2000 Honda InsightFACTORY OEM SERVICE PROCEDURE

Valve Test

  1. Make sure the fuel tank is less than half full.
  2. Remove the fuel fill cap.
  3. Remove the fuel pipe cover. Disconnect the fuel tank vapor signal tube (A).
    Fig 1: Disconnecting Fuel Tank Vapor Signal Tube
    G03681211Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Disconnect the vacuum hoses (A) from the EVAP canister (B), then plug the ports with caps (C).
    Fig 2: Disconnecting Vacuum Hoses From EVAP Canister
    G03681212Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Disconnect the vacuum hose (D) from the EVAP canister vent shut valve (E), and connect a vacuum pump/gauge, 0-30 in.Hg, to the vacuum hose.
  6. Pump the vacuum pump 80 times.
    • If the vacuum holds, go to step 7.
    • If the vacuum does not hold, go to step  9.
  7. Connect a second vacuum pump/gauge, 0-30 in.Hg, to the fuel tank vapor signal tube (A).
    Fig 3: Connecting Second Vacuum Pump/Gauge To Fuel Tank Vapor Signal Tube
    G03681213Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Apply vacuum (1 pump) to the fuel tank vapor signal tube (A), then check the vacuum on the pump in step 6.
  9. Disconnect the fuel tank vapor recirculation tube from the EVAP canister, then cap the port on the canister. Reapply vacuum (80 pumps).
    • If the vacuum holds, replace the fuel tank vapor control valve (see FUEL TANK VAPOR CONTROL VALVE REPLACEMENT ).
    • If the vacuum does not hold, inspect the EVAP canister vent shut valve O-ring. If the O-ring is OK, replace the EVAP canister, and repeat step 4.
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:

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

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