Honda Insight Owner's Manual
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Honda Insight Owner's Manual

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  • Page 2: Table Of Contents

    GENERAL INFORMATION ... 5 ... 6 BOUT THIS NCYCLOPEDIA EHICULE DENTIFICATION UMBER ... 8 EATURES AND PECIFICATIONS ... 12 CALE RAWINGS Non-Scale Drawing of Cargo Area ... 13 MAINTENANCE ... 14 PECIAL AINTENANCE ONSIDERATIONS Engine Oil ... 15 Washing... 15 Vehicle Lift Points ...
  • Page 3 ... 26 IGHTWEIGHT ANELS ... 27 EPAIR NFORMATION Dacro Coated Bolts... 27 Body Repair Techniques... 27 Welding ... 27 Sheet Metal... 27 Grinding ... 27 Assembling ... 27 Inspection ... 27 ... 28 LASTIC Construction... 28 STEERING / SUSPENSION / BRAKES... 29 ...
  • Page 4 Design ... 58 ... 60 ATTERY ODULE ... 61 UNCTION OARD (BCM)... 62 ATTERY ONDITION ONITOR (MCM)... 63 OTOR ONTROL ODULE (MDM)... 64 OTOR RIVE ODULE MDM Components ... 64 DC-DC C ... 65 ONVERTER ADVANCED GASOLINE ENGINE ... 66 ...

  • Page 5: General Information

    ENERAL NFORMATION...

  • Page 6: About This Encyclopedia

    NCYCLOPEDIA This encyclopedia is provided so that you can learn more about the Insight and how it works. While every effort has been made to insure its accuracy, this information shouldn't be used as the basis for repairs or modifications to your Insight. If you wish to do any work with your insight, a Service Manual, Electrical Troubleshooting Manual and Body Repair Manual are all available from your Honda dealer.

  • Page 7: Identification Number (Vin)

    EHICULE DENTIFICATION The Insight's VIN can be found many places on the car. The easiest and most visible location is through a small window at the bottom driver's side corner of the windshield: An Insight VIN is broken into fields as follows:...

  • Page 8: Features And Specifications

    EATURES AND PECIFICATIONS Vehicle type Subcompact, two-seater, front-wheel drive, gasoline-electric hybrid Major features: Other features: Standard features Engine & Motor Engine type Fuel system Ignition system Materials Overview • 5-speed manual transmission • Anti-lock brakes • Electric power steering • Dual air bags (SRS) •...
  • Page 9 Valve train Bore x stroke Displacement Compression ratio Tune-up interval Engine weight Electric motor Size Output Max. power Max. torque Transmission 1st gear ratio 2nd gear ratio 3rd gear ratio 4th gear ratio 5th gear ratio Reverse gear ratio Final drive ratio IMA battery pack Rated capacity Alternator...
  • Page 10 Wheels & Tires Wheels Tires Type All structural components and most body panels are extruded or die-cast Materials Front fenders & rear fender skirts are a recyclable ABS/nylon composite Length Height (excluding antenna) Wheelbase Front track Rear track Ground clearance Headroom Legroom Shoulder room...
  • Page 11 Fuel Consumption & Emissions 3.4 l/100km (EUDC) Fuel consumption 61 mpg city / 70 mpg highway (EPA) CO2 emissions 80 g/km California emission standards ULEV compliance...

  • Page 12: Scale Drawings

    CALE RAWINGS...

  • Page 13: Non-Scale Drawing Of Cargo Area

    Non-Scale Drawing of Cargo Area (Courtesy of John Johnson)

  • Page 14: Maintenance

    AINTENANCE...

  • Page 15: Special Maintenance Considerations

    Space blocks must be used with any plate style lift to avoid damage to the rocker panels or rear strakes. The Mid Center point is for use when lifting the Insight with a floor jack. In this case, a rubber pad should be positioned between the lift platform and support point.

