GENERAL INFORMATION ............................................................................................................... 5 ABOUT THIS ENCYCLOPEDIA................................................................................................................. 6 VEHICULE IDENTIFICATION NUMBER (VIN) ......................................................................................... 7 FEATURES AND SPECIFICATIONS ...............................................................................
LIGHTWEIGHT BODY PANELS ............................................................................................................. 26 BODY REPAIR INFORMATION .............................................................................................................. 27 Dacro Coated Bolts........................................................................................................................ 27 Body Repair Techniques.......................................................................
Design ............................................................................................................................................ 58 BATTERY MODULE ............................................................................................................................. 60 JUNCTION BOARD ............................................................................................................................... 61 BATTERY CONDITION MONITOR (BCM)......................................
GENERAL INFORMATION
ABOUT THIS ENCYCLOPEDIA 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.
VEHICULE IDENTIFICATION NUMBER (VIN) The Insight's VIN can be found many places on the car.
FEATURES AND SPECIFICATIONS Overview Vehicle type Subcompact, two-seater, front-wheel drive, gasoline-electric hybrid Major features: • 5-speed manual transmission • Anti-lock brakes • Electric power steering • Dual air bags (SRS) • Alloy wheels • Digital instrument panel • AM/FM stereo cassette w/clock • Power windows • Power mirrors • Power door locks with keyless entry • Anti-theft "immobilizer" system (engine won't start without code transmitted from the key) • Automatic climate control with micro-f
Valve train 12 valve SOHC VTEC-E variable valve timing and lift technology Bore x stroke 72 mm x 81.5 mm Displacement 0.995 liter Compression ratio Tune-up interval 10.8:1 170,000 km (105,000 mi) Engine weight 56 kg (124 lbs.) Electric motor 10 kW permanent magnet DC brushless motor Size 60 mm (2.4") thick Output Without assist With assist Max. power 50 kW (68 hp) @ 5700 rpm 56 kW (76 hp) @ 5700 rpm Max.
Wheels & Tires 14 x 5.
Fuel Consumption & Emissions Fuel consumption CO2 emissions California emission standards compliance 3.
SCALE DRAWINGS
Non-Scale Drawing of Cargo Area (Courtesy of John Johnson)
MAINTENANCE
SPECIAL MAINTENANCE CONSIDERATIONS Engine Oil The Insight uses an API SJ rated oil with an SAE 0W-20 viscosity. For maximum fuel economy this oil should be used. Washing Remove the rear wheel skirts and the roof mounted antenna before driving in any automated car washes equipped with tire scrubbing type brushes. The rear wheel skirts can be removed by turning the two stud fasteners located at the front and rear of the skirt.
LONG-TERM STORAGE In addition to a conventional 12V battery, the Insight has a . When the vehicle is 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: 1. Remove the 40A EPS Fuse (No. 15) from the Under-Hood Fuse box in the engine compartment, then start the engine. The EPS warning light on the dashboard will illuminate because the EPS fuse is missing.
HATCH ACCESS 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.
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. To install the towing hook, first wrap the flat end of the jack handle or screwdriver with a soft cloth to prevent damage to the painted bumper surface, and then pry the cover off.
SERVICE SAFETY CONSIDERATIONS 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. The rotor should not be handled by people with a pacemaker or other similar medical device.
SERVICE CONNECTORS The Insight uses an industry standard OBD-II onboard diagnostics system. This system allows standard OBD-II diagnostic tools (including OBD-II software and connector cable available for 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.
BODY TECHNOLOGIES
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. In comparison, the Honda Civic Hatchback, with roughly the same 1.9 square-meter frontal area as the Insight, has a Cd of 0.
• 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. • The air dams are used in front of both front and rear wheels to improve aerodynamic characteristics.
ALUMINUM CONSTRUCTION The Honda Insight's body is made of aluminum, offering light weight and a high level of body rigidity to enhance overall fuel economy, handling and passenger safety. Aluminum weighs only one-third as much as steel. In addition, aluminum alloy is highly versatile and readily lends itself to a wide variety of manufacturing techniques. Lastly, aluminum is extensively recycled, which helps lower its cost. The Insight's aluminum body in white (just the sheet metal: doors, hood, etc.
