Repair Procedure

How to use this manual .

WARNING:  

Flammable - Keep Fire Away

NOTICE:  

Refer to the Fuel and Emissions Systems Service Precautions before doing the procedure.

Fuel Tank Area Replacement Component With Torque Specifications (1 Of 2) 

Courtesy of HONDA, U.S.A., INC.

: Torque, Nm (lbfft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

■: SPL Tool

: Required Removal

Fuel Tank Area Replacement Component With Torque Specifications (2 Of 2) 

Courtesy of HONDA, U.S.A., INC.

: Torque, Nm (lbfft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

■: SPL Tool

: Required Removal

Courtesy of HONDA, U.S.A., INC.

: Torque, Nm (lbfft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

■: SPL Tool

: Required Removal

1. A.-

   Key Information 

   Do the following before starting your work.

   Remove: 

   • Left Rear Inner Fender
   • Left Rear Side Trim Panel

   Sub-Procedure 

   Figure 1 

   Courtesy of HONDA, U.S.A., INC.

   Removal 

   1. Refer to figure 1.

   Figure 2 

   Courtesy of HONDA, U.S.A., INC.

   2. Refer to figure 2.

2. B.-

   Key Information 

   Do the following before starting your work.

   Remove: 

   • Left Rear Inner Fender

   Sub-Procedure 

   Courtesy of HONDA, U.S.A., INC.

   Removal 

   • Refer to the figure.
3. C.-

   Sub-Procedure 

   Figure 1 

   Courtesy of HONDA, U.S.A., INC.

   Removal 

   1. Pry out the four lock tabs (a), and turn the mis-fuel inhibit device (b) about 90 degrees. (Figure 1)

   Figure 2 

   Courtesy of HONDA, U.S.A., INC.

   Figure 3 

   Courtesy of HONDA, U.S.A., INC.

   2. Tilt the mis-fuel inhibit device (c) in the direction of the arrow to remove it from the fuel fill pipe. (Figure 2)

   NOTE:

   • Be careful not to damage the fuel fill pipe or the fuel fill pipe top side surface (d). (Figure 3)
   • Never reuse the mis-fuel inhibit device.

   Figure 4 

   Courtesy of HONDA, U.S.A., INC.

   Installation 

   • Install the new mis-fuel inhibit device (e). (Figure 4)

     NOTE:  Align the part (f) on the new mis-fuel inhibit device and the fuel fill pipe (g). (Figure 4)

4. D.-

   Sub-Procedure 

   Removal 

   1. Set the capless wrench and slightly turn the main flap unit (a) counterclockwise. (Figure 1)

   NOTE: The main flap unit may move only a small amount. This is normal.

   Figure 1 

   Courtesy of HONDA, U.S.A., INC.

   2. Remove the capless wrench and install the flapper retainer onto the main flap unit (b) as shown to keep the flap open. (Figure 2)

   Figure 2 

   Courtesy of HONDA, U.S.A., INC.

   3. Insert the capless pick under the lock tab (c) and release the lock by turning the pick counterclockwise. (Figure 3)

   NOTE: The lock tab is unlocked when it folds inside the filler neck opening.

   Figure 3 

   Courtesy of HONDA, U.S.A., INC.

   4. Set the capless wrench onto the main flap unit (d) as shown. (Figure 4)

   NOTE: It may be necessary to move the flapper retainer slightly to install the capless wrench.

   Figure 4 

   Courtesy of HONDA, U.S.A., INC.

   5. Turn the main flap unit clockwise until it stops, then remove it.

   NOTE: If the lock tab was disengaged properly, the main flap unit should turn easily. If you feel resistance, remove the capless wrench and confirm that the lock tab was disengaged.

   Installation 

   1. Position the new main flap unit (e) onto the filler neck (f) with the top arrow (g) at the 1 o'clock position. (Figure 5)

   Figure 5 

   Courtesy of HONDA, U.S.A., INC.

   2. Install the main flap unit (h) by doing the following procedures. (Figure 6)

   • Set the capless wrench onto the main flap unit.
   • While pressing down on the capless wrench, turn the main flap unit counterclockwise until you hear a click. The arrow on the main flap unit should face up.
   • Slightly turn the capless wrench clockwise to confirm that the lock tab is engaged. The main flap unit should not turn.