  • Page 16: Long -Term Storage

    TORAGE In addition to a conventional 12V battery, the Insight has a stored for a long period, the IMA battery will gradually discharge and must be charged periodically (ideally once every three months). To maintain the IMA battery, follow this procedure: Remove the 40A EPS Fuse (No.

  • Page 17: Hatch Access

    ATCH CCESS The Insight rear hatch differs from many Honda models because there is no mechanical linkage between the hatch release on the outside of the vehicle and the actual latch. The exterior latch release is actually a switch that operates a hatch opener relay. A hatch release motor is operated by the relay. The hatch opener switch and hatch unlock (key) switch are both in series with the relay.

  • Page 18: Towing Information

    To accommodate flat-bed towing equipment, the Insight is provided with a front towing hook, and front and rear tie down hook holes. The towing hook can be used with a winch to pull the Insight onto the truck, and the tie down holes can be used to secure the vehicle to the truck.

  • Page 19: Service Safety Considerations

    ERVICE AFETY ONSIDERATIONS The Insight's IMA system employs high-voltage components and highly magnetic components, and so anyone working on the IMA system must exercise caution and follow Service Manual procedures carefully. IMA Motor Rotor The rotor of the IMA motor is highly magnetic. Consequently, all iron, magnetic and electronic materials must be kept away from the rotor if it is to be replaced.

  • Page 20: Service Connectors

    Windows PCs; see below) to be connected to the Insight's engine control computer. This allows access to a wide range of real time performance and status information from the Insight. It also allows access to the log of any "DTC" codes that the computer records when the "Check Engine Light"...

  • Page 21: Body Technologies

    ECHNOLOGIES...

  • Page 22: Aerodynamics

    Regardless of what power source a car is using, the less its aerodynamic drag, the less energy will be needed to travel at any given speed. A great deal of effort has gone into designing the Insight around the goal of achieving excellent aerodynamics, the end result being a drag coefficient of only 0.25, the lowest achieved by any mass produced car.
  • Page 23 • Low-drag door mirrors • Rear wheel wells enclosed by fender skirts and disk-shaped wheels aluminum alloy wheels smooth airflow around the wheel openings • Front fenders extend down below centerline of wheel • To improve airflow over the exposed wheels, the aluminum wheels have a flat-faced design. •...

  • Page 24: Aluminum Construction

    The unit-body part of the Insight's body uses stressed sheet-metal panels to absorb and distribute structural and suspension loads, much like an ordinary steel unit body. However, with the Insight's body all of these panels, including the roof, floor, front and rear wheel wells, rear quarter-panels, bulkhead, and even the doors and hood, are made of aluminum alloy.

  • Page 25: Thixotropic Die Casting

    On the Insight, each frame member's size and strength is optimized so that the frame is strong where it needs to be, and lighter in less critical areas. A variety of shapes are used, including hexagons, ovals, H- sections and reinforced box-sections. The door and windshield pillars, front and rear side-frame members, lower body sills, cross members and floor frame members are all formed in this manner.

  • Page 26: Lightweight Body Panels

    IGHTWEIGHT ANELS The Honda Insight features lightweight plastic panels which are used extensively in non-structural applications. The front fenders, spoilers, under body cover and rear fender skirts are all made of plastic. Also, lightweight sound insulating materials are used throughout the Insight.

  • Page 27: Body Repair Information

    Service Manual and Body Repair Manual. The information below is by no means complete repair procedures; it is simply provided to give you some of the key procedures that should be followed if you ever have someone carry out repairs on your Insight's body. Welding Wash and grind the welding zone.

  • Page 28: Plastic Fuel Tank

    Europe. Plastic is also used for transporting and storing gasoline in the form of the commonly seen red plastic "cans". Construction The Insight's plastic fuel tank is made up of six layers of four different materials: • Ethyl Vinyl Alcohol (EVOH) •...

  • Page 29: Steering / Suspension / Brakes

    TEERING USPENSION RAKES...

