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Fuel Supply System: Diagnosis Honda Insight ZE2

Testing & Diagnostics 20 illustrations ~1521 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 12: Fuel Pump Circuit Troubleshooting
Scheme 12: Fuel Pump Circuit Troubleshooting

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  1. Turn the ignition switch to LOCK (0).
  2. Remove PGM-FI main relay 2 (A) from the auxiliary under-hood fuse/relay box (to the left of the 12 volt battery).
  3. Turn the ignition switch to ON (II).
  4. Measure the voltage between PGM-FI main relay 2 4P connector terminal No. 4 and body ground. Is there battery voltage? YES -Go to step 6 . NO -Go to step 5.
  5. Measure the voltage between under-dash fuse/relay box B connector (36P) terminal No. 8 and body ground. Is there battery voltage? YES -Repair an open in the wire between PGM-FI main relay 2 and the under-dash fuse/relay box. NO - Replace PGM-FI main relay 1. If needed, replace the under-dash fuse/relay box (see «REMOVAL AND INSTALLATION»(ref-360306-S00499054042010042800000) ).
  6. Measure the voltage between PGM-FI main relay 2 4P connector terminal No. 2 and body ground. Is there battery voltage? YES -Go to step 8 . NO -Go to step 7.
  7. Measure the voltage between under-dash fuse/relay box B connector (36P) terminal No. 14 and body ground. Is there battery voltage? YES -Repair an open in the wire between PGM-FI main relay 2 and the under-dash fuse/relay box. NO - Check the No. 20 FUEL PUMP (15A) fuse in the under dash fuse/relay box. If the fuse is OK, replace the under-dash fuse/relay box (see «REMOVAL AND INSTALLATION»(ref-360306-S00499054042010042800000) ).
  8. Turn the ignition switch to LOCK (0).
  9. Connect PGM-FI main relay 2 4P connector terminal No. 3 to body ground with a jumper wire.
  10. Jump the SCS line with the HDS.
  11. Disconnect PCM connector A (44P).
  12. Check for continuity between PCM connector terminal A15 and body ground. Is there continuity? YES -Go to step 13. NO -Repair an open in the wire between PGM-FI main relay 2 and the PCM (A15).
  13. Reinstall PGM-FI main relay 2.
  14. Connect PCM connector terminal A6 to body ground with a jumper wire.
  15. Turn the ignition switch to ON (II).
  16. Measure the voltage between PCM connector terminal A15 and body ground. Is there battery voltage? YES -Go to step 17. NO -Replace PGM-FI main relay 2.
  17. Turn the ignition switch to LOCK (0).
  18. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360310-S19761204892010042800000) ).
  19. Remove the access panel from the floor (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360273-S15365231902010042800000) ).
  20. Disconnect the fuel tank unit 4P connector.
  21. Reconnect PCM connector A (44P).
  22. Turn the ignition switch to ON (II), and measure the voltage between fuel tank unit 4P connector terminal No. 2 and body ground within 2 seconds. Is there battery voltage? YES -Go to step 23. NO -Go to step 25 .
  23. Turn the ignition switch to LOCK (0).
  24. Check for continuity between fuel tank unit 4P connector terminal No. 4 and body ground. Is there continuity? YES -Replace the fuel pump (see «FUEL PUMP/FUEL GAUGE SENDING UNIT REPLACEMENT»(ref-360273-S38097445532010042800000) ). NO -Repair an open in the wire between the fuel tank unit and G602 (see «FLOOR WIRE HARNESS (LEFT BRANCH)»(ref-360302-S11006141632010042800000) ).
  25. Turn the ignition switch to LOCK (0).
  26. Remove PGM-FI main relay 2 (A) from the auxiliary under-hood fuse/relay box (to the left of the 12 volt battery).
  27. Connect PGM-FI main relay 2 4P connector terminals No. 1 and No. 2 with a jumper wire.
  28. Turn the ignition switch to ON (II), and measure the voltage between fuel tank unit 4P connector terminal No. 2 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-360284-S30758408212010042800000) ), or substitute a known-good PCM (see «SUBSTITUTING THE PCM»(ref-360279-S07789660702010042800000) ), then recheck. If the symptom/indication goes away with a known-good PCM, replace the original PCM (see «PCM REPLACEMENT»(ref-360284-S39322714792010042800000) ). NO -Repair an open in the wire between the fuel tank unit and PGM-FI main relay 2.

