Contents Wiring diagrams Section: Wiper/washer Systems All sections

Specifications: Other Honda Insight ZE2

Wiper/washer Systems 1 illustration

Engine Electrical

ItemMeasurementQualificationStandard or NewService Limit
Ignition coilRated voltage12V
Firing order1-3-4-2
Spark plugTypeNGK:DILFR6F11G
Gap1.0-1.1 mm (0.039-0.043 in)
Ignition timingAt idle Check the red markIn N or P10±2°BTDC
Drive beltTensionAuto-tensioner
StarterOutput1.0 kW
Commutator mica depth0 40-0.50 mm (0.016-0.020 in)015 mm (0.006 in)
Commutator runout0.02 mm (0.001 in) max.0.05 mm (0.002 in)
Commutator O.D.28.0-28.1 mm (1.102-1.106 in)27.5 mm (1.083 in)
Brush length11.1-11.5 mm (0.44-0.45 in)4.3 mm (0.17 in)

ENGINE ELECTRICAL SPECIFICATION

Cylinder Head

ItemMeasurementQualificationStandard or NewService Limit
HeadWarpage0.07 mm (0.0028 in)0.08 mm (0.0031 in)
Height119.9-120.1 mm (4.720-4.728 in)
CamshaftEnd play0.05-0.15 mm (0.002-0 006 in)0.3 mm (0.01 in)
Camshaft-to-holder oil clearance0.050-0.089 mm (0.0020-0.0035 in)0.10 mm (0.004 in)
Total runout0.03 mm (0.001 in) max.0.04 mm (0.002 in)
Cam lobe heightIntake PRI29.700 mm (1.1693 in)
Intake SEC35.854 mm (1.4116 in)
Exhaust PRI29.900 mm (1.1772 in)
Exhaust SEC35.470 mm (1.3965 in)
ValveClearance (cold)Intake0.15-0.19 mm (0.006-0.007 in)
Exhaust0.24-0.28 mm (0.009-0.011 in)
Stem O.D.Intake5.48-5.49 mm (0.2157-0.2161 in)5.45 mm (0.215 in)
Exhaust5.45-5.46 mm (0.2146-0.2150 in)5.42 mm (0.213 in)
Stem-to-guide clearanceIntake0.020-0.050 mm (0.0008-0.0020 in)0.08 mm (0.003 in)
Exhaust0.050-0.080 mm (0.0020-0.0031 in)0.11 mm (0.004 in)
Valve seatWidthIntake0.850-1.150 mm (0.0335-0.0453 in)1.80 mm (0.071 in)
Exhaust1.250-1.550 mm (0.0492-0.0610 in)2.00 mm (0.079 in)
Stem installed heightIntake47.4-47.8 mm (1.866-1.882 in)48.1 mm (1.894 in)
Exhaust47.3-47.7 mm (1.862-1.878 in)48.0 mm (1.890 in)
Valve springFree lengthIntake (NIPPON HATSUJO)53.25 mm (2.096 in)
Intake (CHUO HATSUJO)53.26 mm (2.097 in)
Exhaust (SUN CALL)57.32 mm (2.257 in)
Exhaust (CHUO HATSUJO)57.31 mm (2.256 in)
Valve guideI.D.Intake5.51-5.53 mm (0.217-0.218 in)5.55 mm (0.219 in)
Exhaust5.51-5.53 mm (0.217-0.218 in)5.55 mm (0.219 in)
Installed heightIntake16.25-16.75 mm (0.640-0.659 in)
Exhaust16.25-16.75 mm (0.640-0.659 in)
Rocker armArm-to-shaft clearanceIntake0.017-0.045 mm (0.0007-0.0018 in)0.08 mm (0.003 in)
Exhaust0.017-0.045 mm (0.0007-0.0018 in)0.08 mm (0.003 in)

