Honda Recalls More Than 720,000 Vehicles for High-Pressure Fuel Pump Defect

2024 Accord sedans at a Honda dealership in Highlands Ranch, Colo., on April 14, 2023. David Zalubowski/AP Photo

The National Highway Traffic Safety Administration (NHTSA) announced on Oct. 22 that Honda (American Honda Motor Co.) is recalling approximately 720,810 vehicles in the United States due to a high-pressure fuel pump defect that could lead to a dangerous fuel leak.

The recall affects various 2023–2025 models, including the Honda Accord, Accord Hybrid, CR-V Hybrid, and Civic, both the standard and hybrid versions.

According to the NHTSA recall notice, the high-pressure fuel pump in the affected vehicles may develop cracks that lead to fuel leakage. This defect presents a significant safety risk, as “a fuel leak in the presence of an ignition source can increase the risk of a fire,” the notice stated.

The recall impacts these models:

• 2023–2024 Honda Accord and Accord Hybrid
• 2023–2025 Honda CR-V Hybrid
• 2025 Honda Civic and Civic Hybrid

The defect stems from the improper manufacturing of the fuel pump’s solenoid core, which can result in the formation of cracks during operation, recall documents stated.

“During vehicle operation, these cracks can grow, leading to possible fuel leaks,” Honda explained in its communication with the NHTSA.

The recall notice also mentioned that while drivers may notice a fuel odor while the vehicle is either idling or in motion, this can serve as the primary warning signal for the defect.

Honda has confirmed that it has not received any reports of injuries or crashes related to the defect, though there have been 145 warranty claims associated with the issue as of October.

The automaker has voluntarily initiated the recall following an investigation that began in early 2023 and concluded in October, when it confirmed the presence of the defect in certain vehicles.

Registered owners of the affected vehicles will receive official notification from Honda starting Dec. 4.

Honda dealerships will offer a free inspection and replacement of the defective fuel pump as necessary. Owners can also check if their vehicle is part of the recall by visiting Honda’s recall website at www.recalls.honda.com or contacting Honda’s customer service line at 1-888-234-2138.

The fuel pump’s defects were traced to issues in the manufacturing process. Machined chips caused excessive thrust load and torque input during production, which led to the formation of cracks in the fuel pump’s solenoid core component.

Insufficient baking temperatures during the plating process contributed to hydrogen embrittlement, further exacerbating the risk of cracking, documents stated. The improved parts will feature changes in the dimensions, machining, and baking conditions to address these vulnerabilities.

The NHTSA’s safety notice emphasized the importance of timely repairs to reduce the risk of fire, crash, or injury. Drivers who notice the smell of gasoline are urged to contact their dealer immediately, even before receiving the formal recall notice.

Honda is required to submit quarterly status reports regarding the recall’s progress.

Earlier this month, the company also announced a recall of nearly 1.7 million vehicles due to a potential steering defect.