2004 HONDA INSIGHT engine

If you take your vehicle f or a state
emissions test shortly af ter the
battery has been disconnected or
gone dead, it may not pass the test.
This is because of certain ‘‘readiness
codes’’ that must be set in the on-
board diagnostics f or the emissions
systems. These codes are erased
when the battery is disconnected,
and set again only after several days
of driving under a variety of
conditions.
If the testing f acility determines that
the readiness codes are not set, you
will be requested to return at a later
date to complete the test. If you must
get the vehicle re-tested within the
next two or three days, you can
condition the vehicle for re-testing
by doing the f ollowing.Make sure the gas tank is nearly,
but not completely, f ull (around
3/4). Make sure the vehicle has been
parked with the engine of f f or 8
hours or more.
Make sure the ambient
temperature is between 20° and
95°F.
Without touching the accelerator
pedal, start the engine, and let it
idle f or 20 seconds.
Keep the vehicle in Park
(automatic transmission) or
Neutral (manual transmission).
Increase the engine speed to 2,000
rpm,andholditthereuntilthe
temperature gauge rises to at least
1/4of thescale(approximately3
minutes).
Select a nearby highway where
you can maintain a speed of 50 to
60 mph (80 to 97 km/h) f or at
least 20 minutes in D (CVT) or 5th
gear (M/T). When traffic allows,
drive f or 90 seconds without
moving the accelerator pedal.
(Vehicle speed may vary slightly;
this is okay.) If you cannot do this
f or a continuous 90 seconds, drive
f or at least 30 seconds, then repeat
it two more times (f or a total of 90
seconds).
Then drive in city/suburban
traffic for at least 10 minutes.
When traffic conditions allow, let
the vehicle coast f or several
seconds without using the
accelerator pedal or the brake
pedal.
If the testing f acility determines the
readiness codes are still not set, see
your Honda dealer.
St at e Emissions T est ing
T esting of Readiness Codes
T echnical Inf ormation200

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#
) This manual covers maintenance and recommended
procedures f or repair to engine and chassis components.
It is written f or the journeyman mechanic, but is simple
enough f or most mechanically-inclined owners to under-
stand.
This manual complements the Service Manual by
providing in-depth troubleshooting inf ormation f or each
electrical circuit in your vehicle.
This manual describes the procedures involved in the
replacement of damaged body parts.
Authorized Manuals
Service Manual:
Electrical T roubleshooting Manual:
Body Repair Manual:
206
NOTE: Dealers and Companies please provide dealer or company name,
and also the name of the person to whose attention the shipment should
be sent. For purchases outside U.S.A. please write to the address shown
below for a quotation.
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Customer Name Attention
Apartment Number
State & Zip Code
City
Daytime Telephone Number
Check or money order enclosed payable to Helm Inc U.S. funds only.
Do not send cash
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Card VISA
Check here if your billing address is different
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Account Number Expiration: Mo. Yr.
CUSTOMER SIGNATURE DATE
Street Address No P.O. Box Number
()
These Publications cannot be returned for credit without receiving advance authorization within 14
days of delivery. On returns, a restocking fee may be applied against the original order.