CYLINDER HEAD SPECIFICATION

Engine Block

ItemMeasurementQualificationStandard or NewService Limit
BlockWarpage of deck0.07 mm (0.003 in)max.0.10 mm (0.004 in)
Bore diameter73.000-73.015 mm (2.8740-2.8746 in)73.065 mm (2.8766 in)
Bore taperLimit: (difference between first and third measurement)0.05 mm (0.002 in)
Reboring limit0.25 mm (0.010 in)
PistonSkirt O.D. at 16 mm (0.6 in) from bottom of skirt72.969-72.979 mm (2.8728-2.8732 in)72.967 mm (2.8727 in)
Clearance in cylinder0.021-0.046 mm (0.0008-0.0018 in)0.05 mm (0.002 in)
Piston ringRing-to-groove clearanceTop0.065-0.090 mm (0.0026-0.0035 in)0.15 mm (0.006 in)
Second0.030-0.055 mm (0.0012-0.0022 in)0.12 mm (0.005 in)
Ring end gapTop0.15-0.30 mm (0.006-0.012 in)0.60 mm (0.024 in)
Second0.30-0.42 mm (0.012-0.017 in)0.65 mm (0.026 in)
Oil0.20-0.70 mm (0.008-0.028 in)0.80 mm (0.031 in)
Piston pinO.D.17.996-18.000 mm (0.7085-0.7087 in)
Pin-to-piston clearance0.010-0.017 mm (0.0004-0.0007 in)
Connecting rodPin-to-rod interference0.019-0.036 mm (0.0007-0.0014 in)
Small-end bore diameter17.964-17.977 mm (0.7072-0.7078 in)
Large-end bore diameterNormal43.0 mm (1.69 in)
End play installed on crankshaft0.15-0.35 mm (0 006-0 014 in)0.40 mm (0.016 in)
CrankshaftMain journal diameter49.976-50.000 mm (1.9676-1.9685 in)
Rod journal diameter39.976-40.000 mm (1.5739-1.5748 in)
Rod/main journal taper0.005 mm (0.0002 in)max.0.010 mm (0.0004 in)
Rod/main journal out-of-round0.005 mm (0.0002 in)max.0.010 mm (0.0004 in)
End play0.10-0.35 mm (0.004-0.014 in)0.45 mm (0.018 in)
Runout0.030 mm (0.0012 in)max.0.040 mm (0.0016 in)
Crankshaft bearingMain bearing-to-journal oil clearance0.018-0.036 mm (0.0007-0.0014 in)0.050 mm (0.0020 in)
Rod bearing clearance0.026-0.044 mm (0.0010-0.0017 in)0.050 mm (0.0020 in)

ENGINE BLOCK SPECIFICATION

Cooling System

ItemMeasurementQualificationStandard or NewService Limit
RadiatorCoolant capacities (including engine, heater, hoses, and reservoir)Engine overhaul5.04 L (1.332 US gal)
Coolant change4.55 L (1.202 US gal)
Coolant typeHonda Long Life Antifreeze/Coolant Type 2
Coolant reservoirCoolant capacity0.44 L (0.116 US gal)
Radiator capOpening pressure93-123 kPa (0.95-1.25 kgf/cm 2 , 14-18 psi)
ThermostatOpening temperatureBegins to open169-176 °F (76-80 °C)
Fully open194°F(90°C)
Valve lift at fully openAbove 8.0 mm (0.31 in)

COOLING SYSTEM SPECIFICATION

Fuel and Emissions

ItemMeasurementQualificationStandard or NewService Limit
Fuel pressure regulatorPressure with fuel pressure gauge connected260-310 kPa (2.7-3.2 kgf/cm 2 , 38-46 psi)
Fuel tankCapacity40 L (10.6 US gal)
Engine idleIdle speed without load (IMA battery SOC higher than 30 %)In N or P750 ± 50 rpm
Idle speed with high electric load (A/C on, temperature set to max cool, blower fan motor on high, rear window defogger on, headlights on high beam, and IMA battery SOC higher than 30%)In N or P750 ± 50 rpm

