Fuel Supply System: Other Honda Crosstour I

Fuel Pressure Relieving

Before disconnecting fuel lines or hoses, relieve pressure from the system by disabling the fuel pump and disconnecting the fuel line/quick connect fitting in the engine compartment.

Scheme 176

Scheme 177

Scheme 178

Scheme 179

1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the PCM. If it doesn't, go to the DLC circuit troubleshooting (see «DLC CIRCUIT TROUBLESHOOTING»(ref-360057-S07895027512010042600000) ).
4. Turn the ignition switch to LOCK (0).
5. Remove the fuel fill cap to relieve the pressure in the fuel tank.
6. Turn the ignition switch to ON (II).
7. From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls. NOTE: Do not allow the engine to idle above 1,000 rpm or the PCM will continue to operate the fuel pump. A Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed (see «HDS CLEAR COMMAND»(ref-360056-S34212906112010042600000) ).
8. Turn the ignition switch to LOCK (0).
9. Do the battery terminal disconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360074-S34095844792010042600000) ).
10. Remove the cover (A) and the quick-connect fitting cover (B) (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(ref-360067-S09699164122010042600000) ).
11. Check the fuel quick-connect fitting for dirt, and clean it if needed.
12. Place a rag or shop towel over the quick-connect fitting (A).
13. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: Be careful not to damage the line (E) or other parts. Do not use tools. If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
14. After disconnecting the quick-connect fitting* check it for dirt or damage (see step 5 on ).
15. Do the battery terminal reconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360074-S34095844792010042600000) ).

Scheme 180

Scheme 181

Scheme 182

Scheme 183

1. Remove the driver's dashboard lower cover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360087-S14123292982010042600000) ).
2. Remove PGM-FI main relay 2 (A) from the driver's under-dash fuse/relay box.
3. Start the engine, and let it idle until it stalls. NOTE: If any DTCs are stored, clear and ignore them.
4. Turn the ignition switch to LOCK (0).
5. Remove the fuel fill cap to relieve the pressure in the fuel tank.
6. Do the battery terminal disconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360074-S34095844792010042600000) ).
7. Remove the cover (A) and the quick-connect fitting cover (B) (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(ref-360067-S09699164122010042600000) ).
8. Check the fuel quick-connect fitting for dirt, and clean it if needed.
9. Place a rag or shop towel over the quick-connect fitting (A).
10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: Be careful not to damage the line (E) or other parts. Do not use tools. If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
11. After disconnecting the quick-connect fitting, check it for dirt or damage (see step 5 on ).
12. Do the battery terminal reconnection procedure, (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360074-S34095844792010042600000) ).

2WD model

The fuel line/quick-connect fittings (A, B, C, D, and E) connect the fuel joint hose (F) to the fuel feed hose (G), the fuel feed hose to the fuel line (H), the fuel line (I) to the fuel tank unit (J), the fuel vapor line (K) to the EVAP canister (L), and the fuel tank vapor recirculation tube (M) to the fuel fill pipe (N). When removing or installing the fuel feed hose, the fuel tank unit, or the fuel tank, when disconnecting/connecting the quick-connect fittings, pay attention to the following

Scheme 184

Scheme 185

1. The fuel feed hoses, fuel line, and quick-connect fittings are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures.
2. The fuel feed hoses, fuel line, and quick-connect fittings are not acid-proof; do not touch them with a shop towel that was used for wiping battery electrolyte. Replace them if they come in contact with electrolyte or something similar.
3. When connecting or disconnecting the fuel feed hoses, fuel line, and quick-connect fittings, be careful not to bend or twist them excessively. Replace them if they are damaged.

A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Replace the retainer when

1. replacing the fuel rail.
2. replacing the fuel line.
3. replacing the fuel pump.
4. replacing the fuel filter.
5. replacing the EVAP canister.
6. replacing the fuel fill pipe.
7. replacing the fuel tank.
8. it has been removed from the line.
9. it is damaged.

Note. When you replace a retainer, use the same size and manufacturer as the original retainer.

