engine HONDA INSIGHT 2004 1.G Repair Manual

If you don’t f ind an obvious leak,
check the coolant level in the
radiator reserve tank. Add coolant
if the level is below the MIN mark.
If there was no coolant in the
reserve tank, you may need to add
coolant to the radiator. Let the
engine cool down until the reading
reaches the middle of the
temperature gauge, or lower,
bef ore checking the radiator.Using gloves or large heavy cloth,
turn the radiator cap
counterclockwise, without pushing
down, to the f irst stop. Af ter the
pressure releases, push down on
the cap, and turn it until it comes
off.
Start the engine, and set the
temperature control dial to
maximum. Add coolant to the
radiator up to the base of the f iller
neck. If you do not have the
proper coolant mixture available,
you can add plain water.
Remember to have the cooling
system drained and ref illed with
the proper mixture as soon as you
can.Put the radiator cap back on
tightly. Run the engine, and watch
the temperature gauge. If it goes
back to the red mark, the engine
needs repair (see
on page ).
If the temperature stays normal,
check the coolant level in the
radiator reserve tank. If it has
gone down, add coolant to the
MAX mark. Put the cap back on
tightly.
6.
7.
8.
9.
181
11. 10.
If theEngineOverheats
T aking Care of t he Unexpect ed
Emergency
Towing
176
Removing the radiator cap
while the engine is hot can
cause the coolant to spray out,
seriously scalding you.
Always let the engine and
radiator cool down before
removing the radiator cap.

This indicator should never
come on when the engine is
running. If it starts f lashing or stays
on, the oil pressure has dropped very
low or lost pressure. Serious engine
damage is possible and you should
take immediate action. Saf ely pull of f the road, and shut
of f the engine. Turn on the hazard
warning indicators.
Let the vehicle sit f or a minute.
Open the hood, and check the oil
level (see page ). An engine
very low on oil can lose pressure
during cornering and other driving
maneuvers.
If necessary, add oil to bring the
level back to the full mark on the
dipstick (see page ).
Start the engine, and watch the oil
pressure indicator. If it does not go
out within 10 seconds, turn of f the
engine. There is a mechanical
problem that needs to be repaired
bef ore you can continue driving
(see
on page
). The engine running generates the
oil pressure.
When the auto idle stop is
activated, the engine is stopped,
but the low oil pressure indicator
does not come on.
1.
2.
3. 4. 95
133
181
L ow Oil Pressure Indicator
T aking Care of t he Unexpect ed
Emergency T owing
177
NOTICE: Running the engine with low
oil pressure can cause serious
mechanical damage almost immediately.
Turn of f the engine as soon as you can
saf ely get the vehicle stopped.

If you have recently ref ueled your
vehicle, the indicator could come on
because of a loose or missing f uel f ill
cap. Tighten the cap until it clicks at
least three times. Tightening the cap
will not turn the indicator turn of f
immediately; it takes at least three
days of normal driving.If the indicator remains on, or the
f uel cap was not loose or missing,
have your vehicle checked by the
dealer as soon as possible.
This indicator may also come on
along with the ‘‘D’’ indicator.
If the indicator comes on
while driving, it means one
of the engine’s emissions control
systems may have a problem. Even
though you may f eel no dif f erence in
your vehicle’s perf ormance, it can
reduce your f uel economy and cause
increased emissions. Continued
operation may cause serious damage.
Go to a Honda dealer or a service
station where you can get technical
assistance. Immediately turn of f all electrical
accessories. Try not to use other
electrically operated controls such as
the power windows. Keep the engine
running; starting the engine will
discharge the battery rapidly. If the charging system
indicator comes on brightly
when the engine is running, the
battery is not being charged.
Charging System Indicator, Malf unction Indicator L amp
T aking Care of t he Unexpect ed
Malf unction Indicator L amp
Charging System Indicator
178
NOTICE: If you keep driving with the
Malf unction Indicator Lamp on, you
can damage your vehicle’s emissions
controls and the engine. Those repairs
may not be covered by your vehicle’s
warranties.

