Honda Fuel Supply System User manual

2000

06 ENGINE PERFORMANCE

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fuel Supply System - Insight

COMPONENT LOCATION INDEX

2000-2005 M/T MODELS

Fig. 1: Identifying Fuel Supply System Component Location Index (2000-2005 M/T Models) Courtesy of AMERICAN HONDA MOTOR CO., INC.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 2: Identifying Fuel Supply System Component Location Index (2000-2005 CVT Models) Courtesy of AMERICAN HONDA MOTOR CO., INC.

2006 MODEL

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 3: Identifying Fuel Supply System Component Location Index - 2006 Models (1 Of 2) Courtesy of AMERICAN HONDA MOTOR CO., INC.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 4: Identifying Fuel Supply System Component Location Index - 2006

Models (2 Of 2)

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Courtesy of AMERICAN HONDA MOTOR CO., INC.

PGM-FI MAIN RELAY CIRCUIT TROUBLESHOOTING

2000-2004 MODELS

1. Turn the ignition switch OFF, then disconnect the PGM-FI main relay connectors.

2. Check for continuity between body ground and PGM-FI main relay diode 2P connector terminal No. 2.

Fig. 5: Checking For Continuity Between Body Ground And PGM

connector terminal No. 2.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Main Relay Diode 2P Connector Terminal No. 2 Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there continuity?

YES -Go to step 3. NO -Repair open in the wire between the PGM-FI main relay and G101.

3. Measure voltage between body ground and PGM-FI main relay (IGP) 4P

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 6: Measuring Voltage Between Body Ground And PGM-FI Main

Relay (IGP) 4P Connector Terminal No. 2

PGM

FI main relay (IGP) 4P connector terminal No. 4.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there battery voltage?

YES -Go to step 5 . NO -Go to step 4.

4. Check for a blown No. 7 (15 A) fuse in the under-hood fuse/relay box. Is the fuse blown?

YES -Repair short in the wire between the PGM-FI main relay and the No. 7 (15 A) fuse.

NO -Repair open in the wire between the PGM-FI main relay and the No. 7 (15 A) fuse.

5. Turn the ignition switch ON (II). Measure voltage between body ground and PGM-FI main relay (FUEL PUMP) 4P connector terminal No. 2, and between

2 (15 A) fuse.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 7: Measuring Voltage Between Body Ground And PGM-FI Main Relay (Fuel Pump) 4P Connector Terminal No. 2 Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there battery voltage?

6. Check for a blown No. 2 (15 A) fuse in the under-dash fuse/relay box. Is the fuse blown?

YES -Go to step 7 . NO -Go to step 6.

YES -Repair short in the wire between the PGM-FI main relay and the

No. 2 (15 A)fuse. NO -Repair open in the wire between the PGM-FI main relay and the No.

-Go to step 9.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

7. Turn the ignition switch OFF, and disconnect ECM connector A (32P).

8. Check for continuity between PGM-FI main relay (FUEL PUMP) 4P connector terminal No. 3 and ECM connector terminal A15.

Fig. 8: Checking For Continuity Between PGM-FI Main Relay (Fuel Pump) 4P Connector Terminal No. 3 And ECM Connector Terminal A15 Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there continuity?

YES

the ECM (B1, B9). If the wires are OK, replace the PGM

FI main relay.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

NO -Repair open in the wire between the PGM-FI main relay (FUEL PUMP) and the ECM (A15).

9. Reconnect ECM connector A (32P) and the PGM-FI main relay connectors.

10. Turn the ignition switch ON (II), then measure voltage between ECM connector terminals B1 and B20, and between B9 and B20.

Fig. 9: Measuring Voltage Between ECM Connector Terminals B1 And B20 Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there battery voltage?

YES -Go to step 11. NO -Check for an open in the wires between the PGM-FI main relay and

the latest software, or substitute a

ECM UPDATING AND SUBSTITUTION

FOR TESTING

2002

2006 M/T MODELS AND CVT MODEL

), then

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

11. Turn the ignition switch OFF, then ON (II) again, and measure voltage between ECM connector terminals A15 and B2 within the first 2 seconds.