LINE DIAMETER SPECIFICATION

4WD model

The fuel line/quick-connect fittings (A, B, C, D, E, F, and G) connect the fuel joint hose (H) to the fuel feed hose (I), the fuel feed hose to the fuel line (J), the fuel line (K) to the fuel tank unit (L), the fuel vapor line (M) to the EVAP canister (N), the fuel vent tube (O) to the fuel vent tube B (P) and the fuel tank vapor recirculation tube (Q) and fuel fill neck tube (R) to the fuel fill pipe (S). When removing or installing the fuel feed hose, the fuel tank unit, or the fuel tank, or when disconnecting or connecting the quick-connect fittings, pay attention to the following

Scheme 186

Scheme 187

Scheme 188

Scheme 189

1. The fuel feed hoses, the fuel line, the and quick-connect fittings are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures.
2. The fuel feed hoses, the fuel line, the and quick-connect fittings are not acid-proof; do not touch them with a shop towel that was used for wiping battery electrolyte. Replace them if they come in contact with electrolyte or something similar.
3. When connecting or disconnecting the fuel feed hoses, the fuel line, the and quick-connect fittings, be careful not to bend or twist them excessively. Replace them if they are damaged.

A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line.

Replace the retainer when

1. replacing the fuel rail.
2. replacing the fuel line.
3. replacing the fuel pump.
4. replacing the fuel filter.
5. replacing the EVAP canister.
6. replacing the fuel fill pipe.
7. replacing the fuel tank.
8. it has been removed from the line.
9. it is damaged.

Note. When you replace a retainer, use the same size and manufacturer as the original retainer.

LINE DIAMETER SPECIFICATION

Note. Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions (see FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS ).

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

1. If equipped, remove the quick-connect fitting cover from the fuel line. Raise the cover (A) from the fuel line (B), and remove it as shown.
2. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360067-S41893702602010042600000) ).
3. Check the fuel quick-connect fittings (A) for dirt, and. clean them if needed.
4. Place a rag or shop towel over the quick-connect fitting. Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off. NOTE: Be careful not to damage the line (D) or other parts. Do not use tools. If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
5. Check the contact area (A) of the line (B) for dirt or damage. If it is dirty, clean the connector with a pressure washer, and dry it with compressed air. If it is damaged, replace the fuel filter or the fuel feed line.
6. To prevent damage and keep foreign matter out, cover the disconnected connector and line ends with plastic bags (A). NOTE: The retainer cannot be reused once it has been removed from the line. Replace the retainer when: replacing the fuel rail. replacing the fuel line. replacing the fuel pump. replacing the fuel filter. replacing the EVAP canister. replacing the fuel fill pipe. replacing the fuel tank. it has been removed from the line. it is damaged.

Note. Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions (see FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS ).

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

1. If equipped, remove the quick-connect fitting cover from the fuel line. Raise the cover (A) from the fuel line (B), and remove it as shown.
2. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360067-S41893702602010042600000) ).
3. Check the fuel quick-connect fittings (A) for dirt, and clean them if needed.
4. Place a rag or a shop towel over the quick-connect fitting. Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off. NOTE: Be careful not to damage the line (D) or other parts. Do not use tools. If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
5. Check the contact area (A) of the line (B) for dirt or damage. If it is dirty, clean the connector, and dry it with compressed air. If it is rusty or damaged, replace the fuel filter or the fuel feed line.
6. To prevent damage and keep foreign matter out, cover the disconnected connector and line ends with plastic bags (A). NOTE: The retainer cannot be reused once it has been removed from the line. Replace the retainer when: replacing the fuel rail. replacing the fuel line. replacing the fuel pump. replacing the fuel filter. replacing the EVAP canister. replacing the fuel fill pipe. replacing the fuel tank. it has been removed from the line. it is damaged.

Note. Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions (see FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS ).