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, Hsections 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.
LIGHTWEIGHT BODY PANELS 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. The bumper beams, steering hanger, roof, floor, front and rear wheel wells, rear quarter-panels, bulkhead, and even doors and hood, are made of aluminum alloy.
BODY REPAIR INFORMATION Dacro Coated Bolts Bolts that make contact with the aluminum body or aluminum suspension components have a special Dacro coating to prevent corrosion between two dissimilar metals. If these bolts are removed, the Dacro coating is destroyed. Consequently, the Dacro coated bolts must be replaced once they are removed. These bolts can be identified by the light green color of the Dacro coating.
PLASTIC FUEL TANK The Honda Insight uses a plastic fuel tank. Use of a plastic fuel tank reduces weight. Also, since the plastic fuel tank will not corrode, it is far less susceptible to developing a leak whereby gasoline and/or gasoline vapours can escape into the environment. Plastic fuel tanks have been used successfully on other vehicles for a number of years, particularly in Europe. Plastic is also used for transporting and storing gasoline in the form of the commonly seen red plastic "cans".
STEERING / SUSPENSION / BRAKES
ELECTRIC POWER STEERING 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. Because the EPS system only needs to draw electric power when steering assist is required, no extra energy is needed when cruising, improving fuel efficiency.
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.
FRONT SUSPENSION The Insight uses a Macpherson Strut type front suspension withstabilizer bars (0.66 inch). The front suspension geometry has been optimized to exhibit minimal changes in toe and camber throughout its travel, giving the Insight responsive handling, excellent stability and a smooth ride. This differs from the typical Honda double wishbone design. In this design, the damper body is used as a suspension member, performing the function of an upper control arm.
REAR SUSPENSION 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.
BRAKING SYSTEM 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.
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.
CABIN INTERIOR
CABIN INTERIOR Interior Features The interior of the Insight is well equipped, with automatic climate control, power windows, power mirrors and power door locks with keyless entry. An anti-theft system prevents the car from starting without receiving a unique code transmitted from the key. AM/FM stereo cassette is standard, with an optional CD changer being available through Honda dealers. Seats provide basic forward-back and seatback reclining positioning, and include integral head restraints.
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.
ELECTRONIC INSTRUMENT DISPLAY 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.
• Battery charging: The IMA is recharging the battery pack, using energy from vehicle momentum / the gasoline engine. The amount of recharge is indicated by the illumination of green colored bars on the left side of the display. When more bars are illuminated, the battery is being recharged at a higher rate. • Inactive: No bars illuminated. Note that since the IMA motor/generator will generate electricity whenever it is turning, slow charging can take place even when no bars are illuminated.
When the speedometer is set to mph, odometer / trip meter distances are displayed in miles, and fuel efficiency is displayed in miles per gallon. When the speedometer is set to km/h, odometer / trip meter distances are displayed in kilometers, and fuel efficiency is displayed in liters per 100km. Both the instantaneous bar graph and the average fuel efficiency number can be turned off at the driver's discretion. To turn off the bar graph, press and hold the FCD button until the bar & legend disappear.
PASSENGER RESTRAINT SYSTEM 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.
HEATING, COOLING & VENTILATION The Honda Insight Heating and Air 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 driving conditions and Heater and Air Conditioning climate control panel selections. The climate control is thermostatically controlled.
MICRON AIR FILTRATION The Honda Insight is equipped with a cabin air filter located between the blower housing and the evaporator case. The purpose of the filter is to provide a comfortable and healthy environment for the vehicle's occupants. The filter will prevent the intrusion of small particles, such as pollen, diesel smoke and bacteria into the car's interior. A secondary benefit of the micron air filter is reduction in dirt and dust buildup on the car's interior.
IMA HYBRID SYSTEM
IMA HYBRID SYSTEM A hybrid power system for an automobile can have a series configuration or a parallel configuration. 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.
IMA MODES OF OPERATION 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.
