2012 Honda Insight BaseFACTORY OEM SERVICE PROCEDURE

Fuel Tank Replacement

  1. Drain the fuel tank until it is less than half full (see FUEL TANK DRAINING ).
  2. Reinstall the fuel tank unit without connecting the fuel tank unit 4P connector, and the quick-connect fittings (see FUEL TANK UNIT REMOVAL AND INSTALLATION ).
  3. Raise the vehicle on a lift.
  4. Disconnect the quick-connect fittings (A) (see FUEL LINE/QUICK-CONNECT FITTING REMOVAL ).
    Fig 1: Identifying Quick-Connect Fittings
    G08092567Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the hose (A) from the clamp (B).
    Fig 2: Removing Hose From Clamp
    G08092568Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Remove the middle floor undercover (see MIDDLE FLOOR UNDERCOVER REPLACEMENT ).
  7. Remove the trailing arm braces (see REAR WHEELWELL GUSSET REPLACEMENT ).
  8. Place a jack or other support under the fuel tank (A).
    Fig 3: Fuel Tank, Protectors, Straps And Bolts With Torque Specifications
    G08092569Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Remove the strap bolts (B) and the straps (C).
  10. Remove the fuel tank.
  11. Remove the fuel tank protectors (D).
  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 (E).
  13. Install the parts in the reverse order of removal.
    Fig 4: Identifying Ring Pull, Fuel Tank Vapor Recirculation Tube And Fuel Fill Neck Tube
    G08092570Courtesy of AMERICAN HONDA MOTOR CO., INC.
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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