For a printed owner’s manual, click on authorized manuals or go to . Your selection of a Honda Insight was a wise investment. Honda will repair or. Afterwards, keep this owner’s manual in your vehicle so you can refer to Your selection of a Honda Insight was a wise investment. hazards associated with operating or maintaining the engine speed to 2, rpm, and hold it there. Workshop Manual. Honda Insight Workshop Manual L Hybrid; (14, Pages). (Free). Honda Insight Workshop Manual L3 L; (14, Pages).

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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. 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 Space blocks must be used with any plate style lift to avoid damage to the rocker panels or rear strakes. The Mid Center point is for use when lifting the Insight with a floor jack.

In this case, a rubber pad should be positioned between the lift platform and support point. To maintain the IMA battery, follow this procedure: The exterior latch release is actually a switch that operates a hatch opener relay. A hatch release motor is operated isight the relay. The hatch opener switch and hatch unlock key switch are both in series with the relay.

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 oqners vehicle to the truck. Consequently, all iron, magnetic and electronic materials must be kept away from the rotor if it is to be replaced.

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 majual status information from the Insight. Regardless of what power source msnual car is using, the less its aerodynamic drag, the less energy will be needed to travel at any given speed.

A great deal of effort has gone into designing the Insight around the goal of achieving excellent aerodynamics, the end result being a drag coefficient of only 0. The unit-body part of the Insight’s body uses stressed sheet-metal panels to absorb and distribute structural and suspension loads, much like an ordinary steel unit body.

However, with the Insight’s body all inisght these panels, including the roof, floor, front and rear wheel wells, rear quarter-panels, bulkhead, and even the doors and hood, are made of aluminum alloy.

On the Insight, each frame member’s size and strength is optimized so that the frame is strong where it needs to be, and lighter in less critical areas. A variety of shapes are used, including hexagons, ovals, H- sections and reinforced box-sections. The door and windshield pillars, front and rear side-frame members, lower body sills, cross members and floor frame members are all formed in this manner.

The front fenders, spoilers, under body cover and rear fender skirts are all made of plastic. Also, lightweight sound insulating materials are used throughout the Insight.

Service Manual and Body Repair Manual. The information below is by no means complete repair procedures; it is simply provided to give you some of the key procedures that should be followed if you ever have someone carry out repairs on your Insight’s body.

Welding Wash and grind the welding zone. Plastic is also used for transporting and storing gasoline in the form of the commonly seen red plastic “cans”. Construction The Insight’s plastic fuel tank is made up of six layers of four different materials: A typical hydraulic power steering system is continually placing a small load on the engine, even when no steering assist is required.


Electronic Construction The EPS control unit is mounted inside the car on the right side bulkhead, underneath the dash. It receives input from the vehicle speed sensor and torque sensor mounted on the steering pinion shaft.

The torque sensor is identical in construction to the unit on the S The pinion shaft engages the pinion gear via a torsion bar, which twists slightly when there is a high amount of steering resistance.

At the lower end, the strut mounts solidly to the steering knuckle, locating it vertically. The lower end of the knuckle mounts to a lower control arm. On the Insight, the knuckle and lower control arm are aluminum forgings, providing maximum strength but minimizing unsprung weight.

Weight is also saved by These are connected midway along their length by a curved, H-section steel torsion beam that twists to allow a controlled level of independent suspension movement. This arrangement works with very short springs and dampers which allow for a very low rear floor, while the suspension system still sits entirely below the floor.

This helps to reduce the weight and drag of the components significantly without a loss of strength in the components. There are many other new design features which include: While a typical cast iron drum might weigh 3.

The drum’s outside diameter is mm. The modulator unit and ABS control unit are integrated into one component which also includes relays, wires and electrical couplers. Outward visibility, sightlines and control placement are designed to enhance driver concentration and ease of movement.

Honda designers have also designed the Insight’s interior to be comfortable and relaxing. The high-backed bucket seats are highly supportive kanual help minimize fatigue during long periods of driving. To assist in holding cargo in place, the cargo area is equipped with D-rings in four insigth to which a cargo net or cargo bag may be hooked. For more information on the cabin interior, see: This information is presented in a manner that encourages the driver to take an interest in improving the vehicle’s fuel economy.

