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Honda Insight - page 1
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Honda Insight - page 2
2 GENERALINFORMATION ............................................................................................................... 5 A BOUTTHI S E NCYCLOPEDI A ................................................................................................................. 6 V EHICUL E I DENTIFI CAT ...
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3 L IGHTW EIGHT B ODY P A NELS ............................................................................................................. 26 B ODY R EPAI R I NFORMATIO N .............................................................................................................. 27 DacroCoatedBolts ................ ...
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4 Design ............................................................................................................................................ 58 B ATT ERY M ODULE ............................................................................................................................. 60 J UNCTI ON B OARD .............. ...
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5 G ENERAL I NFORMA TION ...
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Honda Insight - page 6
6 A BOUT THIS E NCYC LOPEDIA This encyclopedia is pr ovided so that you ca n learn m ore ab out the Insight and how it works. While every effort has been made to insure its accuracy, this information sh ouldn't be used as the b ...
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Honda Insight - page 7
7 V EHICULE I DE NTIFICA T ION N UMBER (VIN) The I nsight' s VIN c an be found many places on the car. T he easiest and most v isible location is throughasm allwindow atthebottomdriver'ssidecornero fthew indshield: An? ...
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Honda Insight - page 8
8 F EA T URESA N D S PECIFICA T IONS Overview Vehicletype Subco mpact,two- seater,front-wheeldrive,gasoline-electrichy brid Standa rdfeatures Majorfeatures: • 5-speedmanualtransm ission • Anti- lockbrakes • Electricpo wersteering • Dualairbags ...
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Honda Insight - page 9
9 Valvetrain 1 2valveSOHC VTEC-Evariable valvetim ingandlifttechnology Borexstroke 72 mm x81.5mm Displacement 0. 995liter Compressionratio 1 0.8:1 Tune-up interval 17 0,000 km(105,000 mi) Engine weight 56kg(12 4lbs.) Electri ...
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Honda Insight - page 10
10 Wheels&Tires Wheels 14x5.5J Castalum inum Tires BridgestonePotenzaRE9 2165 /65R147 8S Tread wear260T ractionATemperatureB TubelessSteelBe ltedRadialM+S BodyConstruction Type Alum inum monocoque Allstructuralcomponents andmost ...
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Honda Insight - page 11
11 FuelConsum ption&Emissi ons Fuelcon sumption 3 .4l/100 km(EUDC) 61mpgcity/70mpghig hway (EPA) CO2emissions 80g/km California emission stan dards complianc e ULEV ...
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12 S CA LE D R A WINGS ...
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13 Non-ScaleDrawingofCargoArea (CourtesyofJohnJohnson) ...
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14 M AINTENANCE ...
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15 S PECIA L M A INT ENA NCE C ONSIDER A TIONS EngineOil TheInsightusesanAPISJratedo ilwith anSAE0W-20viscosity. Formaxim umf ueleconomy thisoilshouldbeused. Washing Remove the rear wheel skirts and the roof mounted antenna bef ...
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Honda Insight - page 16
16 L ONG -T ERM S TORA GE In ad dition to a conventional 12 V battery, the Insigh t has a . When the vehicleis stored for a long perio d, the IMA batterywill graduallydischarge andmustbe charged ...
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Honda Insight - page 17
17 H A TCH A CCESS The I nsight rear hatch diff ers from m any Honda m odels because there is no mechanical link age between the hatch release on the outside of the vehicle and the ac tual latch. T he exterior latch release is actually? ...
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Honda Insight - page 18
18 T OWING I NFORMA TION To accommodate flat-bed towin g equipment, the Ins ight is provided with a f ront towing h ook, and front and rear tie down hook holes. The towing hoo k can be used with a winch to pull the Insight onto the ...
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Honda Insight - page 19
19 S ERVICE S A FETY C ONS IDERA TIONS The Insight' s IMA system em ploys high- voltage components and highly m agnetic components, and so anyonew or kingontheIMAsy stemmus texercisecautionandfollowServiceManualproceduresc arefully . IMAMot ...
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Honda Insight - page 20
20 S ERVICE C ONNE CTORS TheInsightusesanindustry standar dOBD-IIo nboardd iagnosticssy stem. This system allows standard OB D-II diagnostic too ls (including OBD-II software and co nnector cable available for Windows PCs; see below) to be co ...
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21 B ODY T ECHNOLOGIES ...
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Honda Insight - page 22
22 A ERODYNA MICS Regardless of wh at power source a car is using, the less its aer odynam ic drag, the less energy w ill be needed to travel at any given speed. A great deal of effort has gone into designing the Insight around ...