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

1. Check the contact area (A) of the line (B) for dirt or damage, and clean it if needed.
2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after: replacing the fuel rail. replacing the fuel line. replacing the fuel pump. replacing the fuel filter. replacing the EVAP canister. replacing the fuel fill pipe. replacing the fuel tank. removing the retainer from the line. NOTE: When you replace a retainer, use the same size and manufacturer as the original retainer (see «FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS»(ref-360067-S25762389802010042600000) ).
3. Before connecting a new fuel tube/quick-connect fitting assembly (A), remove the old retainer (B) from the mating line.
4. Align the quick-connect fittings with the line (A), and align the retainer locking tabs (B) with the connector grooves (C). Then press the quick-connect fittings onto the line until both retainer tabs lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. Connection with new retainer Connection to new fuel line Reconnection to existing retainer
5. When you reconnect the connector with the old retainer, make sure the connection is secure and the tabs (A) are firmly locked into place; check visually and also by pulling the connector (B). When you replace the fuel line with a new one, make sure you remove the ring pull (C) upwards after you confirm the connection is secure. NOTE: Before you remove the ring pull, make sure the fuel line connection is secure. If the connection is not secure, the ring pull could break when you try to remove it. Connection to new fuel line
6. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.
7. If equipped, install the quick-connect fitting cover. Set the groove of the cover (A) on the fuel line (B) as shown, then install it. Make sure the cover is firmly locked in place.

Note. Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions (see FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS ).

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

1. Check the contact area (A) of the line (B) for dirt or damage, and clean it if needed.
2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after: replacing the fuel rail. replacing the fuel line. replacing the fuel pump. replacing the fuel filter. replacing the EVAP canister. replacing the fuel fill pipe. replacing the fuel tank. removing the retainer from the line. NOTE: When you replace a retainer, use the same size and manufacturer as the original retainer (see «FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS»(ref-360067-S25762389802010042600000) ).
3. Before connecting a new fuel line/quick-connect fitting assembly (A), remove the old retainer (B) from the mating line.
4. Align the quick-connect fittings with the line (A), and align the retainer locking tabs (B) with the connector grooves (C). Then press the quick-connect fittings onto the line until both retainer tabs lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. Connection with new retainer Connection with new retainer: Fuel fill neck tube Connection to new fuel line Connection to new fuel line: Fuel fill neck tube Reconnection to existing retainer Reconnection to existing retainer: Fuel fill neck tube
5. When you reconnect the connector with the old retainer, make sure the connection is secure and the tabs (A) are firmly locked into place; check visually and also by pulling the connector (B). When you replace the fuel line with a new one, make sure you remove the ring pull (C) upwards after you confirm the connection is secure. NOTE: Before you remove the ring pull, make sure the fuel line connection is secure. If the connection is not secure, the ring pull could break when you try to remove it. Connection to new fuel line
6. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat this two or three times, then make sure there are no fuel leaks.
7. If equipped, install the quick-connect fitting cover. Set the groove of the cover (A) on the fuel line (B) as shown, then install it. Make sure the cover is firmly locked in place.

The fuel filter should be replaced whenever the fuel pressure drops below the specified value (see FUEL PRESSURE TEST ), after making sure that the fuel pump and the fuel pressure regulator are OK.

Scheme 230

1. Remove the fuel tank unit (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360067-S30509578512010042600000) ).
2. Remove the fuel filter set (A).
3. Check these items before installing the fuel tank unit: When connecting the wire harness (B), make sure the connection is secure and the connectors are firmly locked into place. When installing the fuel gauge sending unit (C), make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.
4. Install the parts in the reverse order of removal with new O-rings (D) and a new bracket (E). When installing the fuel tank unit, align the marks on the unit and the fuel tank (see «INSTALLATION (2WD MODEL)»(ref-360067-S32909955702010042600000) ). NOTE: Coat the O-rings with clean engine oil; do not use any other oils or fluids. Do not pinch the O-rings during installation. Use all the new parts supplied in the fuel filter replacement kit.

The fuel filter should be replaced whenever the fuel pressure drops below the specified value (see FUEL PRESSURE TEST ), after making sure that the fuel pump and fuel pressure regulator are OK.