CONT INUED
.....
Accessories and Modif ications . 99
..................................
Accessories .99
............................
Modif ications .100
ACCESSORY (Ignition Key .......................................
Position) .59
...............
Accessory Power Socket . 69
....................
Additives, Engine Oil . 134
...............................
Airbag (SRS) .9, 19
................
Air Conditioning System . 72
.....................................
Usage .73, 76
.........................
Air Outlets (Vents) .74
.......................
Air Pressure, Tires .154
.........................
Normal Driving .155
.........................
Alcohol in Gasoline .92
......................................
Antif reeze .137
Anti-thef t Steering Column ..............................................
Lock .59
..................................
Audio System .78
........................
Auto Idle Stop .109, 116
..............
Automatic Transmission . 111
..........................
Capacity, Fluid .192
...............
Checking Fluid Level . 140
.......................................
Shif ting .112 Shif t Lever Position
...............................
Indicators .111
................
Shif t Lever Positions . 112
....................
Shif t Lock Release . 115
............................
Capacities Chart .192
.............
Carbon Monoxide Hazard . 36
....................
Cargo, How to Carry .102
.............................
Carrying Cargo .101
..............
CAUTION, Explanation of . ii
...........................................
CD Care .85
.............
CD Player Error Message . 86
.........
CD Changer Error Message . 87
.........................................
CD player .83
........................
Certif ication Label .190
Battery
Charging System ...........................
Indicator .42, 178
............................
Jump Starting .173
..............................
Maintenance .160
............................
Specif ications .193
................................
Bef ore Driving .91
....................................
Belts,Seat .8,17
.............................
Beverage Holder .69
..................................
Booster Seats .33
Brakes ................
Break-in, New Linings . 92
...........................................
Fluid .142
....................
Bulb Replacement .147
.........................................
Parking .67
.................
System Indicator . 43,180
........................
Wear Indicators .119
.............................
Braking System .119
...................
Break-in, New Vehicle . 92 ..
Brightness Control, Instruments . 55
........................
Brights, Headlights .54
Bulb Replacement ..........................
Back-up Lights .147
...............................
Brake Light .147
................
Front Parking Lights . 145
........
Front Side Marker Lights . 146
.................................
Headlights .144
............................
Specif ications .193
....................
Turn Signal Lights . 146
..............................
Bulbs, Halogen .144
Index
A
B
C
I

Î
.................................
Chains, Tires .159
....................
Charge/Assist Gauge .51
Changing Oil ........................................
How to .134
......................................
When to .127
....................
Changing a Flat Tire .165
...
Charging System Indicator . 42,178
............
Checklist, Bef ore Driving . 106
.....................................
Child Saf ety .23
..................................
Booster Seats .33
.......................................
Child Seats .28
.........
Important Saf ety Reminders . 26
..............................................
Inf ants .24
................................
Large Children .32
..........................
Risks with Airbags .24
.................................
Small Children .27
.............................................
Tethers .31
.............
Where Should a Child Sit? . 23
Child Seats ..........
Tether Anchorage Points . 31
.................................................
Clock .89
...................................
Clutch Fluid .143
........................
CO in the Exhaust .197
............
Cold Weather, Starting in . 107
......................
Compact Spare Tire .164
...............
Consumer Inf ormation . 202.............
Controls, Instruments and . 39
Coolant ........................................
Adding .137
......................................
Checking .96
.........................
Proper Solution .137
...................
Temperature Gauge . 47
Crankcase Emissions Control ........................................
System .197
.....................................
Cup Holders .69
.....................
Current Fuel Mileage .48
.............
Customer Service Of f ice . 202
................................
Economy, Fuel .97
..................................
Emergencies .163
.............
Battery, Jump Starting . 173
...........
Brake System Indicator . 180
................
Changing a Flat Tire . 165
.....
Charging System Indicator . 178
..................
Checking the Fuses . 184
.............
Hazard Warning Button . 55
................
DANGER, Explanation of . ii
...................................
Dashboard .2, 40
................
Daytime Running Lights . 54
Daytime Running Lights .......................................
Indicator .44
.................................
Dead Battery .173
............
Def ects, Reporting Saf ety . 204
..........................
Def og and Def rost .75
................
Def ogger, Rear Window . 56
................
Def rosting the Windows . 75
....................................
Dimensions .192
...............
Dimming the Headlights . 54Dipstick
....................................
Engine Oil .95
..........................
Directional Signals .54
........
Disc Brake Wear Indicators . 119
.....................
Disposal of Used Oil .136
..................
Display Change Button . 47
Doors ..............
Locking and Unlocking . 60
..........
DOT Tire Quality Grading . 194
Downshif ting, 5-speed Manual
.............................
Transmission .108
...........
Driver and Passenger Safety . 5
...........................................
Driving .105
......................................
Economy .97
..................
Dust and Pollen Filter . 150
Index
D
E
II

