engine HONDA INSIGHT 2004 1.G Workshop Manual

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

Open the hood.
To change the headlight bulb on
the driver’s side, remove the
engine coolant reservoir tank by
pulling it out of its holder.
Your vehicle has halogen headlight
bulbs, one on each side. When
replacing a bulb, handle it by its steel
base and protect the glass from
contactwithyourskinorhard
objects. If you touch the glass, clean
it with denatured alcohol and a clean
cloth.
Theheadlightswereproperlyaimed
when your vehicle was new. If you
regularly carry heavy items in the
cargo area, readjustment may be
required. Adjustments should be
perf ormed by a Honda dealer or
other qualif ied mechanic.
1.
Lights
Maint enance
Replacing a Headlight Bulb
Headlight A iming
144
NOTICE:
HOLDER
Halogen headlight bulbs get
very hot when lit. Oil, perspiration, or a
scratch on the glass can cause the bulb
to overheat and shatter.

CONT INUED
Remove the socket from the
headlight assembly by turning it
one-quarter turn counterclockwise.
Pull the bulb straight out of its
socket.
Install the new bulb into the
socket.
Unclip the end of the hold-down
wire f rom its slot. Pivot it out of
the way, and remove the bulb.
Insert the new bulb into the hole,
making sure the tabs are in their
slots. Pivot the hold-down wire
back in place, and clip the end into
the slot.
Install the rubber seal over the
back of the headlight assembly.
Make sure it is right side up; it is
marked ‘‘TOP’’.
Push the electrical connector onto
the tabs of the new bulb. Make
sure it locks in place.
Turn on the headlights to test the
new bulb.
(Driver’s side)
Reinstall the engine coolant
reserve tank.
Remove the electrical connector
f rom the bulb by squeezing the
connector on both sides to unlock
the tab. Pull the connector straight
off.
Remove the rubber weather seal
by pulling on the tab. 4.
5.
6.
7.
8.
1.
2.
3.
2.
3.
Lights
Maint enance
Replacing a Front Parking L ight
Bulb
145
BULB
CONNECTOR WEATHER SEAL
HOLD-DOWN WIRE

Install the socket back into the
headlight assembly. Turn it
clockwise to lock it in place.
Turn on the lights to make sure
the new bulb is working.To change the bulb on the driver’s
side, start the engine, turn the
steering wheel all the way to the
right, then turn of f the engine. To
change the bulb on the passenger’s
side, turn the steering wheel to the
lef t.
Use a Phillips-head screwdriver to
remove the screw f rom the top of
the f ender.Pull the inner f ender cover back.
Remove the socket from the
headlight assembly by turning it
one-quarter turn counterclockwise.
Pull the bulb straight out of its
socket. Push the new bulb straight
into the socket until it bottoms.
3.
2. 4.
5.
4.
5.
1.
Lights
Maint enance
Replacing the Front Side Marker/
Turn Signal Light Bulb
146

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

This section covers the more
common problems that motorists
experience with their vehicles. It
gives you inf ormation about how to
safely evaluate the problem and what
to do to correct it. If the problem has
stranded you on the side of the road,
you may be able to get going again.
If not, you will also f ind instructions
on getting your vehicle towed.......................
Compact Spare Tire .164
....................
Changing a Flat Tire .165
.............
If the Engine Won’t Start . 171
................................
Jump Starting .173
..............
If the Engine Overheats . 175
.........
Low Oil Pressure Indicator . 177
..........
Charging System Indicator . 178
.......
Malf unction Indicator Lamp . 178
...............
Brake System Indicator . 180
......................
Emergency Towing .181
......
If Your Vehicle Gets Stuck . 182
..............................................
Fuses .183
..............................
Fuse Locations .186
Taking Care of the Unexpected
T aking Care of t he Unexpect ed163

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

If the headlights dim noticeably or
go out when you try to start the
engine, either the battery is
discharged or the connections are
corroded. Check the condition of the
battery and terminal connections
(see page ). You can then try
jump starting the vehicle from a
booster battery (see page ).In this case, the starter motor’s
speed sounds normal, or even f aster
than normal, when you turn the
ignition switch to START (III), but
the engine does not run.
Are you using the proper starting
procedure? Ref er to on page . If youfindnothingwrong,youwill
need a qualif ied technician to f ind
the problem. See
on page .
Do you have f uel? Check the f uel
gauge; the low f uel indicator may
not be working.
There may be an electrical
problem, such as no power to the
f uel pump. Check all the f uses
(see page ).
160
173 107
184 181
If theEngineWon’tStart
T aking Care of t he Unexpect ed
T he Starter Operates Normally
Starting the
Engine Emergency
Towing
172

µ
´ ´
Although this seems like a simple
procedure, you should take several
precautions.
You cannot start a Honda with an
automatic transmission (CVT) by
pushing or pulling it.
Open the hood, and check the
physical condition of the battery.
In very cold weather, check the
condition of the electrolyte. If it
seems slushy or like ice, do not try
jump starting until it thaws.
Turn of f all the electrical acces-
sories: heater, A/C, climate
control, stereo system, lights, etc.
Connect the second jumper cable
to the negative ( ) terminal on
the booster battery. Connect the
other end to the grounding strap
as shown. Do not connect this
jumper cable to any other part of
the engine.
Put the transmission in Neutral or
Park, and set the parking brake.
Connect one jumper cable to the
positive ( ) terminal on your
Honda’s battery. Connect the
other end to the positive ( )
terminal on the booster battery.
1.
2.
3.
4.
CONT INUED
Jump Starting
T aking Care of t he Unexpect ed
To Jump Start Your Vehicle:
173
NOTICE:
A battery can explode if you do
not follow the correct procedure,
seriously injuring anyone
nearby.
Keep all sparks, open flames,
and smoking materials away
from the battery. If a battery sits in extreme
cold, the electrolyte inside can f reeze.
Attempting to jump start with a f rozen
battery can cause it to rupture.

CONT INUED
The reading on your vehicle’s
temperature gauge should stay in
the midrange. If it climbs to the red
mark, you should determine the
reason (hot day, driving up a steep
hill, etc.).
If your vehicle overheats, you should
take immediate action. The only
indication may be the temperature
gauge reading reaching the red
mark. Or you may see steam or
spray coming f rom under the hood.If you see steam and/or spray
coming f rom under the hood, turn
of f the engine. Wait until you see
no more signs of steam or spray,
then open the hood.If you do not see steam or spray,
leave the engine running and
watch the temperature gauge. If
the high heat is due to overloading,
the engine should start to cool
down almost immediately. If it
does, wait until the temperature
gauge reading comes down to the
midpoint, then continue driving.
If the temperature gauge reading
stays at the red mark, turn of f the
engine.
Look f or any obvious coolant leaks,
such as a split radiator hose.
Everything is still extremely hot,
so use caution. If you f ind a leak, it
must be repaired bef ore you
continue driving (see
on page ).
Saf ely pull to the side of the road.
Put the transmission in Neutral or
Park, and set the parking brake.
Turn of f all accessories, and turn
on the hazard warning lights.
1.
2. 3.
4.
5.
181
If theEngineOverheats
T aking Care of t he Unexpect ed
Emergency
Towing
175
NOTICE: Steam and spray from an
overheated engine can
seriously scald you.
Do not open the hood if steam
is coming out.
Driving with the temperature
gauge reading at the red mark can
cause serious damage to your engine.