Honda High Pressure Fuel Pump Could Leak

Honda will be contacting the owners of certain 2023 to 2025 Honda models due to a potential defect in the high-pressure fuel pump. This issue could result in fuel leaks, which may lead to a fire risk if left unchecked.

Affected Honda Models

The Problem with the High-Pressure Fuel Pump

The recall stems from improper manufacturing processes used on the high-pressure fuel pumps in these vehicles. Specifically, the solenoid core component of the fuel pump can develop cracks during production, which may lead to fuel leaks.

The issue has been traced to machining chips that got lodged between the cutting tool and the work piece during the production of the solenoid core at one of Honda’s tier 2 suppliers. This interference caused excessive pressure, leading to both longitudinal and transverse cracks in the component. On top of that, insufficient baking temperature during the plating process at another supplier caused residual hydrogen to remain in the material. This residual hydrogen buildup led to hydrogen embrittlement cracks, further weakening the component.

Over time, as the vehicle is driven and the fuel pump operates, these cracks—whether they were fully penetrated or only partially formed—can grow larger, eventually allowing fuel to leak.

What Happens If the Fuel Pump Cracks?

If the cracks in the fuel pump worsen and fuel begins to leak, drivers may notice a distinct fuel odor, either while the vehicle is being driven or while it is idling. The smell of fuel is often the first warning sign that something is wrong. If left unattended, the leaking fuel could pose a serious fire risk, particularly if it comes into contact with hot engine parts or electrical components.

What Should Affected Owners Do?

Owners of affected Honda vehicles will be notified via mail starting on December 4, 2024. In the meantime, if you notice any unusual fuel odors or suspect a fuel leak, it’s important to contact your dealer right away to arrange an inspection.

Honda dealerships will be inspecting the high-pressure fuel pumps on these vehicles and replacing them as necessary. Honda’s recall number is PJW and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-763.