   Specifications (Figure 6) 

   Specification
   i	30 °

   Figure 6 

   Courtesy of HONDA, U.S.A., INC.

5. E.-

   Courtesy of HONDA, U.S.A., INC.

6. F.-

   Sub-Procedure 

   Removal 

   • Refer to the Figure.

   Courtesy of HONDA, U.S.A., INC.

7. G.-

   NOTICE:  

   Refer to the Fuel Line/ Quick-Connect Fitting Precautions before doing the procedure.

   Preconditions 

   • Fuel Pressure Relieved - Refer to: Fuel Pressure Relieving () or Fuel Pressure Test ()
   • 12 Volt Battery Negative Terminal Disconnected

   Key Information 

   Do the following before starting your work.

   Remove: 

   • Second Row Left Seat Assembly

   Sub-Procedure 

   NOTICE:  

   Be careful not to bend or twist the fuel gauge sending unit arm (a) excessively. (Figure 1)

   Figure 1 

   Courtesy of HONDA, U.S.A., INC.

   Removal 

   1. Refer to figure 2.

   Figure 2 

   Courtesy of HONDA, U.S.A., INC.

   2. Refer to figure 3.

   Figure 3 

   Courtesy of HONDA, U.S.A., INC.

   3. Refer to figure 4.

   Figure 4 

   Courtesy of HONDA, U.S.A., INC.

   4. Hook the lanyard (b) of the ORVR service plug on the hook (c). (Figure 5)

   NOTE: Set the ORVR service plug near the fuel tank unit opening.
   NOTE:

   • Do not damage any part of the ORVR service plug's surface (d). (Figure 5)
   • Damage to the ORVR service plug may cause fuel leaks into the inner fuel vent tube.
   • Use the provided protective cap (e) when the ORVR service plug is not in use. (Figure 5)
   • If there is damage, discard the ORVR service plug and order a new one.

   Figure 5 

   Courtesy of HONDA, U.S.A., INC.

   5. Disconnect fuel vent tube B (f) from the fuel tank unit (g) and hold it. (Figure 6)

   NOTE:

   Do not allow fuel vent tube B to drop into the fuel tank.

   Figure 6 

   Courtesy of HONDA, U.S.A., INC.

   6. Install the ORVR service plug onto fuel vent tube B. (Figure 6)

   NOTE:

   Make sure the ORVR service plug is fully seated by holding fuel vent tube B and gently pulling on the plug's lanyard.

   NOTE:  The ORVR service plug should not come off.

   7. Carefully lower fuel vent tube B (h) into the fuel tank (i), making sure the lanyard (k) of the ORVR service plug is free and away from the fuel tank unit (m). (Figure 7)

   NOTE: It is OK for the tube to be submerged in the fuel.

   Figure 7 

   Courtesy of HONDA, U.S.A., INC.

   Installation 

   1. Grab the lanyard (n) of the ORVR service plug and pull fuel vent tube B (o) up until it is close to the fuel tank unit opening. (Figure 8)

   NOTE: The ORVR service plug should not come off.

   Figure 8 

   Courtesy of HONDA, U.S.A., INC.

   2. Align the tab (p) and the mark (q), and insert the fuel tank unit (r) partially into the fuel tank. (Figure 8)

   3. Move the fuel tank unit aside, allowing space to remove the ORVR service plug from fuel vent tube B (s). (Figure 9)

   NOTE:

   Do not allow fuel vent tube B to fall inside the fuel tank.

   NOTE:  If fuel enters fuel vent tube B, a DTC will set and the fuel tank will need to be replaced.

   Figure 9 

   Courtesy of HONDA, U.S.A., INC.

   4. Hold the plugged fuel vent tube B while reinstalling the fuel tank unit.

   5. Remove the ORVR service plug away from the tank opening and connect fuel vent tube B to the fuel tank unit.

   6. Remove the lanyard (t) of the ORVR service plug from the hook (u), then install the provided protective cap (v). (Figure 10)

   Figure 10 

   Courtesy of HONDA, U.S.A., INC.

   7. Align the tab (w) and the mark (x), and temporarily insert the fuel tank unit cam lock ring (y). (Figure 11)

   NOTE:

   Make sure the fuel tank unit cam lock ring is seated correctly on the fuel tank unit with all tabs fully engaged.