  • Page 30: Electric Power Steering

    OWER TEERING The Honda Insight uses a variable-assist rack and pinion electric power steering (EPS) system rather than a typical hydraulic power steering system. A typical hydraulic power steering system is continually placing a small load on the engine, even when no steering assist is required.

  • Page 31: Electronic Construction

    Electronic Construction The EPS control unit is mounted inside the car on the right side bulkhead, underneath the dash. It receives input from the vehicle speed sensor and torque sensor mounted on the steering pinion shaft. The torque sensor is identical in construction to the unit on the S2000. The pinion shaft engages the pinion gear via a torsion bar, which twists slightly when there is a high amount of steering resistance.

  • Page 32: Front Suspension

    At the lower end, the strut mounts solidly to the steering knuckle, locating it vertically. The lower end of the knuckle mounts to a lower control arm. On the Insight, the knuckle and lower control arm are aluminum forgings, providing maximum strength but minimizing unsprung weight. Weight is also saved by...

  • Page 33: Rear Suspension

    USPENSION The Insight's rear suspension uses trailing arms. These are connected midway along their length by a curved, H-section steel torsion beam that twists to allow a controlled level of independent suspension movement. This arrangement works with very short springs and dampers which allow for a very low rear floor, while the suspension system still sits entirely below the floor.

  • Page 34: Braking System

    YSTEM Front Disc Brakes The front brake single piston calipers fitted to the Insight are made from aluminum. This helps to reduce the weight and drag of the components significantly without a loss of strength in the components. There are many other new design features which include: •...

  • Page 35: Anti-Lock Braking System

    While a typical cast iron drum might weigh 3.4 kg (7.5 lbs.), the Insight's aluminum/cast iron drum weighs 2.1 kg (4.6 lbs.). The drum's outside diameter is 181 mm. Anti-Lock Braking System The Insight is equipped with a compact and lightweight ABS modulator assembly. The modulator unit and ABS control unit are integrated into one component which also includes relays, wires and electrical couplers.

  • Page 36: Cabin Interior

    ABIN NTERIOR...

  • Page 37: Cabin Interior

    Outward visibility, sightlines and control placement are designed to enhance driver concentration and ease of movement. Honda designers have also designed the Insight's interior to be comfortable and relaxing. The high-backed bucket seats are highly supportive to help minimize fatigue during long periods of driving.
  • Page 38 To assist in holding cargo in place, the cargo area is equipped with D-rings in four corners to which a cargo net or cargo bag may be hooked. For more information on the cabin interior, see: • Electronic Instrument Display •...

  • Page 39: Electronic Instrument Display

    LECTRONIC NSTRUMENT Housed in a hooded central pod directly in front of the driver, the Insight's Electronic Instrument Display is a combination analog and digital readout that shows all important information about the Insight's Integrated Motor Assist (IMA) system and its effect on vehicle performance. This information is presented in a manner that encourages the driver to take an interest in improving the vehicle's fuel economy.

  • Page 40: Odometer / Trip Meter / Fuel Efficiency Meter

    The upshift indicator will illuminate when better fuel economy can be achieved by shifting up to a higher gear. The downshift indicator will illuminate when the Insight is unable to maintain the current speed, even with full assist. This light will sometimes illuminate when climbing steep hills at highway speeds.

  • Page 41: Engine Status Meter

    When the Insight goes into Auto Idle Stop mode, a green "Auto Stop" LED at the base of the tachometer illuminates to indicate that the engine is not moving at all, but to remind the driver that the car is still in the "on"...

  • Page 42: Passenger Restraint System

    ESTRAINT YSTEM The Honda Insight Supplemental Restraint System consists of an SRS control unit with integral impact sensors, driver and passenger airbags, and seat belt tensioners. The seat belt pretensioner system also provides a load limiting function, where the seatbelts are released slightly when needed to limit the amount of force exerted on a passengers by the seatbelts during a collision.

