Fuel Supply System: Removal & Installation Honda Insight ZE2

Fuel Line/Quick-Connect Fitting Removal

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 ).

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1. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360273-S39576641402010042800000) ), keep the 12 volt battery connected.
2. Check the fuel quick-connect fittings (A) for dirt, and clean them if needed.
3. 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.
4. 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 pump, the fuel filter, or the fuel feed line.
5. 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 feed line. replacing the fuel pump. replacing the fuel filter. replacing the fuel gauge sending unit. replacing the EVAP purge line. replacing the EVAP canister. replacing the fuel fill pipe. replacing the fuel tank. it has been removed from the fuel line. it is damaged.

Fuel Line/Quick-Connect Fitting Installation

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 ).

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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 feed line. replacing the fuel pump. replacing the fuel filter. replacing the fuel gauge sending unit. replacing the EVAP purge line. replacing the EVAP canister. replacing the fuel fill pipe. replacing the fuel tank. removing the retainer from the fuel line. Use the same manufacturer retainer and the same size when replacing the retainer (see «FUEL LINE/QUICK-CONNECT FITTING PRECAUTIONS»(ref-360273-S28567086642010042800000) ).
3. Before connecting a new fuel tube/quick-connect fitting assembly (A), remove the old retainer (B) from the mating line. NOTE: When replacing the fuel tube/quick - connect fitting assembly at the engine compartment, remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ), and the bracket (C).
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 Connection to new fuel line: Fuel fill neck tube Connection to new fuel line: Fuel vent tube Reconnection to existing retainer Reconnection to existing retainer: Fuel fill neck tube
5. When you are reconnecting 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 are replacing 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. Reconnection to existing retainer Connection to new fuel line
6. 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 check for fuel leaks.

Fuel Tank Unit Removal and Installation

Special Tools Required

Fuel Pump Module Locknut Wrench 07AAA-SNAA100

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1. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360273-S39576641402010042800000) ).
2. Remove the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360310-S19761204892010042800000) ).
3. Remove the access panel. (A) from the floor.
4. Disconnect the fuel tank unit 4P connector (B).
5. Disconnect the quick-connect fittings (C) from the fuel tank unit.
6. Using the special tool, loosen the locknut (A).
7. Remove the locknut (A), the fuel tank unit (B), and the locknut plate (C).

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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. Using the special tool, tighten a new locknut (A) with a new locknut plate (B) to the specified torque. NOTE: Before tightening , align the marks (C) on the locknut with the start of the threads (D).
5. Using the special tool, tighten the locknut (A) to the specified torque. NOTE: After tightening, make sure the marks 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, and the vent tube.
7. Reconnect the negative cable to the 12 volt 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 rises. Repeat this two or three times, then check for fuel leaks.
8. Install the access panel.
9. Install the rear seat cushion (see «REAR SEAT REMOVAL/INSTALLATION»(ref-360310-S19761204892010042800000) ).
10. Install the fuel fill cap.

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1. Remove the fuel tank unit (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360273-S15365231902010042800000) ).
2. Remove the reservoir (A).
3. Remove the bracket (B).
4. Remove the ground ring (C).
5. Remove the fuel pressure regulator (D).
6. Install the parts in the reverse order of removal with new O-rings (E) and a new bracket. When installing the fuel tank unit, align the marks on the unit and the fuel tank (see «INSTALLATION»(ref-360273-S06165995712010042800000) ). 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.

Fuel Filter Replacement

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.

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1. Remove the fuel tank unit (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360273-S15365231902010042800000) ).
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»(ref-360273-S06165995712010042800000) ). 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.

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1. Remove the fuel tank unit (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360273-S15365231902010042800000) ).
2. Remove the fuel level sensor (fuel sending unit) (A) from the fuel tank unit (B).
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 (see «INSTALLATION»(ref-360273-S06165995712010042800000) ).

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1. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360273-S39576641402010042800000) ).
2. Remove the engine cover (see step 2 «IGNITION COIL REPLACEMENT»(ref-360276-S13366270182010042800000) ).
3. Remove the intake manifold (see «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-360272-S27603810092010042800000) ).
4. Remove the fuel rail mounting nuts from the fuel rail.
5. Disconnect the fuel injector connectors.
6. Remove the fuel rail.
7. Place a wrench (A) on the fuel rail (B).
8. Place second wrench (C) on the fuel pulsation damper (D).
9. Remove the pulsation damper by holding the first wrench while turning the second wrench.
10. Install the fuel pulsation damper in the reverse order of removal with new washers. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. If the drain hole (A) of the fuel pulsation damper cover does not face bottom, reinstall it as shown.

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1. Drain the fuel tank until it is less than half full (see «FUEL TANK DRAINING»(ref-360273-S12108613442010042800000) ).
2. Reinstall the fuel tank unit without connecting the fuel tank unit 4P connectors, the quick-connect fitting or the vent tube (see «FUEL TANK UNIT REMOVAL AND INSTALLATION»(ref-360273-S15365231902010042800000) ).
3. Raise the vehicle on a lift.
4. Disconnect the quick-connect fittings (A) (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(ref-360273-S13389400172010042800000) ).
5. Remove the hose (A) from the clamp (B).
6. Remove the middle floor undercover (see «RIGHT SIDE»(ref-360308-S14591769532010042800000) ).
7. Remove the trailing arm braces (A).
8. Place a jack or other support under the fuel tank (B).
9. Remove the strap bolts (C) and the straps (D).
10. Remove the fuel tank.
11. Remove the fuel tank protectors (E).
12. Install the parts in the reverse order of removal. NOTE: When installing the fuel tank protectors, make sure to insert the clips in the direction shown (F).

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1. Drain the fuel tank until it is less than half full (see «FUEL TANK DRAINING»(ref-360273-S12108613442010042800000) ).
2. Remove the fuel fill cap.
3. Raise the vehicle on a lift.
4. Remove the left rear wheel.
5. Remove the fuel fill pipe cover (A).
6. Disconnect the quick-connect fittings (A).
7. Remove the fuel fill pipe (B).
8. Disconnect the quick-connect fittings (C).
9. Remove the clip (D) from the fuel fill pipe.
10. Install the parts in the reverse order of removal.