Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSHONDA2002INSIGHT AUTOMATIC CVTREPAIR AND DIAGNOSISENGINE PERFORMANCESYSTEMFUEL SUPPLY SYSTEMFUEL TANK REPLACEMENT2000-2005 MODELS
2002 Honda Insight Automatic CVT
2000-2005 models
2002 Honda Insight Automatic CVTSECTION 2000-2005 models
- Relieve the fuel pressure; 2000-2003 models (see 2000-2003 MODELS ), 2004-2005 models (see 2004-2005 MODELS ).
- Raise the vehicle, and support it with jackstands.
- Remove the muffler (see COMPONENT LOCATION INDEX ).
- Place a jack, or other support, under the tank.
- Remove the shield (A), remove the strap bolts, and let the straps (B) fall free.
Courtesy of AMERICAN HONDA MOTOR CO., INC.
This illustration shows the 2000-2005 M/T models.
- Disconnect the fuel fill neck tube (C), fuel vapor hoses (D) and quick-connect fittings (E). Disconnect the hoses. Slide back the clamps, then twist the hoses as you pull to avoid damaging them.
- Drain the fuel tank: Using a hand pump, hose, and container suitable for fuel, draw the fuel from the fuel tank.
- Disconnect the fuel tank unit 5P connector (F).
- Remove the fuel tank (G). If it sticks to the undercoat on its mount, carefully pry it off the mount.
- Install the parts in the reverse order of removal.
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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.