CONT INUED
.....................................
Fan, Interior .73
Features, Comfort and ................................
Convenience .71
......................
Filling the Fuel Tank .93
Filter .........................
Dust and Pollen .150
...............................................
Oil .134
5-speed Manual Transmission ...............
Checking Fluid Level . 141
................................
Shif ting the .108
.............
Flashers, Hazard Warning . 55
...................
Flat Tire, Changing a . 165
Fluids Automatic Transmission .....................................
(CVT) .140
..........................................
Brake .142
.........................................
Clutch .143
..............
Manual Transmission . 141
..................
Windshield Washer . 139
FM Stereo Radio .....................................
Reception .81
...................................................
Fuel .92
........................
Fill Door and Cap .93
...........................................
Gauge .47 ..................
Octane Requirement . 92
.................................
Oxygenated .92
........................
Reserve Indicator .44
..........................
Tank, Filling the .93
.....................
Fuses, Checking the .183
.................
Gas Mileage, Improving . 97
...........................................
Gasoline .92
...............
Fuel Reserve Indicator . 44
...........................................
Gauge .47
..................
Octane Requirement . 92
..........................
Tank, Filling the .93
..................
Gas Station Procedures . 93
Gauges ...
Engine Coolant Temperature . 47
...............................................
Fuel .47
Gearshif t Lever Positions Automatic Transmission .....................................
(CVT) .111
5-speed Manual .........................
Transmission .108
........................................
Glove Box .69
............................
Jump Starting .173
.....
Low Oil Pressure Indicator . 177
...
Malf unction Indicator Lamp . 178
..................
Overheated Engine . 175
.......................................
Towing .181
...........................
Emergency Brake .67
......................
Emergency Flashers .55
......................
Emergency Towing .181
.......................
Emissions Controls .197
Engine ....
Coolant Temperature Gauge . 47
.........................
If It Won’t Start .171
Malf unction Indicator ................................
Lamp .43, 178
..............
Oil, What Kind to Use . 133
...............................
Overheating .175
............................
Specif ications .192
.......................................
Starting .107
...............
Engine, If It Won’t Start . 171
..........
Engine Speed Limiter . 109,114
........................
Ethanol in Gasoline .92
.
Evaporative Emissions Controls . 197
...............................
Exhaust Fumes .36
Expectant Mothers, Use of Seat ........................................
Belts by .15
Index
F
G
III

CONT INUED
.....................................
Load Limit .102
......
LOCK (Ignition Key Position) . 59
Locks ..............................
Fuel Fill Door .93
............................................
Hatch .60
..........................
Low Coolant Level .96
.........................
Low Fuel Indicator .44
...
Lower Gear, Downshif ting to a . 108
...
Lubricant Specif ications Chart . 192
...........
Luggage, Storing (Cargo) . 101....................
New Vehicle Break-in .92
..................
NOTICE, Explanation of . ii
...............
Numbers, Identif ication . 190..............
Panel Brightness Control . 55
...........................................
Parking .118
.................................
Parking Brake .67
Parking Brake and Brake .................
System Indicator . 43,180
..
Parking Over Things that Burn . 118
.............................
PGM-FI System .198
..................
Power Socket Location . 68
..............................
Power Windows .65
.........
Pregnancy, Using Seat Belts . 15
.........
Protecting Adults and Teens . 11
...
Additional Safety Precautions . 16
.....
Advice f or Pregnant Women . 15
........................
Protecting Children .23
.......
Protecting Larger Children . 32
.........
Protecting Small Children . 27
Using Child Seats with .....................................
Tethers .31
..................................
Maintenance .123
Owner’s Maintenance ...................................
Checks .126
........................................
Record .129
......................
Required Indicator .45
..........................................
Saf ety .124
....................................
Schedule .125
.
Malf unction Indicator Lamp . 43,178
...................
Manual Transmission . 108
........
Manual Transmission Fluid . 141
.........................
Meters, Gauges .41, 46
..........................
Mirrors, Adjusting .66
...............
Modif ying Your Vehicle . 100 .....
Octane Requirement, Gasoline . 92
.........................................
Odometer .47
...............................
Odometer, Trip .48
Oil ........................
Change, How to .134
......................
Change, When to .127
........................
Checking Engine .95
Selecting Proper Viscosity ......................................
Chart .134
...........
ON (Ignition Key Position) . 59
Onboard Ref ueling Vapor ....................................
Recovery .197
.........................
Opening the Hatch .60
..............................
Outside Mirrors .66
....................
Overheating, Engine .175
....
Owner’s Maintenance Checks . 126
...........................
Oxygenated Fuels .92
Index
M N
O
P
V