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Honda Insight - page 23
23 • Low -dragdoo rmirrors • Rear wh eel wells enclosed by f ender skirts and disk -shaped w heels alum inum alloy w heels smoothairflow aroundthewheelopenings • Frontfendersextenddownbelowcenterlineofw heel • Toimproveairflowov ...
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Honda Insight - page 24
24 A LUMINUM C ONSTRUCT I ON The Honda Insight's body is made of aluminum , offering light weight and a high level of body rigidity to enhance overall fuel econom y, handling and passeng er safety . Alum inum w eighs only one-third a s? ...
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Honda Insight - page 25
25 On the Insight, each fram e m ember's size and strength is optimized so that the frame is strongwhere it needs to be, and lighter in less critical areas. A variety of shapes are used, including hexagons, ovals, H- sections a ...
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Honda Insight - page 26
26 L IGHTWEIGHT B ODY P A NELS The Ho nda Insight features lightw eight plastic panels wh ich are used extensively in non-st ructural applications. T he front fenders, spoilers, under b ody cover and r ear fender skirts are all made o f plastic.? ...
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Honda Insight - page 27
27 B ODY R EPA IR I NFORMA TION DacroCoatedBolts Bolts that make c ontact with the aluminu m bo dy o r alumin um suspension components have a special Dacro coating to prevent corr osion b etween two dissimilar metals. If these bolts a re remov ...
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Honda Insight - page 28
28 P LA STIC F UEL T A NK TheHonda Insightus esaplasticfueltank. Use of a plastic fuel tank reduces w eight. Also, since the p lastic fuel tank willnot corrode , it isfar less susceptible to developing a leak whereby gasoline a ...
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Honda Insight - page 29
29 S TEERING /S USP ENSION /B RAKES ...
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Honda Insight - page 30
30 E LECT RIC P OWER S TEERING The Honda Insight uses a variab le-assist rac k and pinion e lectric power steering (EP S) system rather thanatypicalhy d raulicpowersteeringsy stem. A typical hydraulicp ower steering system is continually plac ...
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Honda Insight - page 31
31 ElectronicConstruction The E PS co ntrol unit is mounted inside the car on the right side bulkhead, underneath the dash. It receivesinputfromtheveh iclespeed sensorandtorquesensormountedonthesteeringpinionshaft. The to rque? ...
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Honda Insight - page 32
32 F RONT S USPENSION The I nsight uses a Ma cpherson Strut type front suspension withstabilizer b ars (0.66 inch). T he front suspension geom etry has been optim ized to exhibit minim al chang es in toe and cam ber throughout its travel,giving ...
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Honda Insight - page 33
33 R EA R S USPENSION The I nsight' s rear suspension uses tr ailing arms. These are co nnected midw ay along their length by a curved, H-section steel torsio n beam that tw ists to allow a controlled level of independent suspension movem en ...
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Honda Insight - page 34
34 B RA KING S YSTEM FrontDiscBrakes The front brake single piston calipers fitted to the Insight are made from alumin um. This h elps to reducetheweightan ddr agofthecomponentssign ificantly with outalossofstrengthinthecomponents ...
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Honda Insight - page 35
35 While a typical cast iro n drum might weig h 3.4 kg (7.5 lbs.), the Insight's aluminum /cast iron drum weig hs2.1kg(4.6 lbs.).T hedrum'souts idediameteris181 mm . Anti-LockBrakingSystem The Insight is eq uipped with ...
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Honda Insight - page 36
36 C ABIN I NTERIOR ...
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Honda Insight - page 37
37 C A BIN I NTERIOR InteriorFe atures The interior of the Insight is well equipped, w ith automatic climate control, po wer w indows, power mirrors and power doo r locks with keyless en try. An an ti-theft sy stem prevents the car f ...
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Honda Insight - page 38
38 To assist in holding ca rgo in place, the cargo area is equipped with D-rings in four co rners to w hich a cargonetorca rgobagmaybehooked. Formoreinformationonthecabininterior,see: • ElectronicInstrum ...
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Honda Insight - page 39
39 E LECT RONIC I NSTRU MENT D ISPLA Y Housed in a hooded central p od direc tly in front of the driver, the Insight's Electronic Instrum ent Displayis a combination analog and digital readout that showsall importantinformation about the ...
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Honda Insight - page 40
40 • Batter y charging : The IM A is recharging the battery pack, using en ergy from vehicle mom entum / the gasoline engine. The amount of r echarge is indicated by the illum ination of green co lored bars on the left side of the ...
