2004 HONDA INSIGHT manual transmission

To thoroughly f lush the transmission,
the technician should drain and ref ill
it with Honda ATF-Z1, then drive the
vehicle f or a short distance. Do this
three times. Then drain and ref ill the
transmission a f inal time.Insert the dipstick all the way back
into the transmission securely as
shown in the illustration. If you
added f luid, return to step 1 to
recheck the f luid level.
The transmission should be drained
and ref illed with new f luid according
to the time and distance recommen-
dations in the maintenance schedule.
If you are not sure how to add f luid,
contact your Honda dealer. Check the f luid level with the
transmission at normal operating
temperature and the vehicle sitting
on the level ground.
Remove the black cover under the
engine.Remove the transmission f iller bolt,
and caref ully f eel inside the bolt hole
with your f inger. The f luid level
should be up to the edge of the bolt
hole. If it is not, add Honda Manual
Transmission Fluid (MTF) until it
starts to run out of the hole. Reinstall
the f iller bolt and tighten it securely.
6.
CONT INUED
T ransmission Fluid
Maint enance
5-speed Manual Transmission
141
Correct Level

Always use Honda Heavy Duty
Brake Fluid DOT 3. If it is not
available, you should use only DOT 3
or DOT 4 f luid, f rom a sealed
container, as a temporary
replacement.
Using any non-Honda brake f luid can
cause corrosion and decrease the lif e
of the system. Have the brake
system f lushed and ref illed with
Honda Heavy Duty Brake Fluid
DOT 3 as soon as possible.
Pour the f luid slowly and caref ully so
you do not spill. Clean up any spills
immediately; it could damage
components in the engine
compartment.
Brake f luid marked DOT 5 is not
compatible with your vehicle’s
braking system and can cause
extensive damage.
Check the f luid level in the
reservoirs monthly. There are up to
two reservoirs, depending on the
model. They are:
Brake f luid reservoir (all models)
Clutch f luid reservoir
(manual transmission only)
Replace the brake f luid according to
the recommendation in the
maintenance schedule.
If Honda MTF is not available, you
may use an SAE 10W-30 or 10W-40
viscosity motor oil with the API
Certif ication seal that says ‘‘FOR
GASOLINE ENGINES’’ as a
temporary replacement. However,
motor oil does not contain the proper
additives, and continued use can
cause stiffer shifting. Replace as
soon as it is convenient.
The transmission should be drained
and ref illed with new f luid according
to the time and distance recommen-
dations in the maintenance schedule.
If you are not sure how to check and
add f luid, contact your Honda dealer.
Transmission Fluid, Brake and Clutch Fluid
Maint enance
Brake and Clutch Fluid
142

If you need to park your vehicle f or
an extended period (more than one
month), there are several things you
should do to prepare it f or storage.
Proper preparation helps prevent
deterioration and makes it easier to
get your vehicle back on the road. If
possible, store your vehicle indoors.Fill the f uel tank.
Change the engine oil and f ilter.
Wash and dry the exterior
completely.
Cleantheinterior.Makesurethe
carpeting, floor mats, etc., are
completely dry.
Leave the parking brake off. Put
the transmission in Reverse (5-
speed manual) or Park (CVT).
Block the rear wheels. If the vehicle is to be stored f or a
longer period, it should be
supported on jackstands so the
tires are of f the ground.
Leave one window open slightly (if
the vehicle is being stored
indoors).
Disconnect the 12 volt battery.
Support the f ront and rear wiper
blade arms with a f olded towel or
ragsotheydonottouchthe
windshield.
To minimize sticking, apply a
silicone spray lubricant to all door
and hatch seals. Also, apply a body
wax to the painted surf aces that
mate with the door and hatch seals.
Cover the vehicle with a
‘‘breathable’’ cover, one made
f rom a porous material such as
cotton. Non-porous materials, suchas plastic sheeting, trap moisture,
which can damage the paint.
Reconnect the 12 volt battery and
drive your vehicle every month f or
about 30 minutes. This will keep
the IMA battery charged and in
good condition.
If you store your vehicle f or 1 year or
longer, have your Honda dealer
perf orm the inspections called f or in
the 2 years/30,000 miles (48,000 km)
maintenance schedule (Normal
Conditions) as soon as you take it
out of storage (see page ). The
replacements called f or in the
maintenance schedule are not
needed unless the vehicle has
actually reached that time or mileage. 127
Vehicle Storage
Maint enance161

If you have a f lat tire while driving,
stop in a saf e place to change it.
Drive slowly along the shoulder until
you get to an exit or an area that is
far away from the traffic lanes.Park the vehicle on f irm, level and
non-slippery ground. Put the
transmission in Reverse (5-speed
manual) or Park (CVT). Apply the
parking brake.
Open the hatch. Raise the cargo
area f loor by lif ting up on the back
edge.
Remove the storage box from the
cargo area well.
Take the tool kit f rom the spare
tire well. Remove the jack (in the
jack cover) f rom the inside of the
spare tire.
Unscrew the wing bolt, and take
the spare tire out of its well.
Turn on the hazard warning
indicators, and turn the ignition
switch to LOCK (0). Have your
passenger get out of the vehicle
while you change the tire.
2.
3. 1.
4.
5.
6.
CONT INUED
Changing a Flat T ire
T aking Care of t he Unexpect ed165
FLOOR BOARDTOOL KIT
STORAGE BOX
SPARE TIRE
JACK
The vehicle can easily roll off
the jack, seriously injuring
anyone underneath.
Follow the directions for
changing a tire exactly, and
never get under the vehicle
when it is supported only by the
jack.

