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Fuel Supply System: Diagnosis Honda Crosstour I

Testing & Diagnostics 27 illustrations ~2025 words

Fuel Pump Circuit Troubleshooting

If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is on, you will hear some noise if you listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is turned to ON (II). If the fuel pump does not make noise, check as follows

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Scheme 115: Fuel Pump Circuit Troubleshooting
Scheme 115: Fuel Pump Circuit Troubleshooting

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  1. Turn the ignition switch to LOCK (0).
  2. Remove the driver's dashboard lower cover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360087-S14123292982010042600000) ).
  3. Remove PGM-FI main relay 2 (A) from the driver's under-dash fuse/relay box.
  4. Turn the ignition switch to ON (II).
  5. Measure the voltage between PGM-FI main relay 2 4P connector terminal No. 3 and body ground. Is there battery voltage? YES -Go to 13 . NO -Go to next step.
  6. Turn the ignition switch to LOCK (0).
  7. Remove PGM-FI main relay 1 (A) and the ETCS control relay (B) from the under-hood fuse/relay box.
  8. Jump the SCS line with the HDS.
  9. Disconnect the engine wire harness 13P connector.
  10. Disconnect driver's under-dash fuse/relay box connector F (33P).
  11. Connect PGM-FI main relay 1 4P connector terminal No. 2 to body ground with a jumper wire.
  12. Check for continuity between driver's under-dash fuse/relay box connector F (33P) terminal No. 12 and body ground. Is there continuity? YES -Replace the driver's under-dash fuse/relay box; USA models (see «DRIVER'S UNDER-DASH FUSE/RELAY BOX (MICU) REMOVAL AND INSTALLATION»(ref-360103-S08550671172010042600000) ), Canada models (see «CANADA MODELS»(ref-360103-S33586290172010042600000) ). NO - Repair an open in the wire between the under-hood fuse/relay box and the driver's under-dash fuse/relay box. If the wire is OK, replace the under-hood fuse/relay box; USA models (see «DRIVER'S UNDER-DASH FUSE/RELAY BOX (MICU) REMOVAL AND INSTALLATION»(ref-360103-S08550671172010042600000) ), Canada models (see «CANADA MODELS»(ref-360103-S33586290172010042600000) ).
  13. Measure the voltage between PGM-FI main relay 2 4P connector terminal No. 2 and body ground. Is there battery voltage? YES -Go to next step. NO - Check the No. B9 FUEL PUMP (20 A) fuse in the driver's under-dash fuse/relay box. If the fuse is OK, replace the driver's under-dash fuse/relay box; USA models (see «DRIVER'S UNDER-DASH FUSE/RELAY BOX (MICU) REMOVAL AND INSTALLATION»(ref-360103-S08550671172010042600000) ), Canada models (see «CANADA MODELS»(ref-360103-S33586290172010042600000) ).
  14. Turn the ignition switch to LOCK (0).
  15. Connect PGM-FI main relay 2 4P connector terminal No. 4 to body ground with a jumper wire.
  16. Jump the SCS line with the HDS.
  17. Disconnect PCM connector A (49P).
  18. Check for continuity between body ground and PCM connector terminal A11. Is there continuity? YES -Go to next step. NO -Repair an open in the wire between PGM-FI main relay 2 and the PCM (A11).
  19. Reinstall PGM-FI main relay 2.
  20. Connect PCM connector terminal A6 to body ground with a jumper wire.
  21. Turn the ignition switch to ON (II).
  22. Measure the voltage between PCM connector terminal A11 and body ground. Is there battery voltage? YES -Go to next step. NO -Replace PGM-FI main relay 2.
  23. Turn the ignition switch to LOCK (0).
  24. Reconnect PCM connector A (49P).
  25. Turn the ignition switch to ON (II), and measure the voltage between driver's under-dash fuse/relay box connector F (33P) terminal No. 33 and body ground within 2 seconds. Is there battery voltage? YES -Update the PCM if it does not have the latest software (see «PCM UPDATE»(ref-360080-S11980508702010042600000) ), or substitute a known-good PCM (see «SUBSTITUTING THE PCM»(ref-360056-S32194616542010042600000) ), then recheck. If the symptom/indication goes away and the PCM was updated, troubleshooting is complete. If the symptom/indication goes away and the PCM was substituted, replace the original PCM (see «PCM REPLACEMENT»(ref-360080-S27881728262010042600000) ). NO -Go to next step.
  26. Turn the ignition switch to ON (II), and measure the voltage between driver's under-dash fuse/relay box connector F (33P) terminal No. 33 and body ground after 2 seconds. Is there battery voltage? YES -Go to next step. NO -Replace the driver's under-dash fuse/relay box; USA models (see «DRIVER'S UNDER-DASH FUSE/RELAY BOX (MICU) REMOVAL AND INSTALLATION»(ref-360103-S08550671172010042600000) ), Canada models (see «CANADA MODELS»(ref-360103-S33586290172010042600000) ).
  27. Turn the ignition switch to LOCK (0).
  28. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360101-S08204536602010042600000) ).
  29. Remove the access panel from the floor (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360067-S30509578512010042600000) ).
  30. Turn the ignition switch to ON (II), and measure the voltage between fuel tank unit 4P connector terminal No. 1 and body ground within 2 seconds. Is there battery voltage? YES -Go to 35 . NO -Go to next step.
  31. Turn the ignition switch to LOCK (0).
  32. Remove PGM-FI main relay 2.
  33. Connect PGM-FI main relay 2 4P connector terminals No. 1 and No. 2 with a jumper wire.
  34. Turn the ignition switch to ON (II), and measure the voltage between fuel tank unit 4P connector terminal No. 1 and body ground. Is there battery voltage? YES -Replace PGM-FI main relay 2. NO - Repair an open in the wire between the driver's under-dash fuse/relay box (D5) and the fuel tank unit 4P connector. If the wire is OK, replace the driver's under-dash fuse/relay box; USA models (see «DRIVER'S UNDER-DASH FUSE/RELAY BOX (MICU) REMOVAL AND INSTALLATION»(ref-360103-S08550671172010042600000) ), Canada models (see «CANADA MODELS»(ref-360103-S33586290172010042600000) ).
  35. Turn the ignition switch to LOCK (0).
  36. Check for continuity between fuel tank unit 4P connector terminal No. 3 and body ground. Is there continuity? YES -Replace the fuel pump (see «FUEL PUMP/FUEL GAUGE SENDING UNIT REPLACEMENT»(ref-360067-S13422340902010042600000) ). NO -Repair an open in the wire between the fuel tank unit 4P connector and G602 (2WD model) (see «LEFT SIDE WIRE HARNESS (2WD) (BH)»(ref-360100-S31128590232010042600000) ), G803 (4WD model) (see «SRS FLOOR WIRE HARNESS (4WD) (SA)»(ref-360100-S37930704872010042600000) ).