Scheme 231

1. Remove the fuel tank unit (see «REMOVAL (4WD MODEL)»(ref-360067-S16093505772010042600000) ).
2. Remove the fuel filter set (A).
3. Check these items before installing the fuel tank unit: When connecting the wire harness (B), make sure the connection is secure and the connectors are firmly locked into place. When installing the fuel gauge sending unit (C), make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.
4. Install the parts in the reverse order of removal with new O-rings (D). When installing the fuel tank unit, align the marks on the unit and the fuel tank (see «INSTALLATION (4WD MODEL)»(ref-360067-S39191643922010042600000) ). NOTE: Coat the O-rings with clean engine oil; do not use any other oil or fluid. Do not pinch the O-rings during installation. Use all the new parts supplied in the fuel filter replacement kit.

Scheme 232

Scheme 233

1. Remove the fuel tank unit; 2WD model (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360067-S30509578512010042600000) ), 4WD model (see «REMOVAL (4WD MODEL)»(ref-360067-S16093505772010042600000) ).
2. Remove the fuel level sensor (fuel gauge sending unit) (A) from the fuel tank unit (B). 2WD model 4WD model
3. Check these items before installing the fuel tank unit: When connecting the wire harness, make sure the connection is secure and the connector (C) is firmly locked into place. When installing the fuel gauge sending unit, make sure the connection is secure. Be careful not to bend or twist it excessively.
4. Install the parts in the reverse order of removal. When installing the fuel tank unit, align the marks on the unit and the fuel tank; 2WD model (see «INSTALLATION (2WD MODEL)»(ref-360067-S32909955702010042600000) ), 4WD model (see «INSTALLATION (4WD MODEL)»(ref-360067-S39191643922010042600000) ).

Note. For the fuel gauge system circuit diagram, refer to CIRCUIT DIAGRAM ).

Scheme 234

Scheme 235

1. Check the No. B5 METER (7.5 A) fuse in the under-dash fuse/relay box, and replace it if needed.
2. Check for body electrical system DTCs. If no DTCs are found, go to next step. If DTC B1175 or B1176 is indicated, go to the indicated DTC's troubleshooting.
3. Turn the ignition switch to LOCK (0).
4. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
5. Remove the access panel (A) from the left side of the floor.
6. Disconnect the fuel tank unit 4P connector (B).
7. Remove the fuel tank unit from the fuel tank (see «REMOVAL (4WD MODEL)»(ref-360067-S16093505772010042600000) ).
8. Measure the resistance between the No. 2 and No. 4 terminals of the fuel tank unit 4P connector with the float at E (EMPTY), LOW (LOW FUEL INDICATOR), and F (FULL) positions. If you do not get the following readings, replace the fuel gauge sending unit (see «FUEL PUMP/FUEL GAUGE SENDING UNIT REPLACEMENT»(ref-360067-S13422340902010042600000) ). If the fuel gauge sending unit readings are OK, do the secondary fuel gauge sending unit test (see «SECONDARY FUEL GAUGE SENDING UNIT TEST»(ref-360067-S05483076372010042600000) ). FLOAT POSITION Float Position F 6.673 in (169.5 mm) LOW 2.783 in (70.7 mm) E 1.189 in (30.2 mm) Resistance (ohms) 9 to 11 235.8 to 280 336.8 to 343.8 NOTE: Remove the No. A15 BACK UP (10 A) fuse from the under-hood fuse/relay box for at least 30 seconds after completing the test, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level.

Scheme 236

Scheme 237

1. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
2. Remove the access panel (A) from the right side of the floor.
3. Disconnect the secondary fuel gauge sending unit 4P connector (B).
4. Remove the secondary fuel gauge sending unit from the fuel tank (see «FUEL PUMP/FUEL GAUGE SENDING UNIT REPLACEMENT»(ref-360067-S13422340902010042600000) ).
5. Measure the resistance between the No. 2 and No. 4 terminals of the secondary fuel gauge sending unit 4P connector with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. FLOAT POSITION Float Position F 6.933 in (176.1 mm) 1/2 1.311 in (33.3 mm) E 1.094 in (27.8 mm) Resistance (0) 9 to 11 453.2 to 444.2 453.2 to 444.2 NOTE: Remove the No. A15 BACK UP (10 A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing the test, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level.