuel fill door, pull out the rear edge of the fuel fill door adapter, then remove the adapter and the door.
6. Separate the fuel fill door from the fuel fill door adapter. While prying the hook up with a trim tool, slide the fuel fill door forward to release the notches in the fuel fill door from the hooks on the hinge arm. The fuel fill door will be reused.
7. Install the fuel fill door onto the new fuel fill door adapter in the reverse order of step 6.
NOTE:
Make sure the hooks are securely installed and that there is no gap between the fuel fill door and the hinge arm.
8. Insert the new fuel fill door adapter into the fuel fill opening, making sure it fits properly around the fuel filler pipe. Do not deform the packing on the adapter.
9. Apply Hondalock 2 Thread lock to the fuel fill pipe bolts, then install the bolts, and torque them to 9.8 N.m (7.2 lb-ft).
10. Reinstall the screw into the fuel fill door adapter, then reinstall the cap tether and the cap.
11. Reinstall the fuel pipe protector, and press its clips firmly into place. Replace any damaged clips.
12. Reinstall the left rear wheel, and torque the wheel nuts to 108 N~m (80 lb-ft).
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