STARTING / RESTARTING MODE Energy flow from battery to gas engine (via electric motor) Under most conditions, the Insight engine is started by the IMA motor, which instantly spins the engine to 1000 rpm. The Insight also has a conventional 12v auxiliary starter motor that is used in the following situations: • The state of charge of the Battery Module is too low. • The ambient temperature is too high or too low. • There is a failure of the IMA system.
ACCELERATION / ASSIST MODE 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. The IMA Motor's output is used together with the gasoline engine's output so that power available for acceleration is maximized.
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. Some of this energy will be delivered to the Insight's 12v accessories, via the DC-DC converter, as necessary.
DECELERATION / REGENERATIVE BRAKING Energy flow from wheels to battery (via electric motor/generator) During deceleration, the gasoline engine is switched into fuel cut mode, and the IMA Motor/Generator is operated in generation mode. 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.
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. During deceleration, if the clutch is engaged and the transmission is in gear, the IMA will typically enter fuel cut mode.
IDLE STOP MODE No Energy Flow (Vehicle stationary, coasting or decelerating) To prevent unnecessary fuel consumption and exhaust emissions, the Insight's gasoline engine is turned off when there is no need for propulsion or air conditioning. During typical deceleration, the regenerative braking and fuel cut mode begin as soon as the driver begins to decelerate. When the engine speed slows down to about 1000 rpm, regenerative braking will stop, and the driver will typically switch into neutral.
may occur, possibly causing the air conditioning compressor to temporarily stop. See the climate control page for more information.
IMA COMPONENT LOCATIONS This view shows the contents of the "IPU" compartment, immediately behind the driver and passenger seats. This compartment contains the following components: • Motor Control Module (MCM): This is the metal box located in the upper right corner, which controls when the motor operates in assist or regeneration mode, and controls the degree of assist/regeneration. • Battery Condition Module (BCM): This it the metal box to the left of the MCM, just right of center.
• Junction Board: This is the black component, located to the right of the DC-DC Converter, and is actually part of the 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.
IMA MOTOR / GENERATOR Role The thin design motor is located between the 3-cylinder engine and the transmission. The IMA motor serves a number of functions: • It assists in vehicle propulsion when needed, allowing the use of a smaller internal combustion engine. • It operates as a generator, allowing excess energy (such as during braking) to be used to recharge the IMA Battery Module, and later be used to provide assist.
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: • Because the electromagnets are located around the perimeter, the electromagnets can be cooled by conduction to the motor casing, requiring no airflow inside the motor for cooling.
BATTERY MODULE 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. The Battery Module is only available as a complete assembly. The Battery Module is constructed in a modular form. The individual NiMH cells are same size as standard D cells.
JUNCTION BOARD 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. When the ignition switch is turned on, the Bypass Contactor is closed first, followed by the High Voltage Contactor.
BATTERY CONDITION MONITOR (BCM) 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. It never allows the battery to become fully charged or fully discharged.
MOTOR CONTROL MODULE (MCM) 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. a computer). The MDM that it communicates with, in turn contains all the high voltage cicuitry that connects directly to the motor itself.
MOTOR DRIVE MODULE (MDM) 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. It can bi-directionally send current from the motor to the battery and from the battery to the motor. During assist mode, power from the Battery Module is supplied to the IMA Motor in the form of 3-phase Alternating Current.
DC-DC CONVERTER The Insight engine is not equipped with an ACG (AC Generator or Alternator). Instead, recharging of the 12V battery and powering of the conventional 12V electrical system is performed by a DC-DC converter located in the IPU compartment. Elimination of the conventional Alternator reduces engine load, leading to better fuel efficiency.
ADVANCED GASOLINE ENGINE
ADVANCED GASOLINE ENGINE The Insight's internal combustion engine is an in-line three-cylinder with a displacement of 995cc. Its design includes comprehensive weight-reducing and friction-reducing features which ensure fuel-efficient, environmentally-friendly operation. The engine employs a VTEC mechanism which maximizes running performance by optimizing the valve timing and lift at all engine speeds.
ENGINE WEIGHT REDUCTION TECHNOLOGIES All engine parts have been made as light as possible. Major weight-reducing features are: • 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.