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Honda Insight - page 41
41 When the sp eedometer is set to mph, od ometer / trip meter d istances are displayed in miles, and fuel efficiency is d isplayed in m iles per gallon. When the s peedo meter is set to km/h , odometer / trip meter distancesared ...
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Honda Insight - page 42
42 P A SSENGER R EST RA INT S YSTEM The Honda Insigh t Supplem ental Restraint System consists of an SRS control unit withintegral impact sensors, driver and passenger airbags, and seat belt tensioners. T he seat belt pretensioner system also p ...
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Honda Insight - page 43
43 H EA TING ,C OOLING &V ENTILA TION The Honda Insight Heating and Air Conditioning (optional) achieves a balance between com fort for the passengers and fuel economy for the vehicle. This unique design allows th e engine ECU and the ...
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Honda Insight - page 44
44 M ICRON A IR F ILTRA TION The Ho nda Insight is equipped with a cabin air filter located between the blower housin g and the evaporator case. The p urpose of the filter is to pro vide a c omfortable and healthy environment for the? ...
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Honda Insight - page 45
45 IMA H Y BRID S YSTEM ...
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46 IMAH YB RID S YSTEM A hybrid power sys tem for an automobile can have a series configuration or a parallel configuration. With a series sys tem, an engine drives a generator, whichin turnp owersa motor, whoseo utputp ropels the? ...
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Honda Insight - page 47
47 IMAM ODESOF O PERA TION As the Insi ght's g oes from being stationary to accelerating, cruis ing an d then decelerating, the IMA hybrid system 's mode of operation changes. In each mode of operation, the gasoline engine and IMA? ...
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Honda Insight - page 48
48 S TA RTING /R ES TA RTING M ODE Energyflow from batteryto gasengine(v iaelectric motor) Under mostconditio ns,the Insight engineis started by theI MAmotor,whichinstantly spinsthe engine to100 0rpm. TheInsightalsohasa ...
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Honda Insight - page 49
49 A CCELERA TION /A SSIST M ODE Energyflow from gasengineto w heels&f rombatteryt oelectric motort owheels During acceleratio n and other high load conditions such as climbing a steep slope, curr ent from the BatteryM od ...
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Honda Insight - page 50
50 C RUISING M ODE Energyflow from gasengineto w heels(&s ometimes alsoto batteryv iamotor/ generator) When the Insight is cruising at a constant speed and the Battery Module state of c harge is relatively low, some engin ...
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Honda Insight - page 51
51 D ECELE RA TION /R EGENERA TIVE B RA KING Energyflow from w heelsto battery(v iaelectric motor/generat or) During deceler ation, the gasoline e ngine is sw itched into fu el cut m o de, and the IMA Moto r/Generator is oper ated in genera ...
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Honda Insight - page 52
52 F UEL C UT M O DE Energyflow from w heelsto crankshaft (nofuel burned) Whenever the Insight is moving wit h the clutch engaged and the transmis sion in gear, the gasoline engine is mechani cally connected to the wheels, and? ...
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Honda Insight - page 53
53 I DLE S TOP M ODE NoEnergyFlow (Vehiclestat ionary,coasting ordecelerating) To prevent unnecessaryfuel consumptionand exhaust emissions , the Insight' s gasolineengine is turned off when there is no need for pro pulsion or ? ...
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Honda Insight - page 54
54 may o ccur, possibly causing the air co nditioning compressor to temporarily stop. See the climate control pageformoreinformation. ConditionsforEn gineRestart Theengineisrestartedwhen: • Agearisselectedwithth eclutchdisengaged, ...
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Honda Insight - page 55
55 IMAC OMPONENT L OCA TIONS This view shows the contents o f the "I PU" compartment, imm ediately b ehind the driver and pa ssenger seats.Thiscompartmentcontainsthef ollowingcom ponents: • Motor Control Module (MCM): T his i ...
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Honda Insight - page 56
56 • Junction Boar d: T his is the black component, lo cated to the right of the DC-DC Converter, and is actually part o f the Battery Module assem bly. The Junction Board contains the battery module sw itch, along with contactors that ...
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Honda Insight - page 57
57 IMAM OTOR /G ENERA TOR Role The thin design motor is located between the 3-cy linder engine and the tr ansm ission. T he IMA motor servesanum bero ffun ctions: • It assistsin vehicle propulsion whenneeded, allo win gthe use of ...