FUEL AND EMISSIONS SPECIFICATION

CVT and CVT Differential

ItemMeasurementQualificationStandard or NewService Limit
Continuously variable transmission fluidCapacity: Use genuine Honda CVTFFluid change2.8 L (3.0 US qt)
Overhaul5.2 L (5.5 US qt)
Hydraulic pressureForward clutch pressureAt 1,700 rpm in D1,570-1,840 kPa (16.0-18.8 kgf/cm 2 , 228-267 psi)
Reverse brake pressureAt 1,700 rpm in R1,570-1,840 kPa (16.0-18.8 kgf/cm 2 , 228-267 psi)
Drive pulley pressureAt 1,700 rpm in N240-540 kPa (2.4-5.5 kgf/cm 2 , 34-78 psi)
Driven pulley pressureAt 1,700 rpm in N830-1,130 kPa (8.5-11.5 kgf/cm 2 , 120-164 psi)
Lubrication pressureAt 3,000 rpm in N250-400 kPa (2.5-4.1 kgf/cm 2 , 36-58 psi)
Stall speedCheck with vehicle on level groundD, S, and L positions: Standard or new1,900 rpm
D, S, and L positions: Service limit1,700-2,000 rpm
R position: Standard or new2,500 rpm
R position: Service limit2,400-2,600 rpm
ClutchClearance between clutch end-plate and top discReverse brake0.55-0.70 mm (0.022-0.028 in)
Clutch return spring free lengthReverse brake18.1 mm (0.71 in)16.1 mm (0.63 in)
Clutch disc thicknessReverse brake2.00 mm (0.079 in)When worn or damaged
Clutch plate thicknessReverse brake1.95 mm (0.077 in)When discolored
Reverse brake end-plate thicknessMark 23.8 mm (0.150 in)When discolored
Mark B3.9 mm (0.154 in)When discolored
Mark 34.0 mm (0.157 in)When discolored
Mark C4.1 mm (0.161 in)When discolored
Mark 44.2 mm (0.165 in)When discolored
Mark D4.3 mm (0.169 in)When discolored
Mark 54.4 mm (0.173 in)When discolored
Mark E4.5 mm (0.177 in)When discolored
Mark 64.6 mm (0.181 in)When discolored
Mark F4.7 mm (0.185 in)When discolored
Mark 74.8 mm (0.189 in)When discolored
Mark 85.0 mm (0.197 in)When discolored
Input shaftDiameter of needle bearing contact areaFlywheel side19.987-20.000 mm (0.7869-0.7874 in)When worn or damaged
Forward clutch side19.987-20.000 mm (0.7869-0.7874 in)When worn or damaged
Thrust clearanceCVTF pump drive sprocket hub0.37-0.65 mm (0.015-0.026 in)
Planetary carrier0.050-0.115 mm (0.0020-0.0045 in)
Feed pipe O.D.Drive pulley feed pipe6.97-6.98 mm (0.274-0.275 in)6.95 mm (0.274 in)
Forward clutch feed pipe11.470-11.480 mm (0.4516-0.4520 in)11.450 mm (0.4508 in)
Clutch feed pipe bushing I.D.Drive pulley feed pipe7.000-7.015 mm (0.2756-0.2762 in)7.030 mm (0.2768 in)
Forward clutch feed pipe11.500-11.518 mm (0.4528-0.4535 in)11.533 mm (0.4541 in)
Width of sealing ring groove2.000-2.100 mm (0.079-0.083 in)2.105 mm (0.083 in)
22 x 28 mm thrust shim thickness (CVTF pump drive sprocket hub)C1.15 mm (0.045 in)When worn or damaged
D1.40 mm (0.055 in)When worn or damaged
E1.65 mm (0.065 in)When worn or damaged
F1.90 mm (0.075 in)When worn or damaged
G2.15 mm (0.085 in)When worn or damaged
H2.40 mm (0.095 in)When worn or damaged
25 x 31 mm thrust shim thickness (planetary carrier)A1.05 mm (0.041 in)When worn or damaged
B1.12 mm (0.044 in)When worn or damaged
C1.19 mm (0.047 in)When worn or damaged
D1.26 mm (0 050 in)When worn or damaged
E1.33 mm (0.052 in)When worn or damaged
F1.40 mm (0.055 in)When worn or damaged
G1.47 mm (0.058 in)When worn or damaged
H1.54 mm (0.061 in)When worn or damaged