ENGINE FRICTION REDUCTION TECHNOLOGIES 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 aluminumalloy piston design for the IMA engine. The pistons have a minimal skirt area and the surface of the skirt has been shot-peened.
VIBRATION CONTROL SYSTEM A three cylinder engine, without balance shafts (which decrease power and thus fuel efficiency), is inherently prone to vibration. To improve idle quality, the IMA motor is used to smooth out speed fluctuations in the engine's crankshaft. During a power stroke, the crankshaft speed increases, and the IMA momentarily switches to the regeneration mode to absorb a little of the power pulse.
OFFSET CYLINDER CONSTRUCTION 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.
SPARK PLUGS 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. Due to variations inherent to the manufacturing process, each engine's head will differ.
ROCKER ARMS & SHAFT 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. The illustration below shows correct timing when the crankshaft pully is at TDC.
VTEC-E SYSTEM 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.
INTEGRATED HEAD 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. The individual exhaust-manifold runners are part of the head casting, just like the exhaust ports.
DIRECT IGNITION SYSTEM 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.
CVT TRANSMISSION The Insight is made with two transmissions: • a conventional 5-speed manual transmission, and • a continuously variable automatic transmission, also referred to at the "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.
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.
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.
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. Therefore, a highly efficient, low-friction oil pump unit was installed as a separate unit.
2) Acceleration Control The acceleration clutch's power transfer amount is controlled via the clutch piston's oil pressure. Additionally, the amount of creep is also controlled here as well. The "smart" creep has two settings - one with the brakes on, and one with the brakes off. 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.
ENGINE PERFORMANCE CURVES
GEAR RATIO GRAPHIC
EMISSIONS CONTROL
EMISSIONS STANDARDS 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.
Comparison to Various Car Emissions Standards Greenhouse Gas Smong-Causing Compounds Category Hydrocarbons TOG (1) g/km (g/mi) Pre-standards (1970) (2) g/km (g/mi) 5.5 (8.8) Nitrogen Oxides CO (3) NOx (4) g/km (g/mi) g/km (g/mi) Particulate Matter Carbon Dioxide PM (5) g/km (g/mi) CO2 (6) g/km (g/mi) 54 (86) 2.2 (3.5) ? ? TLEV (7) - 0.097 (0.156) 2.6 (4.2) 0.37 (0.6) 0.024 (0.04) - LEV (8) - 0.056 (0.090) 2.6 (4.2) 0.04 (0.07) 0.006 (0.01) - ULEV (9) - 0.034 (0.055) 1.
LEAN-BURN OXYGEN SENSOR A normal zirconia oxygen sensor is only capable of measuring the oxygen content of the exhaust in a narrow air-fuel mixture range, right around stoichiometric (14.7:1). This is fine for normal operating conditions. But, when the car is running in the lean burn mode, the oxygen content of the exhaust is higher than a normal oxygen sensor is capable of measuring.
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: • Heater positive • Heater ground • Sensor element positive • Control element positive • Common ground for sensor and control elements.
ADVANCED CATALYST SYSTEM 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. However, the lean mixture also causes a rise in combustion temperature, and high NOx production is the result.
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. If the ECM sets a code for a deteriorated catalyst, both catalysts have to be replaced. It must be assumed that the same conditions that caused the 3--way catalyst to deteriorate also deteriorated the lean NOx catalyst.
EXHAUST GAS RECIRCULATION SYSTEM 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. This high-precision EGR system is required to help control NOx production during lead-burn operation.
ORVR & VACUUM DISTRIBUTION 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.
1. Primary heated oxygen sensor (primary HO2S) 2. Secondary heated oxygen sensor (secondary HO2S) 3. Manifold absolute pressure (MAP) sensor 4. Intake air temperature (IAT) sensor 5. Engine coolant temperature (ECT) sensor 6. Top dead center 2 (TDC2) sensor 7. Top dead center 1 (TDC1) sensor 8. Crankshaft position (CKP) sensor 9. Knock sensor (KS) 10. Master power vacuum sensor 11. Check valve 12. Brake booster 13. Idle air control (IAC) valve 14. Fuel injector 15.