The upshift indicator will illuminate when better fuel economy can be achieved by shifting up to a higher gear. The downshift indicator will illuminate when the Insight is unable to maintain the current speed, even with full assist. This light will sometimes illuminate when climbing steep hills at highway speeds.

When the Insight goes into Auto Idle Stop mode, a green “Auto Stop” LED at the base of the tachometer illuminates to indicate that the engine is not moving at all, but to remind the driver that the car is still in the “on” The seat imsight pretensioner system also provides a load limiting function, where the seatbelts are released slightly when needed to limit the amount of force exerted on a passengers by the seatbelts during a collision.

The filter should be replaced every 15, miles 24, km or 12 months, whichever comes first. This filter can be accessed below the dashboard from the passenger, near the center of the car. With a series system, an engine drives a generator, which in turn powers a motor, whose output propels the vehicle.

With a parallel system, the engine and motor can both be used to propel the vehicle. In each mode of operation, the gasoline engine and IMA electric motor each play a different role.

Honda Insight

Click on the links below to learn more about a particular mode of operation. Because the Insight won’t enter idle stop mode in any of the above situations, all engine starts other than the initial start will always be done using the IMA motor. To test the 12v auxiliary starting system, first disable the IMA starting system by removing fuse In this mode, the IMA Motor is driven by the wheels, generating electricity to be stored in the Battery Module, and slowing the Insight in the process.


The amount that the IMA Motor slows the car is in proportion to the amount of regeneration being done. There are two deceleration modes: Energy flow from wheels to crankshaft no fuel burned Whenever the Insight is moving with the clutch engaged and the transmission in gear, the gasoline engine is mechanically connected to the wheels, and so it must continue to turn also. However, this doesn’t necessarily mean that it is consuming any fuel.

The engine speed is less than rpm If the brake pedal is released while the Insight is slowing down, the engine starts again instantly, unless vehicle speed is below a certain speed. Even in this case, the engine will be restarted if a gear is selected or the gas pedal is touched. See the insigth control page for more information.

Honda Insight – Wikipedia

Conditions for Engine Restart The engine is restarted when: This tracks the battery state of charge and decides how much energy can be supplied to or delivered from the battery. The Junction Board contains the battery module switch, along with contactors that are used to connect the Battery Module to the electronics when the Insight is turned on.

Power is carried between the components in the “IPU” compartment behind the seats and the IMA electric motor ohnda the hood by three orange cables than run below the floor, under the left seat.

IMA Battery Module, and later be used to provide assist. This allows the internal combustion engine to be turned off when not need, without any delay in restarting on demand.

The only moving part in this type of motor, the rotor, consists of nothing but permanent magnets. The electromagnets are located owers the perimeter of the stator. There are several key attributes ownera this type of motor: The battery is manufactured by Panasonic EV Energy and weighs only 48 lbs.

Honda Insight Owner’s Manual

Most small components, ownerx the main connections of the high voltage system, are located on the junction board. The Junction Board itself is not serviceable.

If a component attached to the board fails, the Battery Module assembly must be replaced. The Motor Control Module controls all these actions.

The MCM is a low-voltage, microprocessor controlled device i. It must also recharge the Battery Module by using power generated by the motor. This power has to be reduced to 12V to charge the Insight’s 12V battery and to support the conventional 12V electrical system.

It is the DC-DC converter that performs this task. Honda engineers designed a completely new 5-speed manual transmission for the Insight. Like the rest of the Insight, its new transmission is designed to be as lightweight and as compact as possible, and is sized to the power requirements of the IMA system. The new transmission weighs just 91 pounds and is 9.

The entire manifold weighs only 2. The pistons have a minimal skirt area and the surface of the skirt has been shot-peened. The results are a much more consistent crankshaft rotational velocity and smoother idle quality.

The Insight also uses lightweight aluminum-alloy engine mounting brackets that incorporate hydraulic liquid-filled mounts that help damp engine vibration.

The mounts are located on the axis of the engine’s principal inertial moment the axes about which the engine vibrates. Maximum combustion pressure occurs at a point where the connecting rod is straight up and down in the cylinder.