I1.61 mm (0.063 in)When worn or damaged
J1.68 mm (0.066 in)When worn or damaged
K1.75 mm (0.069 in)When worn or damaged
L1.82 mm (0.072 in)When worn or damaged
M1.085 mm (0.0427 in)When worn or damaged
N1.155 mm (0.0455 in)When worn or damaged
O1.225 mm (0.0482 in)When worn or damaged
P1.295 mm (0.0510 in)When worn or damaged
Q1.365 mm (0.0537 in)When worn or damaged
R1.435 mm (0.0565 in)When worn or damaged
S1.505 mm (0.0593 in)When worn or damaged
T1.575 mm (0.0620 in)When worn or damaged
U1.645 mm (0.0648 in)When worn or damaged
V1 715 mm (0 0675 in)When worn or damaged
W1.785 mm (0.0703 in)When worn or damaged
Drive pulley shaftDiameter of needle bearing contact areaFlywheel side24 007-24.020 mm (0.945-0.946 in)When worn or damaged
Forward clutch side24.007-24.020 mm (0.945-0.946 in)When worn or damaged
I.D.Sealing ring24.007-24.020 mm (0.945-0.946 in)When worn or damaged
Driven pulley shaftDiameter of needle bearing contact areaStart clutch side43.981-43.991 mm (1.7315-1.7319 in)When worn or damaged
Thrust clearanceStart clutch side0-0.13 mm (0-0.005 in)
25.5 mm cotter thickness (start clutch hub)A2.90 mm (0 114 in)When worn or damaged
B3.00 mm (0.118 in)When worn or damaged
C3.10 mm (0.122 in)When worn or damaged
D3 20 mm (0.126 in)When worn or damaged
Feed pipe O.D.Canceler pressure6.970-6.980 mm (0.2744-0.2748 in)6.950 mm (0.2736 in)
Clutch pressure8.97-8.98 mm (0.353-0.354 in)8.95 mm (0.352 in)
Driven pulley shaft feed pipe O.D.11.470-11.480 mm (0.4516-0.4520 in)11.450 mm (0.4508 in)
Clutch feed pipe bushing I.D.Canceler pressure7.000-7.015 mm (0.2756-0.2762 in)7.030 mm (0.2768 in)
Clutch pressure9.000-9.015 mm (0.354-0.355 in)9.030 mm (0.356 in)
Driven pulley shaft feed pipe bushing I.D.11.500-11.518 mm (0.4528-0.4535 in)11.533 mm (0.4541 in)
Secondary drive gear sealing ring groove width2.500-2.650 mm (0.098-0.104 in)2.655 mm (0.105 in)
Start clutch end plate I.D.88.900-88.935 mm (3.500-3.501 in)When worn or damaged
Final drive shaftSecondary drive gear thrust clearance0-0.15 mm (0-0.006 in)
25 x 35 mm thrust shim thicknessA2.80 mm (0.110 in)When worn or damaged
B2.90 mm (0.114 in)When worn or damaged
C3.00 mm (0.118 in)When worn or damaged
D3.10 mm (0.122 in)When worn or damaged
E3.20 mm (0.126 in)When worn or damaged
F3.30 mm (0.130 in)When worn or damaged
G3.40 mm (0.134 in)When worn or damaged
H3.50 mm (0.138 in)When worn or damaged
I3.60 mm (0142 in)When worn or damaged
J3.70 mm (0.146 in)When worn or damaged
K3.80 mm (0.150 in)When worn or damaged
L3.90 mm (0.154 in)When worn or damaged
M4.00 mm (0.157 in)When worn or damaged
Park gear and pawlWhen worn or damaged
CVT differential carrierPinion shaft contact area I.D.15.010-15.028 mm (0.591-0.592 in)
Clearance between carrier and pinion shaft0.026-0.062 mm (0.001-0.002 in)0.1 mm (0.004 in)
Driveshaft/intermediate shaft contact area I.D.26.025-26.045 mm (1.0246-1.0254 in)
Clearance between carrier and driveshaft/intermediate shaft0.045-0.086 mm (0.002 - 0.003 in)0.12 mm (0.005 in)
Clearance between set ring and carrier bearing outer race0-0.15 mm (0-0.006 in)Adjust
CVT differential pinion gearBacklash0.05-0.15 mm (0.002-0.006 in)