  • Page 43: Heating , Cooling & Ventilation

    & V EATING OOLING ENTILATION Honda Insight Heating Conditioning (optional) achieves a balance between comfort for the passengers and fuel economy for the vehicle. This unique design allows the engine ECU and the IMA to control the auto(idle)-stop feature based upon various...

  • Page 44: Micron Air Filtration

    The filter should be replaced every 15,000 miles (24,000 km) or 12 months, whichever comes first. This filter can be accessed below the dashboard from the passenger, near the center of the car. For additional information, refer to the Insight Service Manual or Owners Manual.

  • Page 45: Ima Hybrid System

    IMA H YBRID YSTEM...

  • Page 46: Ima Hybrid System

    With a series system, an engine drives a generator, which in turn powers a motor, whose output propels the vehicle. With a parallel system, the engine and motor can both be used to propel the vehicle. The Insight employs a parallel system that is described by Honda as the Integrated Motor Assist (IMA) system.

  • Page 47: Ima Modes Of Operation

    ODES OF PERATION As the Insight's goes from being stationary to accelerating, cruising and then decelerating, the IMA hybrid system's mode of operation changes. In each mode of operation, the gasoline engine and IMA electric motor each play a different role. Click on the links below to learn more about a particular mode of operation.

  • Page 48: Starting / Restarting Mode

    • There is a failure of the IMA system. Because the Insight won't enter idle stop mode in any of the above situations, all engine starts other than the initial start will always be done using the IMA motor. To test the 12v auxiliary starting system, first disable the IMA starting system by removing fuse #2...

  • Page 49: Acceleration / Assist Mode

    CCELERATION SSIST Energy flow from gas engine to wheels & from battery to electric motor to wheels During acceleration and other high load conditions such as climbing a steep slope, current from the Battery Module is converted to AC by the MDM and supplied to the IMA Motor, which then functions as a motor.

  • Page 50: Cruising Mode

    Energy flow from gas engine to wheels (& sometimes also to battery via motor/generator) When the Insight is cruising at a constant speed and the Battery Module state of charge is relatively low, some engine output is used by the IMA motor/generator being operated in generation mode to charge the Battery Module.

  • Page 51: Deceleration / Regenerative Braking

    In this mode, the IMA Motor is driven by the wheels, generating electricity to be stored in the Battery Module, and slowing the Insight in the process. The amount that the IMA Motor slows the car is in proportion to the amount of regeneration being done. There are two deceleration modes: •...

  • Page 52: Fuel Cut Mode

    Energy flow from wheels to crankshaft (no fuel burned) Whenever the Insight is moving with the clutch engaged and the transmission in gear, the gasoline engine is mechanically connected to the wheels, and so it must continue to turn also. However, this doesn't necessarily mean that it is consuming any fuel.

  • Page 53: Idle Stop Mode

    The engine speed is less than 1000 rpm If the brake pedal is released while the Insight is slowing down, the engine starts again instantly, unless vehicle speed is below a certain speed. Even in this case, the engine will be restarted if a gear is selected or the gas pedal is touched.

  • Page 54: Conditions For Engine Restart

    may occur, possibly causing the air conditioning compressor to temporarily stop. See the climate control page for more information. Conditions for Engine Restart The engine is restarted when: • A gear is selected with the clutch disengaged, or • The brake pedal is release during deceleration, or •...

  • Page 55: Ima Component Locations

    This tracks the battery state of charge and decides how much energy can be supplied to or delivered from the battery. • Battery Module: Located below the MCM and BCM, this is the Insight's 144 volt primary battery pack. •...
  • Page 56 Battery Module assembly. The Junction Board contains the battery module switch, along with contactors that are used to connect the Battery Module to the electronics when the Insight is turned on. Power is carried between the components in the "IPU" compartment behind the seats and the IMA electric motor under the hood by three orange cables than run below the floor, under the left seat.