Î
Î...................
Radiator Overheating . 175
...........................
Readiness Codes .200
...............
Radio/CD Sound System . 78
..
Rear Lights, Bulb Replacement . 147
............................
Rear View Mirror .66
.................
Rear Window Def ogger . 56
....................
Rear Window Washer .53
.......................
Rear Window Wiper .53
...............
Reclining the Seat Backs . 64
Replacement Inf ormation ................
Engine Oil and Filter . 134
..........................................
Fuses .184
................................
Light Bulbs .144
....................................
Schedule .127
...........................................
Tires .157
.............................
Wiper Blades .151
Replacing Seat Belts Af ter a ............................................
Crash .18
Reserve Tank, Engine .................................
Coolant .96, 137
...............................
Restraint, Child .23
................................
Roof Antenna .150
................................
Rotation, Tire .157 ..................................
Saf ety Belts .8, 17
.........
Safety Defects, Reporting . 204
.................................
Saf ety Features .7
...........................................
Airbags .9
.......................................
Seat Belts .8
.............
Saf ety Labels, Location of . 37
...............................
Saf ety Messages .ii
.....................................
Seat Belts .8, 17
...............
Additional Information . 17
.....................................
Cleaning .149
......................
Lap/Shoulder Belt .17
................................
Maintenance .18
Reminder Indicator and ................................
Beeper .17, 42
...................
System Components . 17
...............
Use During Pregnancy . 15
...
Wearing a Lap/Shoulder Belt . 13
........................
Seats, Adjusting the .64
...............................
Serial Number .190
...........................
Service Intervals .127
...........................
Service Manual .205
...........
Service Station Procedures . 93
............................
Setting the Clock .89
...
Shif t Lever Position Indicators . 111........................
Shif t Lock Release .115
...............................
Signaling Turns .54
.....................................
Snow Tires .159
..................................
Sound System .78
Spare Tire ......................................
Inf lating .164
............................
Specif ications .193
....................
Specif ications Charts . 192
..........
SRS, Additional Inf ormation . 19
...
Additional Safety Precautions . 22
How the SRS Indicator .......................................
Works .21
...........
How Your Airbags Work . 19
........................
SRS Components .19
..................................
SRS Service .22
.............................
SRS Indicator .21 ,42
....
START (Ignition Key Position) . 59
.......................
Starting the Engine .107
In Cold Weather at High ..................................
Altitude .107
................
With a Dead Battery . 173
..............
State Emissions Testing . 200
........
Steam Coming f rom Engine . 175
Steering Wheel .............
Anti-theft Column Lock . 59
.....................
Stereo Sound System .78
Index
RS
VI

Service Inf ormat ion Summary
Gasoline:
Fuel Tank Capacity:
Recommended Engine Oil:Automatic Transmission Fluid
(CVT):
5-speed Manual Transmission
Fluid:Brake Fluid:
Tire Pressure (measured cold):
10.6
US gal (40
)
2.6 US qt ( 2.5
)
1.6US qt ( 1.5
)
5.8
US qt ( 5.5
)
Unleaded gasoline, pump octane
number of
86or higher.
API Premium grade 0W-20
detergent oil (see page ).
Oil change capacity (including
filter): Use Honda ATF-Z1
(Automatic
Transmission Fluid) only.
Capacity:
Honda Manual Transmission
Fluid preferred, or an SAE 10W-30
or 10W-40 motor oil as a
temporary replacement (see page ).
Capacity (including differential): Honda Heavy Duty Brake Fluid
DOT
3preferred, or a DOT 3or
DOT 4brake fluid as a temporary
replacement (see page ).
Front:
Rear:
Spare Tire: 38 psi (260 kPa)
35 psi (240 kPa)
60 psi (420 kPa)
141
133 142