Fig. 10: Measuring Voltage Between ECM Connector Terminals A15 And B2 Within First 2 Seconds Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there 1.0 V or less?

YES -The PGM-FI main relay may be faulty (see PGM-FI MAIN RELAY TEST ).

NO -Update the ECM if it does not have known-good ECM; 2000-2001 M/T models (see HOW TO TROUBLESHOOT CIRCUITS AT THE ECM ), 2002-2004 M/T

models and CVT model (see

connector terminal No. 3.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM (see ECM REPLACEMENT ).

2005-2006 MODELS

1. Turn the ignition switch OFF.

2. Disconnect the PGM-FI main relay (IGP) 4P connector.

3. Check for continuity between body ground and PGM-FI main relay (IGP) 4P

Courtesy of AMERICAN HONDA MOTOR CO., INC.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 11: Checking For Continuity Between Body Ground And PGM-FI Main Relay (IGP) 4P Connector Terminal No. 3

connector terminals No. 2 and No. 4 individually.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Is there continuity?

YES -Repair short in the wire between ECM connector terminal A8 and the PGM-FI main relay (IGP).

NO -Go to step 4.

4. Measure voltage between body ground and PGM-FI main relay (IGP) 4P

YES

-Go to step

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 12: Measuring Voltage Between Body Ground And PGM-FI Main Relay (IGP) 4P Connector Terminals No. 2 And No. 4 Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there battery voltage?

terminal No. 2 and body ground.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

NO -Go to step 5.

5. Check for a blown No. 7 (15 A) fuse in the under-hood fuse/relay box. Is the fuse blown?

YES -Repair short in the wire between the PGM-FI main relay (IGP) and the No. 7 (15 A) fuse.

NO -Repair open in the wire between the PGM-FI main relay (IGP) and the No. 7 (15A)fuse.

6. Turn the ignition switch ON (II).

7. Measure voltage between PGM-FI main relay (FUEL PUMP) 4P connector

-Go to step 8.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 13: Measuring Voltage Between PGM-FI Main Relay (Fuel Pump) 4P Connector Terminal No. 2 And Body Ground Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there battery voltage?

YES -Go to step 9 . NO

connector terminal No. 3 and ECM connector terminal A15.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

8. Check for a blown No. 2 (15 A) fuse in the under-dash fuse/relay box. Is the fuse blown?

YES -Repair short in the wire between the PGM-FI main relay (FUEL PUMP) and the No. 2 (15 A) fuse.

NO -Repair open in the wire between the PGM-FI main relay (FUEL PUMP) and the No. 2 (15 A) fuse.

9. Turn the ignition switch OFF, and wait for 10 seconds.

10. Disconnect ECM connector A (32P).

11. Check for continuity between PGM-FI main relay (FUEL PUMP) 4P

13.

Turn the ignition switch ON (II).

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 14: Checking For Continuity Between PGM-FI Main Relay (Fuel Pump) 4P Connector Terminal No. 3 And ECM Connector Terminal A15 Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there continuity?

YES -Go to step 12. NO -Repair open in the wire between the PGM-FI main relay (FUEL

PUMP) and the ECM (A15).

12. Reconnect ECM connector A (32P) and the PGM-FI main relay (FUEL PUMP) connectors.

15.

Turn the ignition switch OFF.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

14. Measure voltage between body ground and ECM connector terminals B1 and B9 individually.

Fig. 15: Measuring Voltage Between Body Ground And ECM Connector Terminals B1 And B9 Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there battery voltage?

YES -Go to step 15. NO -Check for an open in the wires between the PGM-FI main relay

(IGP) and the ECM (B1, B9). If the wires are OK, replace the PGM-FI main relay.

Turn the ignition switch ON (II), and measure voltage between ECM connector

Update the ECM if it does not have the latest software, or substitute a

), then

replace the original ECM (see

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

16. terminals A15 and B2 within 2 seconds.

Fig. 16: Measuring Voltage Between ECM Connector Terminals A15 And B2 Within 2 Seconds Courtesy of AMERICAN HONDA MOTOR CO., INC.

