2004 Honda Insight Service & Repair Manual

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🏷️ Basic Information Identification Make: Honda Model: Insight Year: 2004 Generation Generation Code: Ze1 Codes Chassis Code: ZE1 👋 Introduction Market Position Positioning: Pioneering hybrid vehicle in the compact segment,...

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Sku: 203233

Tags: 2004 Car Cars Honda Insight

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Description

🏷️ Basic Information

Identification

Make:

Honda

Model:

Insight

Year:

Generation

Generation Code:

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

Pioneering hybrid vehicle in the compact segment, known for its fuel efficiency and unique aerodynamic design.

Competitive Analysis

Competitors Era:

Early competitor in the emerging hybrid market, often compared to early Toyota Prius models.

Key Features

Aerodynamics:

Highly aerodynamic 'teardrop' profile for improved fuel economy.

Hybrid Powertrain:

Honda's Integrated Motor Assist (IMA) system, combining a gasoline engine with an electric motor.

Manual Advantage:

Provides DIY enthusiasts with factory-level repair information, enabling cost savings and empowerment.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Scope:

Comprehensive vehicle systems and components

Page Count

Estimated Page Count:

Extensive (digital format, access dependent)

Manual Type

Type:

Official Licensed Service & Repair Manual Software

Language

Language:

English

Format

Format:

Online Digital Access (Web Browser Based)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, lubrication system, cooling system, engine overhaul

Engine Performance:

Fuel injection, ignition system, emission control, engine tuning and diagnostics

Hybrid System:

Integrated Motor Assist (IMA) system, battery management, electric motor, power control unit, high-voltage system safety

Transmission:

Continuously Variable Transmission (CVT), internal components, fluid specifications, removal and installation

Drivetrain:

Front wheel drive, axles, differential, wheel bearings

Suspension:

Front suspension, rear suspension, shock absorbers, springs, control arms, alignment specifications

Steering:

Power steering system, steering gear, steering column, tie rods

Brakes:

Front and rear brakes, ABS (Anti-lock Braking System), brake fluid, caliper and rotor service, parking brake

Electrical System:

12V battery, charging system, starter, lighting, horns, wipers, power windows, power locks

Body And Interior:

Body panels, doors, hood, trunk, interior trim, seats, safety belts

HVAC:

Heating, ventilation, and air conditioning system, refrigerant, compressor, evaporator, heater core

Wiring Diagrams:

Complete electrical wiring diagrams for all systems

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement

Troubleshooting:

Diagnostic procedures, common fault diagnosis, symptom-based troubleshooting guides

Repair And Overhaul:

Detailed step-by-step instructions for component removal, repair, and reinstallation

Diagnostics:

On-Board Diagnostics (OBD-II) interpretation, diagnostic trouble codes (DTCs), system testing

Replacement:

Component replacement procedures for all major systems

Technical Depth

Depth:

Factory-level, including detailed specifications, torque values, and diagnostic procedures

Diagnostic Tools:

Information on specific Honda diagnostic tools and procedures

📊 Manual Specifications

File Format

Format Details:

Web-based, accessible via internet browser on PC, laptop, smartphone, or tablet

Print Quality

Print Quality:

N/A (Digital Format)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

Access

Subscription Period:

1 Year Included, with discounts for renewal

⚙️ Engine Specifications

Primary Engine

Engine Code:

D13B1 (for gasoline engine)

Configuration:

Inline 3-cylinder, SOHC VTEC

Displacement:

1.3 L (1339 cc)

Bore X Stroke:

74.0 mm x 77.4 mm

Performance

Gasoline Engine Hp:

88 hp @ 5700 rpm (combined with IMA)

Gasoline Engine Torque:

84 lb-ft @ 3000 rpm (combined with IMA)

Electric Motor Hp:

13 hp (IMA motor)

Electric Motor Torque:

36 lb-ft (IMA motor)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (PGM-FI)

Recommended Fuel:

87 Octane Regular Unleaded Gasoline

Hybrid Components

Battery Type:

Nickel-Metal Hydride (NiMH)

🔧 Transmission

Standard

Type:

Continuously Variable Transmission (CVT) with Integrated Motor Assist (IMA)

Optional

Transmission Options:

N/A (CVT was standard)

Features

Cvt Features:

Variable gear ratios for optimal engine efficiency, smooth acceleration

Fluid Specifications

Transmission Fluid Type:

Honda HMMF (Honda Multi Matic Fluid)

Transmission Fluid Capacity:

Approximately 4.0-4.5 Liters (refer to manual for exact capacity)

📐 Dimensions

Exterior

Length:

156.7 inches

Width:

66.1 inches

Height:

50.8 inches

Wheelbase:

98.9 inches

Weights

Curb Weight:

2147 lbs

Cargo

Cargo Volume:

10.4 cu ft (rear seats up)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Driver:

NHTSA Frontal Crash Passenger:

NHTSA Side Crash Driver:

NHTSA Side Crash Rear Passenger:

IIHS Side Impact:

Acceptable

Active Features

Standard Anti-lock Braking System

Vehicle Stability Assist (Not typically available on 2004 Insight)

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

Three-point seatbelts with pretensioners

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD audio system. Optional premium audio available.

Display:

Digital odometer, fuel economy display, IMA system status indicator.

Driver Assistance

Eco Mode:

IMA system actively assists for optimal fuel efficiency.

Cruise Control:

Standard cruise control.

Connectivity

Connectivity Features:

Limited by era; typically no Bluetooth or USB connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months (refer to manual for specific conditions)

Transmission Fluid Interval:

Every 60,000 miles or 48 months (check for severe conditions)

Spark Plug Replacement:

Platinum tipped plugs; typically every 100,000 miles

Fluid Specifications

Engine Oil Type:

0W-20 Synthetic Motor Oil

Engine Oil Capacity:

3.7 US quarts (3.5 L) with filter change

Coolant Type:

Honda All Season Antifreeze/Coolant Type 2 (Blue)

Coolant Capacity:

Approximately 4.5-5.0 Liters (refer to manual)

Brake Fluid Type:

DOT 3 Brake Fluid

Known Issues

Hybrid Battery:

Degradation of the NiMH battery pack over time, leading to reduced electric assist and fuel economy (though typically very robust for its era).

Transmission Issues:

While generally reliable, CVT fluid changes are critical. Some reports of solenoid issues in high-mileage units.

Exhaust Manifold:

Cracking of the exhaust manifold due to heat cycles can occur.

Condenser Fan:

The condenser fan for the A/C system can fail over time.

📚 Vehicle History

Brand Heritage

Honda Focus:

Honda's long-standing commitment to fuel efficiency, innovation, and reliable engineering.

Model Evolution

First Generation:

The first generation Insight (ZE1) was introduced in 1999 (for the 2000 model year) and concluded in 2006. The 2004 model is a mid-cycle refresh.

Production

Production Years:

1999-2006

Manufacturing Location:

Suzuka Factory, Japan

🏆 Awards & Recognition

Recognitions

Eco Friendly Award:

Recognized for its exceptional fuel economy and low emissions, often cited as a benchmark in its class.

Car Of The Year Nominations:

Received numerous accolades for its innovative hybrid technology and environmental consciousness.