Fuel Pressure Test

Special Tools Required

  1. Fuel Pressure Gauge 07406-004000B
  2. Fuel Pressure Gauge Attachment Set 07AAJ-S6MA150

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  1. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360067-S41893702602010042600000) ).
  2. Attach the fuel pressure gauge set and the fuel pressure gauge.
  3. Start the engine, and let it idle. If the engine starts, go to 5 . If the engine does not start, go to next step.
  4. Check to see if the fuel pump is running: Listen to the fuel filler port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned to ON (II). If the pump runs, go to next step. 2WD model: If the pump does not run, do the fuel pump circuit troubleshooting (see «FUEL PUMP CIRCUIT TROUBLESHOOTING»(ref-360067-S41704584722010042600000) ). 4WD model: If the pump does not run, check for DTCs, then do the appropriate DTC troubleshooting procedure.
  5. Read the fuel pressure gauge. The pressure should be 390-440 kPa (4.0-4.5 kgf/cm 2 , 57-64 psi) . If the pressure is OK, the test is complete. If the pressure is out of specification, replace the fuel pressure regulator; 2WD model (see «FUEL PRESSURE REGULATOR REPLACEMENT»(ref-360067-S19477298432010042600000) ), 4WD model (see «FUEL PRESSURE REGULATOR REPLACEMENT»(ref-360067-S19477298432010042600000) ) and the fuel filter; 2WD model (see «FUEL FILTER REPLACEMENT»(ref-360067-S35106764042010042600000) ), 4WD model (see «FUEL FILTER REPLACEMENT»(ref-360067-S35106764042010042600000) ), then recheck the fuel pressure.

