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2 GENERAL INFORMATION ............................................................................................................... 5 ABOUT THIS ENCYCLOPEDIA................................................................................................................. 6 VEHICULE IDENTIFICATION NUMBER (VIN) ......................................................................................... 7 FEATURES AND SPECIFICATIONS.....................................................
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3 LIGHTWEIGHT BODY PANELS ............................................................................................................. 26 BODY REPAIR INFORMATION .............................................................................................................. 27 Dacro Coated Bolts........................................................................................................................ 27 Body Repair Techniques.......................................................
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4 Design ............................................................................................................................................ 58 BATTERY MODULE ............................................................................................................................. 60 JUNCTION BOARD ............................................................................................................................... 61 BATTERY CONDITION MONITOR (BCM)......................
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5 GENERAL INFORMATION
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6 ABOUT THIS ENCYCLOPEDIA This encyclopedia is provided so that you can learn more about the Insight and how it works. While every effort has been made to insure its accuracy, this information shouldn't be used as the basis for repairs or modifications to your Insight. If you wish to do any work with your insight, a Service Manual, Electrical Troubleshooting Manual and Body Repair Manual are all available from your Honda dealer. Information contained in this encyclopedia is a compilation
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7 VEHICULE IDENTIFICATION NUMBER (VIN) The Insight's VIN can be found many places on the car. The easiest and most visible location is through a small window at the bottom driver's side corner of the windshield: An Insight VIN is broken into fields as follows: JHM ZE1 3 7 - 1 T 000001 Where each field can be decoded as follows: JHM Manufacturer / make / vehicle type JHM: Honda Motor Co Ltd / Honda / Passenger Car ZE1 Model / engine ZE1: Insight / ECA1 3 Body / transmission 3: 2
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8 FEATURES AND SPECIFICATIONS Overview Vehicle type Subcompact, two-seater, front-wheel drive, gasoline-electric hybrid Major features: · 5-speed manual transmission · Anti-lock brakes · Electric power steering · Dual air bags (SRS) · Alloy wheels · Digital instrument panel · AM/FM stereo cassette w/clock · Power windows · Power mirrors · Power door locks with keyless entry · Anti-theft "immobilizer" system (engine won't start without code transmitted from the key) ·
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9 12 valve SOHC Valve train VTEC-E variable valve timing and lift technology Bore x stroke 72 mm x 81.5 mm Displacement 0.995 liter Compression ratio 10.8:1 Tune-up interval 170,000 km (105,000 mi) Engine weight 56 kg (124 lbs.) Electric motor 10 kW permanent magnet DC brushless motor Size 60 mm (2.4") thick Output Without assist With assist 50 kW (68 hp) 56 kW (76 hp) Max. power @ 5700 rpm @ 5700 rpm 91 Nm (67 lb-ft) 113 Nm (83 lb-ft) Max. torque @ 4800 rpm @ 1500 rpm 5-speed
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10 Wheels & Tires 14 x 5.5J Wheels Cast aluminum Bridgestone Potenza RE92 165/65R14 78S Tires Treadwear 260 Traction A Temperature B Tubeless Steel Belted Radial M+S Body Construction Type Aluminum monocoque All structural components and most body panels are extruded or die-cast aluminum Materials Front fenders & rear fender skirts are a recyclable ABS/nylon composite Dimensions and Weight (see also Scale Drawings) Length 3945 mm (155 1/8") Height (excluding antenna) 1355 mm (
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11 Fuel Consumption & Emissions 3.4 l/100km (EUDC) Fuel consumption 61 mpg city / 70 mpg highway (EPA) CO2 emissions 80 g/km California emission standards ULEV compliance
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12 SCALE DRAWINGS
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13 Non-Scale Drawing of Cargo Area (Courtesy of John Johnson)
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14 MAINTENANCE
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15 SPECIAL MAINTENANCE CONSIDERATIONS Engine Oil The Insight uses an API SJ rated oil with an SAE 0W-20 viscosity. For maximum fuel economy this oil should be used. Washing Remove the rear wheel skirts and the roof mounted antenna before driving in any automated car washes equipped with tire scrubbing type brushes. The rear wheel skirts can be removed by turning the two stud fasteners located at the front and rear of the skirt. Vehicle Lift Points The Insight's plastic and aluminum
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16 LONG-TERM STORAGE In addition to a conventional 12V battery, the Insight has a
. When the vehicle is stored for a long period, the IMA battery will gradually discharge and must be charged periodically (ideally once every three months). To maintain the IMA battery, follow this procedure: 1. Remove the 40A EPS Fuse (No. 15) from the Under-Hood Fuse box in the engine compartment, then start the engine. The EPS warning light on the dashboard will illuminate because the EPS
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17 HATCH ACCESS The Insight rear hatch differs from many Honda models because there is no mechanical linkage between the hatch release on the outside of the vehicle and the actual latch. The exterior latch release is actually a switch that operates a hatch opener relay. A hatch release motor is operated by the relay. The hatch opener switch and hatch unlock (key) switch are both in series with the relay. If the battery is discharged or disconnected, the hatch must be opened manually by use
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18 TOWING INFORMATION To accommodate flat-bed towing equipment, the Insight is provided with a front towing hook, and front and rear tie down hook holes. The towing hook can be used with a winch to pull the Insight onto the truck, and the tie down holes can be used to secure the vehicle to the truck. To install the towing hook, first wrap the flat end of the jack handle or screwdriver with a soft cloth to prevent damage to the painted bumper surface, and then pry the cover off. Next, screw
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19 SERVICE SAFETY CONSIDERATIONS The Insight's IMA system employs high-voltage components and highly magnetic components, and so anyone working on the IMA system must exercise caution and follow Service Manual procedures carefully. IMA Motor Rotor The rotor of the IMA motor is highly magnetic. Consequently, all iron, magnetic and electronic materials must be kept away from the rotor if it is to be replaced. The rotor should not be handled by people with a pacemaker or other similar med
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20 SERVICE CONNECTORS The Insight uses an industry standard OBD-II onboard diagnostics system. This system allows standard OBD-II diagnostic tools (including OBD-II software and connector cable available for Windows PCs; see below) to be connected to the Insight's engine control computer. This allows access to a wide range of real time performance and status information from the Insight. It also allows access to the log of any "DTC" codes that the computer records when the "Check Engine L
