I had the fuel pump out, so I thought I might as well take some pictures, and maybe it will help someone else do this task. The Fuel-Pump or Senders rarely fail (unless your get in an accident/rear-ended), so I doubt this guide will get much use.
Note how many bars show on the Dash Fuel Guage. So that after you have installed it all back, you can check again to see if its the same amount of bars, just to check if you didnt accidentally damage the sender (very delicate!!)
The fuel pump is accessible without dropping the fuel tank which is convenient. This is for the Manual Insight. The CVT is probably very similar
Disconnect 12v battery and Flip IMA relay switch to OFF for safety.
Fuel Pressure can be relieved by unbolting the nut on the left side of the fuel rail.
Remove Rear speakers if you have.
Pop off the side trim panels and the runner panels.
Remove the Center Cargo Net pocket (7 Phillips screws)
Remove HandBrake Cover. (2 screws on rear sides)
Remove 6 Grey push fasteners at bottom of carpet to remove and fold back carpet over rear.
Remove Middle Panel (13 Bolts (10mm) )
Remove Fuel Hoses (Squeeze Retainer Clip and Pull pipe away)
*According to the manual, do not remove the retainer clips from the pipes or they have to be replaced*
Unscrew Plastic Retainer ring on FuelPump (Use Special honda tool, or tap the ridges with a flathead and a hammer to turn it loose)
*Make note of the position of the FuelPump Assembly. There will be marks on the right side*
Pull out the Fuel Pump Assembly carefully at an angle, as the Fuel Sender unit is still attached. It should pop up since its got a spring inside.
Fuel Pump assembly has 2 Connectors. One for the FuelPump and one for the sender assembly. Everything slides/pops in or out of its place. Pretty simple actually. Here are some pictures of the fuel pump. There is a Suction Filter at the bottom and another FuelFilter near the center of the assembly (not visible)
Installation is reverse of removal.
When inserting the fuel pump assembly, make sure you insert it carefully with the sender attached, and at an angle. Its easier to slide the fuelPump assembly inside if the gasket is on the tank instead of the fuelPump assembly.
Make sure it is lined up with the correct marks.
Make sure the fuel hoses are connected securely, and possibly plug FuelPump connector and 12v Battery back, and do a key-on to pressurize the fuel system and check there are no leaks
Great Photos and Details... I had pack rats that chewed up a rubber hose at the top of the fuel tank/sender unit, starting leaking gas... so I took it to Honda. They said they had to lower the fuel tank to access the $1.25 piece, cost $300 for their time. Now if it happens again I will know how to do it. Thanks a lot!
Re Hitech comment about the IMA fan vent - What 02Insight means is to remove the Fan Intake, the fan actually vents back into the IMA battery area and then into the Tire well area via holes in the IMA Battery area cage.
#1 - 2000 Silver #4965, not working now, 175k Miles, 61 LMPG - will probably turn into all Electric
#2 - 2000 Silver #4095, 212k Miles, 55 LMPG, OBDIIC&C by Peter, GCIM1 by Mike, New MaxIMA by Eli www.TucsonEV.com
I was looking for a better way to judge nut torque other than a screwdriver and a hammer. The two best tools in a man's toolbox.
I did get a large channel lock set and that made the difference. Lower half of the pump module had bent tabs. It's all back together now.
You would think that since the assembly is sprung against the tank floor that there would be a knob or something to prevent the pump module from exploding like that in a crash.
I'm letting it all dry overnight. With the fuel lines off, full tank, and 107 degrees, the fuel was expanding into the catch basin around the fuel pump. Don't want to connect the battery yet. Not in a rush.
2000 Insight #5488 AC MT
Best Tank 875
The AutoGuide.com network consists of the largest network of enthusiast-owned enthusiast-operated automotive communities.
AutoGuide.com provides the latest car reviews, auto show coverage, new car prices, and automotive news. The AutoGuide network operates more than 100 automotive forums where our users consult peers for shopping information and advice, and share opinions as a community.