   Figure 11 

   Courtesy of HONDA, U.S.A., INC.

   8. Using the fuel sender wrench, turn the fuel tank unit cam lock ring (z) clockwise. (Figure 12)

   NOTE:

   • Make sure the fuel sender wrench engages fully with the fuel tank unit cam lock ring.
   • Securely set the positioning edges (aa) of the fuel tank at the tabs (ab) on the fuel tank unit cam lock ring. (Figure 12)
   • Make sure the fuel tank unit cam lock ring is seated correctly on the fuel tank unit with all tabs fully engaged.

   Figure 12 

   Courtesy of HONDA, U.S.A., INC.

   9. Refer to figure 13.

   Figure 13 

   Courtesy of HONDA, U.S.A., INC.

   After Installation 

   • 12 Volt Battery Negative Terminal Reconnect
   • Fuel Leak Check (Low Pressure Side)
8. H.-

   Preconditions 

   • Fuel Pressure Relieved - Refer to: Fuel Pressure Relieving () or Fuel Pressure Test ()
   • Fuel Tank Drained - Refer to: Fuel Tank Draining () or Fuel Tank Removal and Installation ()

     NOTICE:  

     • Make sure to drain the fuel until the fuel tank is at or below 3/4, or drain the fuel until the fuel tank is empty as necessary.
     • After draining the fuel tank, temporarily install the fuel tank cam rock ring and the fuel tank unit without connecting the fuel tank unit connector and the quick-connect fitting and the connectors.
   • 12 Volt Battery Negative Terminal Disconnected
   • Park Lock Released - Refer to: A/T Road Test () or How to Release Park Lock () (AWD)

   Key Information 

   NOTE:  For the removal and installation procedure, refer to Fuel Tank Removal and Installation - Refer to: Fuel Tank Draining () or Fuel Tank Removal and Installation () and the sub-procedure below.

   Sub-Procedure 

   NOTICE:  

   • Be careful not to interfere with the surrounding parts when removing/installing the pipe.
   • To support the fuel tank, use a transmission jack or other support.

   Removal 

   1. Remove the clamps as shown. (Figure 1)

   Figure 1 

   Courtesy of HONDA, U.S.A., INC.

   After Installation 

   • 12 Volt Battery Negative Terminal Reconnect
   • Fuel Leak Check (Low Pressure Side)
   • Shift the transmission to P position/mode - Refer to: A/T Road Test () or How to Release Park Lock () . (AWD)
9. I.-

   NOTICE:  

   Refer to the Fuel Line/ Quick-Connect Fitting Precautions before doing the procedure.

   Key Information 

   Do the following before starting your work.

   Remove: 

   • Muffler (AWD)

   Disconnect: 

   • Propeller Shaft (Rear Differential Assembly Side) (AWD)

   Move: 

   • Rear Differential Assembly (as needed) (AWD)

   Sub-Procedure 

   Figure 1 (AWD) 

   Courtesy of HONDA, U.S.A., INC.

   Removal 

   1. Disconnect the connectors (a). (AWD) (Figure 1)

   2. Lower the rear differential assembly (b) as needed. (AWD) (Figure 1)

   Tool Details (Figure 1) 

   Name
   c	Transmission Jack(Commercially Available)

   NOTICE:  

   • To support the rear differential assembly, use a transmission jack or other support.
   • Be careful not to damage the connecting parts.

   Figure 2 

   Courtesy of HONDA, U.S.A., INC.

   3. Refer to figure 2.

10. J.-

    Key Information 

    Do the following before starting your work.

    Remove: 

    • Air Cleaner Housing

    Sub-Procedure 

    Installation 

    • Make sure the hose clamps are properly positioned and tightened .
11. K.-

    Courtesy of HONDA, U.S.A., INC.

12. L.-

    Sub-Procedure 

    Courtesy of HONDA, U.S.A., INC.

    Removal 

    • Refer to the figure.

      NOTICE:  

      Make sure to release from the clip tabs and not this tab (a).

13. M.-

    Sub-Procedure 

    Courtesy of HONDA, U.S.A., INC.

    Removal 

    • Refer to the figure.