Fuel Supply System: Removal & Installation Honda Crosstour I

Fuel Tank Unit Removal and Installation

Special Tools Required

Fuel Sender Wrench 07AAA-S0XA100

Scheme 142

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Scheme 144

1. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360067-S41893702602010042600000) ).
2. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
3. Remove the access panel (A) from the floor.
4. Disconnect the fuel tank unit 4P connector (B).
5. Disconnect the quick-connect fitting (C) from the fuel tank unit.
6. Using the special tool, loosen the locknut (A).
7. Remove the locknut (A) and the fuel tank unit (B).

Scheme 145

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Scheme 148

1. Temporarily attach a new base gasket (A) to the fuel tank unit (B), then insert the fuel tank unit partially into the fuel tank. NOTE: Be careful not to damage the new base gasket. Be careful not to bend the fuel gauge sending unit. Do not coat the base gasket with oil.
2. Transfer the base gasket (A) from the fuel tank unit to the fuel tank.
3. Align the marks (B) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank until the fuel tank unit rests on top of the base gasket. NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
4. Tighten a new locknut (A) by hand with a new locknut plate (B). NOTE: Before tightening, align the mark (C) on the locknut with the start of the threads (D).
5. Using the special tool, tighten the locknut to the specified torque. NOTE: After tightening, make sure the marks (A) are still aligned. After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
6. Connect the fuel tank unit 4P connector, then connect the quick-connect fitting.
7. 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.
8. Install the access panel.
9. Install the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
10. Install the fuel fill cap.

Special Tools Required

Fuel Sender Wrench 07AAA-S0XA100

Scheme 149

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Scheme 151

1. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360067-S41893702602010042600000) ).
2. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
3. Remove the access panel (A) from the left side of the floor.
4. Disconnect the fuel tank unit 4P connector (B).
5. Disconnect the quick-connect fitting (C) from the fuel tank unit.
6. Using the special tool, loosen the locknut (A).
7. Remove the locknut (A), and lift up the fuel tank unit (B).
8. Disconnect the transfer tube (C), and remove the fuel tank unit.

Scheme 152

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Scheme 155

1. Temporarily attach a new base gasket (A) to the fuel tank unit (B), position the mark of the transfer tube (C) up, connect the transfer tube (D), then insert the fuel tank unit partially into the fuel tank. NOTE: Be careful not to damage the new base gasket. Make sure the clamp (E) is positioned as shown. Be careful not to bend the fuel gauge sending unit. Do not coat the base gasket with oil.
2. Transfer the base gasket (A) from the fuel tank unit to the fuel tank.
3. Align the marks (B) on the fuel tank and the fuel tank unit, then insert the fuel tank unit into the fuel tank until the fuel tank unit rests on top of the base gasket. NOTE: To prevent a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
4. Tighten a new locknut (A) by hand with a new locknut plate (B). NOTE: Before tightening, align the mark (C) on the locknut with the start of the threads (D).
5. Using the special tool, tighten a new locknut to the specified torque. NOTE: After tightening, make sure the marks (A) are still aligned. After installation, check the base gasket, visually or by hand, to be sure it is not pinched.
6. Connect the fuel tank unit 4P connector, then connect the quick-connect fitting.
7. 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 two or three times, then make sure there are no fuel leaks.
8. Install the access panel.
9. Install the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
10. Install the fuel fill cap.

Scheme 156

1. Remove the fuel tank unit (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360067-S30509578512010042600000) ).
2. Remove the reservoir (A).
3. Remove the bracket (B).
4. Remove the fuel pressure regulator (C).
5. Install the parts in the reverse order of removal with new O-rings (D) and a new bracket. 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 pressure regulator replacement kit.

Scheme 157

1. Remove the fuel tank unit (see «REMOVAL (4WD MODEL)»(ref-360067-S16093505772010042600000) ).
2. Remove the bracket (A).
3. Remove the pressure regulator (B).
4. Install the parts in the reverse order of removal with a new O-ring (C). When installing the fuel tank unit, align the marks on the fuel tank unit and the fuel tank (see «INSTALLATION (4WD MODEL)»(ref-360067-S39191643922010042600000) ). NOTE: Coat the O-ring with clean engine oil; do not use any other oil or fluid. Do not pinch the O-ring during installation. Use all the new parts supplied in the pressure regulator replacement kit.

Secondary Fuel Gauge Sending Unit Removal and Installation

Special Tools Required

Fuel Sender Wrench 07AAA-S0XA100

Scheme 158

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Scheme 160

1. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360067-S41893702602010042600000) ).
2. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
3. Remove the access panel (A) from the right side of the floor.
4. Disconnect the secondary fuel gauge sending unit 4P connector (B).
5. Using the special tool, loosen the locknut (A).
6. Remove the locknut (A), and lift up the secondary fuel gauge sending unit (B) from the fuel tank.
7. Disconnect the transfer tube (C), and remove the secondary fuel gauge sending unit.

Scheme 161

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Scheme 164

1. Temporarily attach a new base gasket (A) to the secondary fuel gauge sending unit (B), position the mark on the transfer tube (C) up, connect the transfer tube (D), then insert the secondary fuel gauge sending unit partially into the fuel tank. NOTE: Be careful not to damage the new base gasket. Make sure the clamp (E) is positioned as shown. Be careful not to bend the secondary fuel gauge sending unit. Do not coat the base gasket with oil.
2. Transfer the base gasket (A) from the secondary fuel gauge sending unit to the fuel tank.
3. Align the marks (B) on the fuel tank and the secondary fuel gauge sending unit, then insert the secondary fuel gauge sending unit into the fuel tank until the fuel tank unit rests on top of the base gasket. NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
4. Tighten a new locknut (A) by hand with a new locknut plate (B). NOTE: Before tightening, align the mark (C) on the locknut with the start of the threads (D).
5. Using the tool, tighten a new locknut to the specified torque. NOTE: After tightening, make sure the marks (A) are still aligned. After installation, check the base gasket, visually or by hand, to be sure it is not pinched.
6. Connect the secondary fuel gauge sending unit 4P connector.
7. 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 two or three times, then make sure there are no fuel leaks.
8. Install the parts in the reverse order of removal.