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-360273-S39576641402010042800000) ).
  2. Disconnect the quick-connect fitting. Attach the fuel pressure gauge set and the fuel gauge.
  3. Reinstall the air cleaner (A) (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
  4. Install PGM-FI main relay 2.
  5. Start the engine, and let it idle. If the engine starts, go to step 7 . If the engine does not start, go to step 6.
  6. 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 step 7. If the pump does not run, do the fuel pump circuit troubleshooting (see «FUEL PUMP CIRCUIT TROUBLESHOOTING»(ref-360273-S34346135242010042800000) ).
  7. Read the fuel pressure gauge. The pressure should be 260-310 kPa (2.7-3.2 kgf/cm 2 , 38-46 psi). If the pressure is OK, the test is complete. If the pressure is out of specification, replace the fuel pressure regulator (see «FUEL PRESSURE REGULATOR REPLACEMENT»(ref-360273-S12774623602010042800000) ) and the fuel filter (see «FUEL PRESSURE REGULATOR REPLACEMENT»(ref-360273-S12774623602010042800000) ), then recheck the fuel pressure.

Fuel Line Inspection

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

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Scheme 27: Fuel Line Inspection
Scheme 27: Fuel Line Inspection

Check all quick - connect fittings, and make sure they are properly positioned and tightened.

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Fuel Gauge Sending Unit Test

Note. For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram (see CIRCUIT DIAGRAM ).

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Scheme 29: Fuel Gauge Sending Unit Test
Scheme 29: Fuel Gauge Sending Unit Test

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  1. Check the No. 22 METER (7.5 A) fuse in the under-dash fuse/relay box before testing.
  2. Check for body electrical system DTCs. If no problem is found, go to step 3. 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-360310-S19761204892010042800000) ).
  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. 1 and No. 3 with the ignition switch turned to ON (II). There should be battery voltage. If the voltage is OK, go to step 8. If the voltage is not as specified, check for: a short in the LT GRN wire to ground. an open in the LT GRN or BLK 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-360273-S15365231902010042800000) ).
  10. Measure the resistance between fuel tank unit 4P connector terminals No. 1 and No. 3 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-360273-S38097445532010042800000) ). FLOAT POSITION (2010) Float Position F 136.3 mm (5.4 in) 1/2 78.6 mm (3.1 in) LOW 30.1 mm (1.2 in) E 16.4 mm (0.6 in) Resistance (ohms) 19 to 21 197.3 to 207.3 489.6 to 639.6 772 to 788 FLOAT POSITION (2011) Float Position F 136.3 mm (5.4 in) 1/2 78.6 mm (3.1 in) LOW 30.1 mm (1.2 in) E 16.4 mm (0.6 in) Resistance (ohms) 19 to 21 202.9 to 212.9 508.3 to 653.1 772 to 788
  11. Reconnect the fuel tank unit 4P connector.
  12. Remove the No. 1 BACK UP (15 A) fuse from the under-dash fuse/relay box for at least 10 seconds, then reinstall it.
  13. Turn the ignition switch to ON (II).
  14. Check that the pointer of the fuel gauge indicates F with the float at F. If the pointer of the fuel gauge does not indicate F, replace the gauge control module. If the gauge is OK, the test is complete. NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is in ACC (I) and to LOCK (0), regardless of the fuel level. Remove the No. 1 BACK UP (15 A) fuse from the under-dash fuse/relay box for at least 10 seconds after completing troubleshooting, 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 function (see «SELF-DIAGNOSTIC FUNCTION»(ref-360289-S15994914432010042800000) ). If the low fuel indicator flashes, go to step 2. If the low fuel indicator does not flash, replace the gauge control module (see «FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS»(ref-360273-S28567086642010042800000) ).
  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 step 3.
  3. Do the fuel gauge sending unit test (see «FUEL FILL PIPE REMOVAL/INSTALLATION»(ref-360273-S32893298822010042800000) ).

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