Your vehicle has certain ‘‘readiness
codes’’ that are part of the on-board
diagnostics f or the emissions
systems. In some states, part of the
emissions testing is to make sure
these codes are set. If they are not
set, the test cannot be completed.
If your 12 volt vehicle’s battery has
been disconnected or gone dead,
these codes are erased. It takes at
least three days of driving under
various conditions to set the codes
again.To check if they are set, turn the
ignition switch to ON (II), without
starting the engine. The Malf unction
Indicator Lamp will come on f or 20
seconds.If itthengoesoff,the
readiness codes are set. If it blinks 5
times, the readiness codes are not
set. If possible, do not take your
vehicle f or a state emissions test
until the readiness codes are set.
Refer to State Emissions Testing for
more inf ormation (see page ).
200
Malf unction Indicator L amp
T aking Care of t he Unexpect ed
Readiness Codes
179

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.

The interior f use is underneath the
dashboard on the driver’s side.
Remove the storage pocket by
swinging the lid down, pushing up,
and pulling it straight out of its
hinges. The vehicle’s f uses are located in
two f use boxes.The under-hood f use box is in the
engine compartment. To open it,
pushthetabsasshown.If something electrical in your
vehicle stops working, the first thing
youshouldcheckforisablownfuse.
Determine f rom the chart on pages
and , or the diagram on the
f use box lid, which f use or f uses
control that device. Check those
f uses f irst, but check all the f uses
bef ore deciding that a blown f use is
the cause. Replace any blown f uses,
and check if the device works.
Turn the ignition switch to LOCK
(0). Make sure the headlights and
all other accessories are off.
Remove the cover f rom the f use
box.
1.
2. 186 187
CONT INUED
Checking and Replacing Fuses
Fuses
T aking Care of t he Unexpect ed183
INTERIOR
TABUNDER-HOOD

Your vehicle has several identif ying
numbers in various places.
The Vehicle Identif ication Number
(VIN) is the 17-digit number your
Honda dealer uses to register your
vehicle f or warranty purposes. It is
also necessary f or licensing and
insuring your vehicle. The easiest
placetofindtheVINisonaplate
fastened to the top of the dashboard.
Youcanseeitbylookingthrough
the windshield on the driver’s side. It
is also on the Certification label at-
tached to the driver’s doorjamb, and
is stamped on the engine com-
partment bulkhead. The VIN is also
provided in bar code on the
Certif ication label.
Identif ication Numbers
T echnical Inf ormation190
VEHICLE IDENTIFICATION NUMBERCERTIFICATION LABEL

The Engine Number is stamped into
the engine block.
The Transmission Number is on a
label on top of the transmission.
The IMA Motor Number is stamped
on the motor housing.
Identif ication Numbers
T echnical Inf ormation191
ENGINE NUMBER
IMA MOTOR NUMBER
AUTOMATIC TRANSMISSION (CVT)
NUMBER TRANSMISSION NUMBER

ÎÎÎ
Î
Î
Î
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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

Î
ÎThe burning of gasoline in your
vehicle’s engine produces several by-
products. Some of these are carbon
monoxide (CO), oxides of nitrogen
(NOx) and hydrocarbons (HC).
Gasoline evaporating f rom the tank
also produces hydrocarbons. Con-
trolling the production of NOx, CO,
and HC is important to the environ-
ment. Under certain conditions of
sunlight and climate, NOx and HC
react to f orm photochemical ‘‘smog.’’
Carbon monoxide does not contri-
bute to smog creation, but it is a
poisonous gas. The United States Clean Air Act
sets standards f or automobile
emissions. It also requires that
automobile manufacturers explain to
owners how their emissions controls
workandwhattodotomaintain
them. This section summarizes how
the emissions controls work.
Scheduled maintenance is on page
.
In Canada, Honda vehicles comply
with the Canadian emission
requirements, as specif ied in an
agreement with Environment
Canada, at the time they are
manuf actured.
Your vehicle has a Positive
Crankcase Ventilation System. This
keeps gasses that build up in the
engine’s crankcase f rom going into
the atmosphere. The Positive Crank- case Ventilation valve routes them
from the crankcase back to the
intake manif old. They are then
drawn into the engine and burned.
As gasoline evaporates in the f uel
tank, an evaporative emissions
control canister f illed with charcoal
adsorbs the vapor. It is stored in this
canister while the engine is of f . Af ter
the engine is started and warmed up,
the vapor is drawn into the engine
and burned during driving.
The Onboard Ref ueling Vapor
Recovery (ORVR) system captures
the f uel vapors during ref ueling. The
vapors are adsorbed in a canister
f illed with activated carbon. While
driving, the f uel vapors are drawn
into the engine and burned of f .
127
Emissions Cont rols
T echnical Inf ormation
The Clean Air Act
Crankcase Emissions Control
System Evaporative Emissions Control
System
Onboard Ref ueling Vapor
Recovery
197