Scheme 165

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Scheme 167

1. Drain the fuel tank (see «FUEL TANK DRAINING»(ref-360067-S03147460382010042600000) ).
2. Reinstall the fuel tank unit without connecting the fuel tank unit 4P connector and the quick-connect fitting (see «INSTALLATION (2WD MODEL)»(ref-360067-S32909955702010042600000) ).
3. Remove the fuel fill pipe cover (see «FUEL FILL PIPE REMOVAL/INSTALLATION»(ref-360067-S17235066662010042600000) ).
4. Disconnect the quick-connect fittings (A) (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(ref-360067-S09699164122010042600000) ) disconnect the fuel fill hose (B) from the fuel fill pipe. Slide back the clamps, then twist the hose as you pull to avoid damaging the hose or the pipe).
5. Raise the vehicle on a lift.
6. Disconnect the hose (A) from the EVAP canister.
7. Remove the hose (B) from the clamp (C). NOTE: Be careful not to damage the hose.
8. Remove the muffler (see «EXHAUST PIPE AND MUFFLER REPLACEMENT»(ref-360066-S26221145352010042600000) ).
9. Remove left and right the middle floor under covers (see «MIDDLE FLOOR UNDERCOVER REPLACEMENT - 2WD»(ref-360102-S36589609472010042600000) ).
10. Remove the fuel tank protector (A).
11. Remove the right parking brake cable mounting bolts (see «PARKING BRAKE CABLE REPLACEMENT»(ref-360059-S10860804002010042600000) ).
12. Place a jack or other support under the fuel tank (B).
13. Remove the strap bolts (C) and the straps (D).
14. Remove the fuel tank.
15. Install the parts in the reverse order of removal. NOTE: New fuel tanks have a ring pull (E) at the fuel vapor hose connector (F). When you connect the hose and confirm that the connection is secure, remove the ring pull by pulling it down. Before connecting the fuel fill pipe and the quick-connect fitting, check for dirt, and clean it if needed, taking care not to damage the fuel fill pipe and other parts. When installing the fuel tank protector, make sure to insert it into the clip (G) in the direction shown.

Scheme 168

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Scheme 171

1. Drain the fuel tank (see «FUEL TANK DRAINING»(ref-360067-S03147460382010042600000) ).
2. Reinstall the fuel tank unit without connecting the fuel tank unit 4P connector and the quick-connect fitting (see «INSTALLATION (4WD MODEL)»(ref-360067-S39191643922010042600000) ). Then reinstall the secondary fuel gauge sending unit without connecting the secondary fuel tank unit 4P connector (see «INSTALLATION (4WD MODEL)»(ref-360067-S29050052312010042600000) ).
3. Remove the fuel fill pipe cover (see «FUEL FILL PIPE REMOVAL/INSTALLATION»(ref-360067-S17235066662010042600000) ).
4. Disconnect the quick-connect fittings (A) from the fuel fill pipe (B).
5. Raise the vehicle on a lift.
6. Remove the muffler (see «4WD MODEL»(ref-360066-S42738491082010042600000) ).
7. Remove the propeller shaft (see «PROPELLER SHAFT RUNOUT»(ref-360062-S27938504032010042600000) ).
8. Remove left and right the middle floor under covers (see «MIDDLE FLOOR UNDERCOVER REPLACEMENT - 4WD»(ref-360102-S05989559742010042600000) ).
9. Support the rear differential with a transmission jack, then remove the rear differential mounting bolts (A and B), and lower the rear differential (C).
10. Place a jack or other support under the fuel tank (A).
11. Remove the strap bolts (B) and the straps (C).
12. Slowly lower the fuel tank, and disconnect the hose (D) and the quick-connect fitting (E).
13. Remove the fuel tank.
14. Remove the fuel tank protector (A) from the fuel tank.
15. Install the parts in the reverse order of removal. NOTE: When installing the fuel tank protector, make sure to insert it into the clip (B) in the direction shown. Before connecting the fuel fill pipe and the quick-connect fittings, check for dirt, and clean them if needed, taking care not to damage the fuel fill pipe and other parts.

Scheme 172

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Scheme 175

1. Drain the fuel tank (see «FUEL TANK DRAINING»(ref-360067-S03147460382010042600000) ).
2. Remove the left rear wheel.
3. Remove the fuel fill pipe cover (A).
4. Disconnect the fuel fill tube: 2WD model: Disconnect the quick-connect fitting (A) (see «2WD MODEL»(ref-360067-S15479247342010042600000) ), then disconnect the fuel fill hose (B) from the fuel fill pipe by sliding back the clamp on the hose and twisting as you pull, to avoid damaging the hose or the pipe. 4WD model: Disconnect the quick-connect fittings (A) (see «4WD MODEL»(ref-360067-S15404952152010042600000) ). 2WD model 4WD model
5. Remove the fuel fill pipe (A).
6. Install the parts in the reverse order of removal. NOTE: Before connecting the fuel fill pipe and the quick-connect fitting, check for dirt, and clean it if needed, taking care not to damage the fuel fill pipe and other parts.