2000–2006 Honda Insight Service Manual (OEM)

• Coverage and file structure: Covers 2000–2006 Honda Insight repair information. Most system chapters are labeled 2000–06; the 369-page Advanced Diagnostics volume and 95-page System Wiring Diagrams volume are specifically labeled 2006.
• Package size: 62 PDF files totaling 4,517 pages as packaged. A 24-page Engine Lubrication chapter appears under two filenames, leaving 4,493 pages of distinct content.
• Powertrain coverage: Includes the 0.995-liter inline three-cylinder, SOHC, 12-valve PGM-FI engine, five-speed manual transmission and clutch, and Continuously Variable Transmission (CVT).
• Hybrid system coverage: Documents the 144 V Ni-MH Integrated Motor Assist system, including its 20 battery modules, 120 cells, 6.5 Ah rating, Motor Control Module, Battery Condition Monitor, Power Control Unit, Motor Drive Module, DC-DC converter, junction board, and IMA motor.
• Diagnostic depth: The 2006 Advanced Diagnostics PDF contains more than 230 numbered figures, over 160 Monitor Description Charts, and over 160 Enable Conditions Charts covering ECM, emissions, CVT, and IMA faults.
• Document identity: The pages carry Mitchell Repair Information Company, LLC copyright notices, while many technical illustrations are credited to American Honda Motor Co., Inc.
• This listing is a contents overview. It does not reproduce the repair steps contained in the PDF package.

Model-Year and Configuration Coverage

The manual set separates procedures and diagnostics where hardware or control strategies changed. Examples include the 2000 data-link connector location versus 2001–2006 models, ECM substitution for 2000–2001 M/T vehicles versus ECM updating and substitution for 2002–2006 M/T and CVT vehicles, 2001–2004 versus 2005–2006 CVT DTC coverage, and separate CVT hydraulic circuits for 2001–2003 and 2004–2006. It also identifies the brake fluid pressure sensor system used on 2005–2006 M/T models and the creep-aid solenoid arrangement used with the CVT.

IMA, Engine, and Emissions Repair

The 394-page IMA section covers high-voltage shutdown and verification, HDS fault retrieval, MCM reset, MCM and BCM connector input/output data, contactors, battery-current and temperature monitoring, battery-module and MPI-module fan tests, power-relay tests, and removal or installation of the battery module, PCU, and IMA motor. The system description records up to 49 N·m (36 lbf·ft) of motor-assist torque. Dedicated tools include Rotor Puller 07YAC-PHM010B, Battery Module Lift 07YAK-001010A, and Backprobe Set 07SAZ-001000A.

Engine repair coverage extends well beyond tune-up specifications. Procedures address engine removal and installation, compression and VTEC rocker-arm tests, valve-clearance adjustment, cam-chain service, cylinder-head removal and overhaul, valve-guide replacement, camshaft and rocker inspection, crankshaft and piston work, bearing selection, cylinder-bore honing, oil-seal installation, lubrication testing, cooling-system service, ignition, intake, and exhaust systems.

PGM-FI, fuel-supply, EVAP, EGR, catalytic-converter, and advanced-diagnostic chapters document HDS use, freeze data, readiness-code setting, ECM connector checks, sensor circuit tests, monitor execution logic, and model-specific DTCs. Recorded diagnostic thresholds include a 40 mV MAP comparison lasting at least five seconds for P0106, 37 successive missing CKP signals for the no-signal monitor, and a 158°F (70°C) minimum coolant-temperature condition used by several monitor routines. A/F ratio sensors, secondary and third HO2S circuits, MAP, IAT, ECT, TP, CKP, CMP, and knock-sensor monitoring are covered individually.

Transmission, Chassis, and Climate Control

The manual-transmission section contains removal, disassembly, shaft and synchronizer inspection, thrust-clearance adjustment, and reassembly procedures. Honda MTF capacity is listed as 1.5 L at fluid change and 1.6 L at overhaul.

The 669-page CVT section covers HDS and SCS flash-code diagnostics, road and stall tests, hydraulic pressure testing, start-clutch calibration, speed sensors, pressure-control valves, lower and manual valve bodies, ATF pump, forward clutch, reverse brake, start clutch, pulley assemblies, differential, backlash, and bearing side-clearance checks. Honda CVT Fluid capacity is 3.3 L at change and 5.5 L at overhaul. Start-clutch service tools include remover 07TAE-P4VA120 and installer 07TAE-P4VA130.

Chassis and safety-system content includes conventional brakes, ABS modulator and wheel-sensor diagnostics, front caliper overhaul, rear drum brakes, brake bleeding, driveshaft overhaul, front and rear suspension, EPS control-unit and steering-gear repair, and SRS DTC troubleshooting and component replacement after deployment. HVAC coverage includes climate-control electronics, sensor and actuator testing, compressor and clutch overhaul, evaporator and condenser replacement, performance and leak testing, R-134a service, and SANDEN SP-10 PAG oil requirements.

Representative visuals include the IMA System Diagram, Start Clutch Control Functional Diagram, Hydraulic Circuit – D Position, At Low Speed Range (2004–2006 Models), Manifold Absolute Pressure Sensor Circuit Diagram, ABS Circuit Diagram, and Climate Control Circuit Diagram. The separate 2006 wiring volume adds schematics for 1.0L engine controls, transmission, SRS, EPS, power and ground distribution, lighting, locks, windows, and starting/charging systems.

Several manual-specific warnings matter during overhaul work. A jaw-type puller can damage third- or fifth-gear teeth, while incorrect 1st/2nd synchronizer-sleeve orientation can damage the spring ring. Positioning the CVT start-clutch remover pawl against the clutch guide can damage that guide. Mixing the specified SP-10 oil with another refrigerant oil can cause A/C compressor failure.

IMA work requires the battery-module switch to be turned OFF, a minimum five-minute capacitor discharge period, and confirmation that voltage has fallen below 30 V before high-voltage terminals are disturbed. Insulated gloves and insulated tools are specified for the applicable procedures.