CONT INUED
Diagnosing why the engine won’t
start f alls into two areas, depending
on what you hear when you turn the
key to START (III):You hear nothing, or almost
nothing. The engine’s starter
motor does not operate at all, or
operates very slowly.
You can hear the starter motor
operating normally, or the starter
motor sounds like it is spinning
f aster than normal, but the engine
does not start up and run. When you turn the ignition switch to
START (III), you do not hear the
normal noise of the engine trying to
start. You may hear a clicking sound
or series of clicks, or nothing at all.
Check these things:
Check the transmission interlock.
If you have a manual transmission,
the clutch pedal must be pushed
all the way to the f loor or the
starter will not operate. With an
automatic transmission, it must be
in Park or Neutral.
Are you using a properly coded
key? An improperly coded key will
cause the immobilizer system
indicator in the instrument panel
to blink rapidly (see page ). Turn the ignition switch to ON (II).
Turn on the headlights, and check
their brightness. If the headlights
are very dim or don’t light at all,
the battery is discharged. See
on page .
Turn the ignition switch to START
(III). If the headlights do not dim,
check the condition of the f uses. If
the f uses are OK, there is
probably something wrong with
the electrical circuit f or the
ignition switch or starter motor.
You will need a qualif ied
technician to determine the
problem (see
on page ).
58 173
181
If theEngineWon’tStart
T aking Care of t he Unexpect ed
Nothing Happens or the Starter
Motor Operates Very Slowly Jump Starting
Emergency T owing
171

µµ
µ
If your vehicle needs to be towed,
call a prof essional towing service or
organization. Never tow your vehicle
with just a rope or chain. It is very
dangerous.
There are three popular types of
prof essional towing equipment.
The operator
loads your vehicle on the back of a
truck.
The tow
truck uses two pivoting arms that go
under the tires (f ront or rear) and lif t
them of f the ground. The other two
tires remain on the ground.
The tow
truck uses metal cables with hooks
on the ends. These hooks go around
parts of the f rame or suspension and the cables lif t that end of the vehicle
of f the ground. Your vehicle’s sus-
pension and body can be seriously
damaged.
If your Honda cannot be transported
by f lat-bed, it should be towed by
wheel-lif t equipment with the f ront
wheels of f the ground. If , due to
damage, your vehicle must be towed
with the f ront wheels on the ground,
do the f ollowing:
Release the parking brake.
Shif t the transmission to Neutral.
Release the parking brake.
Start the engine.
ShifttoD,thentoN.
Turn of f the engine. With the f ront wheels on the ground,
it is best to tow the vehicle no farther
than 50 miles (80 km), and keep the
speedbelow35mph(55km/h).
If your vehicle is equipped with a
f ront spoiler, remove it bef ore
towing so it is not damaged.
5-speed Manual Transmission:
Automatic Transmission (CVT):
Emergency T owing
T aking Care of t he Unexpect ed
Flat -bed Equipment
Wheel-lif t Equipment
Sling-t ype Equipment
This is the best way to trans-
port your Honda.
T his is
an acceptable way to tow your
Honda. T his method of towing
is unacceptable.
181
NOTICE:
NOTICE: Improper towing preparation
will damage the transmission. Follow
the above procedure exactly. If you
cannot shif t the transmission or start
the engine (CVT), your vehicle must be
transported with the f ront wheels of f
the ground.
Trying to lif t or tow your
vehicle by the bumpers will cause
serious damage. The bumpers are not
designed to support the vehicle’s weight.

ÎÎÎ
Î
Î
Î
Î
Î
Specif ications
T echnical Inf ormation192
Dimensions
Weights
EngineCapacities
66.7 in (1,695 mm)
53.3 in (1,355 mm)
94.5 in (2,400 mm)
56.5 in (1,435 mm)
52.2 in (1,325 mm) 10.6 US gal (40
)
155.0 in (3,938 mm)
0.61 US gal (2.3)
ILZFR5A-11 10.3 : 1 10.8 : 1
60.8 cu-in (995 cm
)
2.8x3.21in(72x81.5mm)
0.11 US gal (0.4
)
4.8 US qt (4.5
)
5.8 US qt (5.5)
3.5 US qt (3.3)
1.7 US qt (1.6
)
1.6 US qt (1.5)
3.2 US qt (3.0
)
2.4 US qt (2.3)
2.6 US qt (2.5)
Length
Width
Height
Wheelbase
Track
Gross vehicle weight rating
Type
BorexStroke
Displacement
Compression ratio
Spark plugs Fuel tank
Engine
coolant
Engine oil
Manual transmission
fluid
Automatic transmission
fluid (CVT)
Windshield washer reservoir
Including the coolant in the reserve tank and that remaining in the
engine.
Reserve tank capacity:
See the certification label attached
to the driver’s doorjamb.
Water cooled 4-strokeSOHC VTEC in line
3-cylinder gasoline engine 1.06 US gal (4.0
)
1.03 US gal (3.9)
Contact your Honda dealer when replacement is necessary. Front
Rear
Approx.
U.S. model
M/T
CVT
1: 2:
3:M/T
CVT
Change
Total
Change
Without filter
Total
Change
Total
Change
Total
4 : Excluding the oil remaining in the engine.
1 32
4
Including filter

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