2000 Honda InsightFACTORY OEM SERVICE PROCEDURE

2000-2005 models

The fuel line/quick-connect fittings (A), (B) connect the fuel tank unit to the fuel feed line and the fuel return line. When removing or installing the fuel pump and fuel tank, it is necessary to disconnect or connect the quick-connect fittings.

Pay attention to the following:

  • The fuel feed hose (C), fuel return hose (D), and quick-connect fittings are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures.
  • The fuel feed hose, fuel return hose, and quick-connect fittings are not acid-proof; do not touch them with a shop towel that was used for wiping battery electrolyte. Replace them if they come in contact with electrolyte or something similar.
  • When connecting or disconnecting the fuel feed hose, fuel return hose, and quick-connect fittings, be careful not to bend or twist them excessively. Replace them if they are damaged.

M/T modelΒ 

Fig 1: Identifying Fuel Line/Quick-Connect Fittings (M/T Model)
G03681045Courtesy of AMERICAN HONDA MOTOR CO., INC.

CVT modelΒ 

Fig 2: Identifying Fuel Line/Quick-Connect Fittings (CVT Model)
G03681046Courtesy of AMERICAN HONDA MOTOR CO., INC.

A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Replace the retainer when:

  • replacing the fuel tank.
  • replacing the fuel pump.
  • replacing the fuel filter.
  • replacing the fuel gauge sending unit.
  • replacing the fuel feed line.
  • replacing the fuel return line.
  • it has been removed from the line.
  • it is damaged.
    QUICK-CONNECT FITTING SPECIFICATIONS

    Location Manufacturer Retainer color Line diameter
    A Sanoh White 0.4 in.
    (9.5 mm)
    B Sanoh White 0.3 in.
    (8 mm)
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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