  • Page 57: Ima Motor / Generator

    IMA Battery Module, and later be used to provide assist. • It takes the place of the conventional alternator, providing energy that ultimately feeds the Insight's conventional 12v electrical system. • It is used to start the internal combustion engine very quickly and quietly. This allows the internal combustion engine to be turned off when not need, without any delay in restarting on demand.

  • Page 58: Design

    Design The IMA motor is a permanent-magnet type, brushless DC motor. The only moving part in this type of motor, the rotor, consists of nothing but permanent magnets. The electromagnets are located around the perimeter of the stator. There are several key attributes of this type of motor: •...

  • Page 60: Battery Module

    ATTERY ODULE The Battery Module uses nickel metal hydride (NiMH) technology for high energy density and long service life. The battery is manufactured by Panasonic EV Energy and weighs only 48 lbs. or 22 kg. Its operating temperature range is -30C degrees ~ +60C degrees.

  • Page 61: Junction Board

    UNCTION OARD The Junction Board is located in the IPU compartment and is attached directly to the Battery Module. Most small components, and the main connections of the high voltage system, are located on the junction board. The Junction Board itself is not serviceable. If a component attached to the board fails, the Battery Module assembly must be replaced.

  • Page 62: Battery Condition Monitor (Bcm)

    ATTERY ONDITION ONITOR The Battery Condition Monitor Module (BCM) monitors the condition of the main battery, via four temperature sensors and 10 voltage sensors in the Battery Module. It also uses one current sensor to determine rate of charge/discharge, and supplies information to the Motor Control Module. The BCM maintains the IMA battery state of charge in a range of 20% to 80%, which optimizes battery life.

  • Page 63: Motor Control Module (Mcm)

    OTOR ONTROL ODULE The IMA Motor/Generator's function is to charge the Battery Module, to assist the gasoline engine under acceleration, and to start the engine under specific conditions. The Motor Control Module controls all these actions. The MCM is a low-voltage, microprocessor controlled device (i.e.

  • Page 64: Motor Drive Module (Mdm)

    (MDM) OTOR RIVE ODULE The IMA system assists the engine with an electric motor using power from the Battery Module. It must also recharge the Battery Module by using power generated by the motor. It is the Motor Drive Module or MDM which makes this possible.

  • Page 65: Dc-Dc Converter

    IMA Motor/Generator though the MDM, or by the NiMH Battery Module. This power has to be reduced to 12V to charge the Insight's 12V battery and to support the conventional 12V electrical system. It is the DC-DC converter that performs this task. It transforms 144V DC as an input source into 12V DC output power.

  • Page 66: Advanced Gasoline Engine

    DVANCED ASOLINE NGINE...

  • Page 67: Dvanced Asoline Ngine

    Honda engineers designed a completely new 5-speed manual transmission for the Insight. Like the rest of the Insight, its new transmission is designed to be as lightweight and as compact as possible, and is sized to the power requirements of the IMA system. The new transmission weighs just 91 pounds and is 9.25 pounds lighter and almost a half an inch shorter than the current Civic manual transmission.

  • Page 68: Engine Weight Reduction Technologies

    Sleeveless cylinders with minimal dimension between bores • The intake manifold used on the Insight's 1.0-liter engine is made out of plastic resin instead of aluminum alloy. The entire manifold weighs only 2.2 pounds, roughly half the weight of a comparable aluminum manifold.

  • Page 69: Engine Friction Reduction Technologies

    NGINE RICTION EDUCTION To minimize energy losses, friction between moving parts is minimized by utilizing the following features: • Offset cylinder construction • In the interest of friction reduction, Honda engineers specified a new lightweight aluminum- alloy piston design for the IMA engine. The pistons have a minimal skirt area and the surface of the skirt has been shot-peened.