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Honda Insight - page 58
58 Design TheIMAmotorisaper manen t-mag nettype,brushlessDCm otor. The only moving part in this type of motor, the roto r, consists of nothing but permanent magnets. T he electromagnets ar e located around the perimeter ofthestator.? ...
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59 ...
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Honda Insight - page 60
60 B A TTER Y M ODULE The Battery Module uses nickel metal h ydride (NiMH) technologyf orhighenergydensity and longservicelife. The battery is manu factured by P anasonic E V Energy and weig hs only 48 lb s. or 22 kg. Its ope ratingte ...
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Honda Insight - page 61
61 J UNCT ION B OA RD The J unction Board is located in the IP U compartment and is attached directly to the Battery M odule. Most small co mponents, and the main connections o f the high voltage system , are lo cated o n the junction b ...
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Honda Insight - page 62
62 B A TTER Y C ONDITION M ONITOR (BCM) The Battery Condition Mo nitor Mod ule (BCM) monitors the condition o f the main b attery, via four temperature sensors and 10 voltage sensors in the Battery Module. It also uses one current sensor to? ...
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Honda Insight - page 63
63 M OTOR C ONTR OL M ODULE (MCM ) The I MA Motor/Generator's function is to charge the Battery Module, to assist the g asoline engine underacceleration,and tostarttheengineunderspecificconditions. The Motor Control Module contro ls all? ...
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Honda Insight - page 64
64 M OTOR D RIVE M ODULE (M DM) The IMA system assists the engine with an ele ctric motorusing powerfro mthe Battery Module. It mustalso recharge the Battery Module by using power generated by the motor. It is the Motor Drive M ...
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Honda Insight - page 65
65 DC-DCC ONV ERTER The Insight engine is not equipped w ith an ACG (AC Generator or Alternator). Instead, recharging of the 12V battery and powering of the conventional 12V electrical system is performed by a DC-DC co nverter located ...
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66 A DV ANCED G ASOLINE E N GINE ...
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67 A DVA NCED G A SOLINE E NGINE The Insight's internal combustion engine is an in-line three-cylinder with a displacement of 995cc. Its design includes comprehensive w eight-reducing and friction-reducing features which ensure fuel-ef ficient, environm en ...
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Honda Insight - page 68
68 E NGINE W EIGHT R ED UCTION T EC HNOLOGIES Allengin epartshavebeenmadeaslightaspossible.M ajor weig ht-reducingfeatu resare: • Sleevelesscylin derswithm inimaldimensionbetw e enbores • The intake manifold used on the Insight' s 1. ...
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Honda Insight - page 69
69 E NGINE F RICT ION R EDUCTION T EC HNOLOGIES To minim ize energy losses, friction between m o ving parts is m inim ized by utilizing the f ollowing features: • Offsetcy linderconstruction • In the interest o f friction red uction, Honda engineer ...
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Honda Insight - page 70
70 V IBRA TION C ONTROL S YST EM A three cy linder engine, w ithout balance shafts (w hich decr ease power and thus fuel efficien cy), is inherently pro ne to vibration. T o improve idle quality, the IMA m o tor is used to smooth out speed ...
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Honda Insight - page 71
71 O FFSET C YLINDER C ONST RUCTION The e ngineb lock has a unique,o ffsetcylinder d esign in which the b ore centeris offset 14mm fromthe crank center. Maximum combustion pressure o ccurs at a point wh ere the connecting r od is str ...
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Honda Insight - page 72
72 S PA RK P LUGS TheInsightusesanew ,iridiumsparkplugthatisuniquetothisv ehicle. There are four different pa rtn umbers for thespark plugs,and eachhasthe electrode aligned differently with the plug threads. This allows the? ...
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Honda Insight - page 73
73 R OCKER A RMS &S HA FT In order to r educe friction and weigh t, L-shaped, roller rocker ar ms are mounted on a single shaft. A narrow valve angle (30 degrees) and a compact combustion chamber contribute toa nincreased sw irl ...
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Honda Insight - page 74
74 VTEC-ES YST EM The Ho nda Insight'sengine employs a newly designed VT EC system . I nthis system , thec amfollowers of theintake primaryro cker armsare fitted withroller s thatminim izefrictio nonthe cam'scontactsurfaces. ( ...
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Honda Insight - page 75
75 I NTEGRA TE D H EA D The Honda Insight's cylin der head has a unique, cast-in exh aust man ifold that saves w eight and increasesexhaustheatretention. The exhaust ports are loca ted inside the cylinder head and are surrounded bya w ...