Is there 1.0 V or less?

YES -The PGM-FI main relay may be faulty (see PGM-FI MAIN RELAY TEST ).

NO known-good ECM (see ECM UPDATING AND SUBSTITUTION FOR TESTING-2002-2006 M/T MODELS AND CVT MODEL

recheck. If the symptom/indication goes away with a known-good ECM,

ECM REPLACEMENT

PGM

FI MAIN RELAY TEST

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Check for continuity between the terminals.



There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals.



There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected.

Fig. 17: Terminals Continuity Table Courtesy of AMERICAN HONDA MOTOR CO., INC.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 18: Identifying Connector Terminals Courtesy of AMERICAN HONDA MOTOR CO., INC.

FUEL PRESSURE RELIEVING

theft code for the radio, then write down the audio

Use a wrench on the sealing nut (A) at the fuel rail.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Before disconnecting fuel pipes or hoses, release pressure from the system by loosening the sealing nut on top of the fuel rail.

2000-2003 MODELS

1. Make sure you have the antipresets.

2. Disconnect the negative cable from the battery.

3. Remove the fuel fill cap.

Reconnect the battery negative cable.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 19: Loosening Sealing Nut At Fuel Rail Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Place a rag or shop towel (B) over the sealing nut.

6. Slowly loosen the sealing nut one complete turn.

NOTE: Replace all washers whenever the sealing nut is

loosened or removed.

7. Tighten the sealing nut.

theft code for the radio, then write down the audio

Use a wrench on the 6 mm service bolt (A) at the fuel rail.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

9. Do the ECM idle learn procedure (see ECM IDLE LEARN PROCEDURE

10. Remove the No. 15 (40 A) fuse from the under-hood fuse/relay box.

11. If the IMA battery level gauge (BAT) displays no segments, start the engine, and hold it between 3,500 RPM and 4,000 RPM without load (in Park or neutral) until the BAT displays at least three segments.

12. Reinstall the No. 15 (40 A) fuse.

13. Do the start clutch calibration procedure (see START CLUTCH CALIBRATION PROCEDURES ).

14. Enter the anti-theft code for the radio, then enter the audio presets, and set the clock.

Before disconnecting fuel lines or hoses, release pressure from the system by loosening the 6 mm service bolt sealing nut on top of the fuel rail.

2004-2005 MODELS

1. Make sure you have the antipresets.

2. Disconnect the negative cable from the battery.

3. Remove the fuel fill cap.

10.

Remove the No. 15 (40 A) fuse from the under

hood fuse/relay box.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

Fig. 20: Loosening Service Bolt At Fuel Rail Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Place a rag or shop towel (B) over the sealing nut.

6. Slowly loosen the 6 mm service bolt one complete turn.

NOTE: Replace all washers whenever the 6 mm service bolt is

loosened or removed.

7. Tighten the sealing nut.

8. Reconnect the battery negative cable.

9. Do the ECM idle learn procedure (see ECM IDLE LEARN PROCEDURE

stopping the fuel pump and then disconnecting the fuel tube/quick connect fitting in

theft code for the radio, then write down the audio

Remove the quick

connect fitting cover (A).

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

12. Reinstall the No. 15 (40 A) fuse.

13. Do the start clutch calibration procedure (see START CLUTCH CALIBRATION PROCEDURES ).

14. Enter the anti-theft code for the radio, then enter the audio presets, and set the clock.

Before disconnecting fuel lines or hoses, relieve pressure from the system by the engine compartment.

2006 MODEL

1. Make sure you have the antipresets.

2. Remove the PGM-FI main relay (FUEL PUMP) from the multi relay box.

3. Start the engine, and let it idle until it stalls.

NOTE: If any DTCs are stored, clear and ignore them.

4. Turn the ignition switch OFF.

5. Remove the fuel fill cap.

6. Disconnect the negative cable from the battery.

2006 Honda Insight

2000-06 ENGINE PERFORMANCE Fuel Supply System - Insight

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