  • Page 70: Vibration Control System

    The results are a much more consistent crankshaft rotational velocity and smoother idle quality. The Insight also uses lightweight aluminum-alloy engine mounting brackets that incorporate hydraulic (liquid-filled) mounts that help damp engine vibration. The mounts are located on the axis of the engine's principal inertial moment (the axes about which the engine vibrates).

  • Page 71: Offset Cylinder Construction

    FFSET YLINDER ONSTRUCTION The engine block has a unique, offset cylinder design in which the bore center is offset 14mm from the crank center. Maximum combustion pressure occurs at a point where the connecting rod is straight up and down in the cylinder. In this position there is zero lateral force so friction and piston slap are reduced. As a result of the offset construction, the combustion pressure is used more efficiently since the rod is near it maximum leverage point with the crankshaft.

  • Page 72: Spark Plugs

    PARK LUGS The Insight uses a new, iridium spark plug that is unique to this vehicle. There are four different part numbers for the spark plugs, and each has the electrode aligned differently with the plug threads. This allows the orientation of the ground electrode in relation to the intake valve to be optimized for maximum economy and power, and optimum combustion efficiency.

  • Page 73: Rocker Arms & Shaft

    & S OCKER HAFT In order to reduce friction and weight, L-shaped, roller rocker arms are mounted on a single shaft. A narrow valve angle (30 degrees) and a compact combustion chamber contribute to an increased swirl ration of the air/fuel mixture, leading to better combustion. Timing Chain System Crankshaft rotation is transmitted via a silent type timing chain to the camshaft sprocket.

  • Page 74: Vtec-E System

    VTEC-E S YSTEM The Honda Insight's engine employs a newly designed VTEC system. In this system, the cam followers of the intake primary rocker arms are fitted with rollers that minimize friction on the cam's contact surfaces. (Each roller turns on a needle roller bearing.) The VTEC rocker arms are a new, compact, low-friction design, adapted from the S2000 roadster, with the VTEC switching mechanism (pistons) located coaxially with the roller elements.

  • Page 75: Integrated Head

    NTEGRATED The Honda Insight's cylinder head has a unique, cast-in exhaust manifold that saves weight and increases exhaust heat retention. The exhaust ports are located inside the cylinder head and are surrounded by a water jacket. As coolant passes through the jacket, its temperature is increased by the exhaust heat.

  • Page 76: Direct Ignition System

    GNITION YSTEM The Insight engine employs a direct ignition system similar to those used on the Honda S2000 and the 1999 Odyssey. Separate ignition coils for each cylinder are located directly above the spark plugs. Two TDC (Top Dead Center) sensors are mounted at the rear of the single camshaft. A Crankshaft Fluctuation Sensor (CKF) is located near the bottom of the timing cover where it generates a signal as the crankshaft timing chain sprocket rotates past it.

  • Page 77: Cvt Transmission

    "CVT" or "Honda Multimatic" transmission. Note that while the Honda Insight and Toyota Prius both offer CVT transmissions that both provide stepless acceleration and a continuous range of motor speed to vehicle speed ratios, the Prius CVT (called 'ECVT' by Toyota) system is mechanically entirely different.

  • Page 78: Cvt Operation

    Honda claims that their CVT transmission is the world's first mass-produced, high-power, stepless transmission. While such transmissions existed previously, they claim the CVT is "far superior in quality, endurance, power output [and] cost". They have also specifically designed the CVT to respond in the way that drivers are accustomed to other automatic tranmissions responding.
  • Page 79 1) Driven-Shaft-Placed Acceleration Clutch The Honda Multimatic differs from previously existing step-less transmissions is that the acceleration clutch is placed on the driven shaft. The primary reason we took this route was to control torque at the closest possible place to the axle, allowing for smooth acceleration. In addition, we were able to apply a modest creep* which most automatic transmission users have grown accustomed to.
  • Page 80 changes. At the same time, this allows for a more direct connection to the engine, resulting in less slip-loss - which ultimately leads to higher fuel economy. 5) High-Performance Oil Pump The Honda Multimatic requires a high-pressure oil pump in order to operate the pulleys at optimum settings.