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Honda Insight - page 76
76 D IRECT I GNITION S YSTEM The Insight engi ne employ s a direct ignition system similar to those used on the Honda S2000 and the 1999 Odyssey . Separateignitioncoilsforeachcylinderarelo cateddire ctlyabovethesparkplugs. Two T DC? ...
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Honda Insight - page 77
77 CVTT RA NSMISSION TheInsightismadew ithtw otransmissions: • aconventional5-speedmanualtransm ission,and • a continuously variable automatic transmission, also referred to at the "CVT" or "Honda Multimatic" tr ansm ission ...
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Honda Insight - page 78
78 Honda claims that their CVT transm ission is the w or ld's first m ass-pro duced, high- power, stepless transmis sion. While such tr ansm issions existed previously, they claim the CVT is " far super ior in quality, endurance, power output ...
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Honda Insight - page 79
79 1) Driven-Shaft- PlacedAccelera tionClutch The Honda Multimatic differs from p reviously existing step-less transmissions is that the acceleratio n clutch is placed on the d riven shaft. T he p rimary reason we too k this route was to co n ...
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Honda Insight - page 80
80 changes. At the same time, this allow s for a more dir ect connection to the engine, resulting in less slip-loss -w hichultim atelyleadstohigherfueleconom y. 5) High-Perfo rmanceOilPum p The Honda Multimatic req uires a high- ...
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Honda Insight - page 81
81 2) AccelerationCo ntrol The accelera tion clutch's power transfer amoun t is controlled via the clutch piston's oil pressure. Additionally, the amount of creep is also controlled here as well. T he "smart" creep has two ...
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Honda Insight - page 82
82 E NGINE P ERFORMA NCE C URVE S ...
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83 G EA R R A TIO G RAP HIC ...
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84 E MISSIONS C ONTROL ...
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Honda Insight - page 85
85 E MISSIONS S TA NDA RDS We know that Honda has gone to great le ngths in eng ineering the Insig ht in the pursuit of low emissi onslevels,butjusthowlow havetheyactually achieved? Therear etwom ajor categoriesofvehicleemissions? ...
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Honda Insight - page 86
86 ComparisontoVariousCar Em issionsStandards Smong -CausingComp ounds Greenhouse Gas Hydrocarbo ns Carbon Monoxide Nitrog en Oxides Particulate Matter Carbon Dioxide Category TOG (1) g/km (g/mi) NMOG (2) g/km (g/mi) CO (3) g/km(g/mi) ...
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Honda Insight - page 87
87 L EA N -B URN O XYGEN S ENSOR A normal zirco nia oxygen sensor is only capa ble of measuring the oxy gen content of the exhaust in a narrow air-fuel mix ture range, r ight around stoichiometric (14. 7:1). T his is fine f or normal operatin ...
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Honda Insight - page 88
88 Unlike a conventional sensor, the voltage c an be positive or negative, and it reads the opposite direction. T hat is, positive voltage indicates a lean mixtu re, and negative voltage indicates a rich mixtu re. Thenormaloperating ...
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Honda Insight - page 89
89 A DVA NCED C A TA LYST S YSTE M The insightisdesignedto oper ateat averylean air fuelratio duringlightthrottlec ruiseconditions.The mix ture can be as lean as 22:1 ifco nditions allow. This p rovides very good fuel economy , an ...
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Honda Insight - page 90
90 CatalyticConverter DeteriorationDet ection/Replaceme nt The Insightuses2 oxygensensorsto monitortheco nditionof the3-way catalystas required byOBD-II and EU2000 regulations. However, the detection system is not able to directly mo ...
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Honda Insight - page 91
91 E XHA UST G A S R ECIRCULA TION S YST EM The Insight uses a linear-s olenoid-oper ated EGR valve that feeds recirculated exhaust g as into an equal-lengthEGRm anifoldthatissandwichedbetweentheint akemanifoldandthecyl inderhead. This design ...
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Honda Insight - page 92
92 ORVR&V A CUUM D ISTRIBU TION U.S. and Canada model Insights are equipped with On -board Refueling Vapor Recovery (ORVR) syst emsthatareidenticaltothesystem introducedonthe19 98Accord. Thefollowingdiagram showsth eentirevacuum? ...
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Honda Insight - page 93
93 1. Primaryheatedoxygen sensor(pr imary HO2S) 2. Secondaryheatedoxygensensor(secondaryHO2S) 3. Manifoldabsolutep ressure(MAP)sensor 4. Intakeairtemperature(IAT )sensor 5. Enginecoolanttemperature(ECT )sensor 6. To pdead center2(T DC2 ...
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