Honda Insight 2000–2006 Service & Repair Manual Set

The system chapters provide repair procedures, while Advanced Diagnostics explains fault-monitor operation. The wiring and component-location references support circuit tracing alongside the relevant diagnostic section.

Coverage limits: The three separately listed diagnostic and electrical references are labeled 2006. Trouble Shooting — Basic Procedures contains general guidance rather than additional Insight-specific repair coverage.

Searchable Text and Diagram Navigation

Search and drawing detail: Procedure text and many headings are searchable, but labels embedded in illustrations generally are not. This particularly affects the wiring diagrams, component-location drawings, and the one-page SRS and HVAC tool sheets. None of the PDFs has embedded bookmarks. Small connector numbers and wire-color labels in dense diagrams require zooming.

The ZIP contains 62 printable PDFs totaling 4,517 pages, plus an HTML index. That total includes two additional notice pages and a 24-page Engine Lubrication chapter supplied under two filenames; excluding that duplicate leaves 4,493 pages.

Hybrid Diagnostics and Powertrain Repair

These selected coverage highlights summarize the main workshop content. Other included topics include keyless-entry transmitter programming and rear-window defogger wire repair.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head overhaul, cam-chain service, crankshaft and piston work, bearing selection, and oil-seal installation.

• IMA system: HDS fault retrieval, MCM reset, connector input/output checks, battery and inverter cooling-fan tests, and battery-module, PCU, and motor removal.

• Fuel and emissions: PGM-FI diagnosis, fuel-pressure testing, EVAP and EGR troubleshooting, oxygen-sensor circuit checks, freeze-data interpretation, and readiness-code procedures.

• Transmission service: Manual-transmission disassembly and synchronizer inspection, plus CVT hydraulic testing, start-clutch calibration, valve-body service, and internal overhaul procedures.

• Brakes and chassis: Conventional brake repair, ABS diagnosis, driveshaft overhaul, suspension and wheel-bearing replacement, and EPS steering-gear service.

• Climate control: Sensor and actuator diagnosis, compressor-clutch overhaul, evaporator and condenser replacement, and refrigerant performance and leak testing.

• Electrical and body systems: Wiring diagrams, connector views, starter testing and overhaul, lighting and accessory diagnosis, and body-component removal and adjustment.

The diagnostic and overhaul sections are suited to experienced technicians with electrical-testing skills, access to the specified diagnostic equipment, and appropriate training for high-voltage hybrid work.

Model-Year and Configuration Differences

The procedures distinguish the 2000 data-link connector location from the 2001–2006 arrangement. ECM testing separates substitution on 2000–2001 M/T vehicles from updating and substitution on 2002–2006 M/T and CVT vehicles.

CVT documentation separates 2001–2004 and 2005–2006 DTC coverage, with hydraulic circuits for 2001–2003 and 2004–2006 configurations. Brake information also identifies the pressure-sensor system used on 2005–2006 M/T models and the CVT creep-aid solenoid arrangement.

These distinctions help match the diagnostic procedure to the installed configuration before testing circuits or selecting replacement components.

IMA Controls and High-Voltage Components

The IMA chapter covers the Motor Control Module, Battery Condition Monitor, Power Control Unit, Motor Driver Module, DC-DC converter, junction board, contactors, and battery-current and temperature monitoring.

Its system description explains the 144 V Ni-MH battery with 20 modules and 120 cells, a maximum capacity of 6.5 Ah, and motor assist of up to 49 N·m (36 lbf·ft).

Tool references include Rotor Puller 07YAC-PHM010B, Battery Module Lift 07YAK-001010A, and Backprobe Set 07SAZ-001000A. IMA service requires the documented high-voltage shutdown and verification procedures, insulated gloves, and insulated tools.

Engine Overhaul and Fault-Monitor Logic

The engine information covers the 0.995-liter inline three-cylinder SOHC, 12-valve PGM-FI engine. Compression and VTEC rocker-arm tests accompany valve-clearance adjustment, valve-guide replacement, camshaft inspection, cylinder-bore honing, lubrication testing, cooling-system service, ignition, intake, and exhaust work.

Advanced Diagnostics contains 234 numbered figures, 168 Monitor Description Charts, and 169 Enable Conditions Charts. These explain when a monitor runs and what triggers a fault, supporting interpretation of a stored code alongside the circuit tests.

Examples include the P0106 MAP comparison of 40 mV or less for at least five seconds and the CKP no-signal criterion of 37 successive missing detections. Individual coverage addresses A/F sensors, secondary and third HO2S circuits, MAP, IAT, ECT, TP, CKP, CMP, and knock-sensor monitoring.

Manual Transmission and CVT Overhaul

Manual-transmission information includes shaft inspection, synchronizer checks, and thrust-clearance adjustment. It warns that jaw-type pullers can damage third- or fifth-gear teeth and that incorrect first/second synchronizer-sleeve orientation can damage the spring ring.

The CVT material extends to road and stall tests, speed sensors, pressure-control valves, lower and manual valve bodies, the ATF pump, forward clutch, reverse brake, start clutch, pulley assemblies, and differential backlash and bearing clearances.

Start-clutch tools include Remover 07TAE-P4VA120 and Installer 07TAE-P4VA130. The removal instructions identify a puller-pawl position that can damage the clutch guide.

Chassis, Climate Control, and Electrical References

Brake procedures include front-caliper overhaul, rear drum-brake service, and bleeding. ABS sections cover the modulator and wheel sensors; steering sections address EPS control-unit replacement and steering-gear overhaul. SRS information includes DTC troubleshooting and component inspection or replacement after deployment.

Climate-control coverage includes electronic controls and R-134a service. It specifies SANDEN SP-10 PAG oil and warns that mixing it with another refrigerant oil can cause compressor failure.

Representative illustrations include the IMA System Diagram, Start Clutch Control Functional Diagram, and Hydraulic Circuit — D Position, At Low Speed Range (2004–2006 Models). Electrical examples include the Manifold Absolute Pressure Sensor Circuit Diagram, ABS Circuit Diagram, and Climate Control Circuit Diagram.

The separate wiring reference covers 1.0L engine controls, transmission, SRS, EPS, power and ground distribution, lighting, locks, windows, and starting/charging circuits. Body chapters cover doors, glass and regulators, seats, trim, dashboard, bumpers, hatch, and selected frame components.

Transmission Fluid-Capacity Examples

For the manual transmission, the fluid-service section lists Honda MTF capacities of 1.5 L at a fluid change and 1.6 L at overhaul.

The CVT fluid-replacement section specifies Honda CVT Fluid and distinguishes 3.3 L at a change from 5.5 L at overhaul. These entries illustrate the separate service and overhaul quantities provided for each transmission.