Transfer Fuel Pump Test

Special Tools Required

Vacuum Pump/Gauge, 0-30 inHg Snap-on YA4000A or equivalent, commercially available

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Scheme 132: 4WD model
Scheme 132: 4WD model

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  1. Remove the secondary fuel gauge sending unit (see «FUEL PUMP/FUEL GAUGE SENDING UNIT REPLACEMENT»(ref-360067-S13422340902010042600000) ).
  2. Connect a vacuum pump/gauge, 0-30 inHg, to the transfer tube (A).
  3. Turn the ignition switch to ON (II).
  4. From the INSPECTION MENU of the HDS, select Fuel Pump ON.
  5. Read the vacuum pump/gauge. The vacuum should be 4.0 kPa (1.2 inHg, 30 mmHg). If the vacuum is OK, the transfer fuel pump and the transfer tube is OK. If the vacuum is out of specification, go to next step.
  6. Turn the ignition switch to LOCK (0).
  7. Install the secondary fuel gauge sending unit (see «INSTALLATION (4WD MODEL)»(ref-360067-S29050052312010042600000) ).
  8. Remove the fuel tank unit (see «REMOVAL (4WD MODEL)»(ref-360067-S16093505772010042600000) ).
  9. Connect the vacuum pump/gauge, to the fuel tank unit (A).
  10. Lower the fuel tank unit (A) into the fuel tank until the pick up screen is submerged in the fuel.
  11. Connect the fuel tank unit 4P connector (B).
  12. Turn the ignition switch to ON (II).
  13. From the INSPECTION MENU of the HDS, select Fuel Pump ON.
  14. Read the vacuum pump/gauge. The vacuum should be 4.0 kPa (1.2 inHg, 30 mmHg). If the vacuum is OK, replace the transfer tube, then recheck the fuel vacuum. If the vacuum is out of specification, replace the fuel tank unit (see «REMOVAL (4WD MODEL)»(ref-360067-S16093505772010042600000) ), then recheck the fuel vacuum.

Fuel Line Inspection

Check the fuel system lines and hoses for damage, leaks, and deterioration. Replace any damaged parts.

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Scheme 135: 2WD model
Scheme 135: 2WD model

Check all clamps, and make sure they are properly positioned and tightened.

2WD model

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Check the fuel system lines and hoses for damage, leaks, and deterioration. Replace any damaged parts.

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Scheme 137: 4WD model
Scheme 137: 4WD model

Check all clamps, and make sure they are properly positioned and tightened.

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Scheme 138: 4WD model
Scheme 138: 4WD model

Fuel Gauge Sending Unit Test

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

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Scheme 139: 2WD model
Scheme 139: 2WD model

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  1. Check the No. B5 METER (7.5 A) fuse in the driver's 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 floor.
  6. Disconnect the fuel tank unit 4P connector (B).
  7. Measure the voltage between fuel tank unit 4P connector terminals No. 2 and No. 4 with the ignition switch turned to ON (II). There should be battery voltage. If the voltage is OK, go to next step. If the voltage is not as specified, check for: a short in the PUR wire to ground. an open in the PUR or ORN wire.
  8. Turn the ignition switch to LOCK (0).
  9. Remove the fuel tank unit from the fuel tank (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360067-S30509578512010042600000) ).
  10. Measure the resistance between fuel tank unit 4P-connector terminals No. 2 and No. 4 with the float at E (EMPTY), LOW (LOW FUEL INDICATOR), 1/2 (HALF FULL), 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) ). FLOAT POSITION Float Position F 6.110 in (155.2 mm) 1/2 3.843 in (97.6 mm) LOW 1.606 in (40.8 mm) E 0.626 in (15.9 mm) Resistance (ohms) 19 to 21 196.7 to 206.7 503.8 to 589.4 772 to 788
  11. Reconnect the fuel tank unit 4P connector.
  12. Remove the No. A15 BACK UP (10 A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it.
  13. Turn the ignition switch to ON (II).
  14. Check that the fuel gauge pointer indicates F with the float at F. If the fuel gauge pointer does not indicate F, replace the gauge control module. If the fuel gauge pointer indicates F, the test is complete. NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is turned to ACC (I) and LOCK (0), regardless of the fuel level. 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.

Low Fuel Indicator Test

  1. Do the gauge self-diagnostic test (see «SELF-DIAGNOSTIC FUNCTION»(ref-360081-S05232586632010042600000) ). If the low fuel indicator flashes, go to next step. If the low fuel indicator does not flash, replace the gauge control module (see «GAUGE CONTROL MODULE REPLACEMENT»(ref-360081-S32262066982010042600000) ).
  2. Check for body electrical system DTCs. If any DTCs are indicated, do the indicated DTC's troubleshooting. If no DTCs are indicated, go to next step.
  3. Do the fuel gauge sending unit test; 2WD model (see «FUEL GAUGE SENDING UNIT TEST»(ref-360067-S25451088922010042600000) ), 4WD model (see «4WD MODEL»(ref-360067-S26457115352010042600000) ). (4WD model: Also do the secondary fuel gauge sending unit test (see «SECONDARY FUEL GAUGE SENDING UNIT TEST»(ref-360067-S05483076372010042600000) ).

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