  • Page 81: Cvt Advantages

    While the brake pedal is depressed, there is very little to no creep, while releasing the brake pedal will engage creep again. By dropping the creep level while the automobile is stopped, additional fuel efficiency is realized. 3) Side Pressure Control In addition to the standard step-less transmission's oil-pressure controlled layout, we considered the effects of torque on the pulleys and belt.

  • Page 82: Engine Performance Curves

    NGINE ERFORMANCE URVES...

  • Page 83: Gear Ratio Graphic

    ATIO RAPHIC...

  • Page 84: Emissions Control

    MISSIONS ONTROL...

  • Page 85: T Echnologies

    MISSIONS TANDARDS We know that Honda has gone to great lengths in engineering the Insight in the pursuit of low emissions levels, but just how low have they actually achieved? There are two major categories of vehicle emissions that people are concerned about: Air polluting compounds that contribute to smog and are health hazards These are the compounds measured by the various emissions standards.
  • Page 86 Comparison to Various Car Emissions Standards Hydrocarbons Category g/km (g/mi) Pre-standards (1970) TLEV ULEV (10) SULEV Canada 1975 standards Canada 1987 standards Canada 1997 0.25 standards (0.4) Notes: Total organic gases (hydrocarbons) Non-methane organic gases (hydrocarbons) Carbon monoxide Nitrogen oxides Particulate matter, 2.5 microns and less.

  • Page 87: Lean -Burn Oxygen Sensor

    The Insight uses a LAF (Linear Air-Fuel) sensor for the primary oxygen sensor that is capable of measuring air-fuel ratios as lean as 23:1. This allows the ECM to maintain precise control over the mixture during both normal and lean burn conditions.
  • Page 88 Unlike a conventional sensor, the voltage can be positive or negative, and it reads the opposite direction. That is, positive voltage indicates a lean mixture, and negative voltage indicates a rich mixture. The normal operating range is about 1.5 volts. The LAF sensor can be identified by its five wire configuration: •...

  • Page 89: Advanced Catalyst System

    YSTEM The insight is designed to operate at a very lean air fuel ratio during light throttle cruise conditions. The mixture can be as lean as 22:1 if conditions allow. This provides very good fuel economy, and low HC and CO emissions.

  • Page 90: Catalytic Converter Deterioration Detection / Replacement

    Catalytic Converter Deterioration Detection / Replacement The Insight uses 2 oxygen sensors to monitor the condition of the 3-way catalyst as required by OBD-II and EU2000 regulations. However, the detection system is not able to directly monitor the condition of the lean NOx catalyst.

  • Page 91: Exhaust Gas Recirculation System

    XHAUST ECIRCULATION The Insight uses a linear-solenoid-operated EGR valve that feeds recirculated exhaust gas into an equal-length EGR manifold that is sandwiched between the intake manifold and the cylinder head. This design ensures equal distribution of recirculated exhaust gas between the three cylinders and prevents the exhaust gas from liquefying before reaching the intake ports.

  • Page 92: Orvr & Vacuum Distribution

    ORVR & V ACUUM ISTRIBUTION U.S. and Canada model Insights are equipped with On-board Refueling Vapor Recovery (ORVR) systems that are identical to the system introduced on the 1998 Accord. The following diagram shows the entire vacuum distribution system including the ORVR system:...
  • Page 93 Primary heated oxygen sensor (primary HO2S) Secondary heated oxygen sensor (secondary HO2S) Manifold absolute pressure (MAP) sensor Intake air temperature (IAT) sensor Engine coolant temperature (ECT) sensor Top dead center 2 (TDC2) sensor Top dead center 1 (TDC1) sensor Crankshaft position (CKP) sensor Knock sensor (KS) Master power vacuum sensor Check valve...

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