CVT AND CVT DIFFERENTIAL SPECIFICATION

Steering

ItemMeasurementQualificationStandard or NewService Limit
Steering wheelRotational play measured at outside edge with engine running0-10 mm (0-0.39 in)
Initial turning load measured at outside edge with engine running34 N (3.5 kgf, 7.7 lbf)
GearboxAngle of rack guide screw loosened from locked position17 ± 3°

STEERING SPECIFICATION

Suspension

ItemMeasurementQualificationStandard or NewService Limit
Wheel alignmentCamberFront0°00' ± 1 °
Rear1 °00' ± 1 °
CasterFront3°20' ± 1 °
Total toe-ianFront0 ± 3 mm (0 ± 0.12 in)
Rear2.5 ± 2.5 mm (0.10 ± 0.10 in)
Front wheel turning angleInward38°28' ± 2°
Outward (reference)32° 21' ±1 °
WheelAluminum wheel runoutAxial0-0.7 mm (0-0.03 in)2.0 mm (0.08 in)
Radial0-0.7 mm (0-0.03 in)1.5 mm (0.06 in)
Steel wheel runoutAxial0-1.0 mm (0-0.04 in)2.0 mm (0.08 in)
Radial0-1.0 mm (0-0.04 in)1.5 mm (0.06 in)
Wheel bearingEnd playFront0-0.05 mm (0-0.002 in)
Rear0-0.05 mm (0-0.002 in)

SUSPENSION SPECIFICATION

Brakes

ItemMeasurementQualificationStandard or NewService Limit
Parking brakeDistance traveled when lever pulled with 196 N (20 kgf, 44 lbf) of force6 to 8 clicks
Brake pedalPedal height (carpet moved aside)147 mm (5.79 in)
Free play1.0-5.0 mm (0.04-0.20 in)
Brake discThickness21.0 mm (0.83 in)19.0 mm (0.75 in)
Runout0.04 mm (0.0016 in)
Parallelism0.015 mm (0.0006 in)
Brake padThickness10.0 mm (0.39 in)1.6 mm (0.06 in)
Brake drumDrum I.D.200 mm (7.874 in)201 mm (7.91 in)
Brake shoeShoe lining thickness4.5 mm (0.18 in)1.0 mm (0.04 in)

BRAKES SPECIFICATION

Air Conditioning

ItemMeasurementQualificationStandard or NewService Limit
RefrigerantTypeHFC-134a(R-134a)
Capacity of system450-500 g (15.8-17.6 oz)
Refrigerant oilTypeSP-10(P/N38897-P13-A01AH)
Capacity of componentsCondenser (Including receiver/dryer)25mL(5/6 fl.oz)
Evaporator35 mL (1 1/6 fl.oz)
Each line and hose10 mL (1/3 fl.oz)
Receiver/Dryer10 mL (1/3 fl.oz)
Compressor80-90 mL (2 2/3-3 fL.oz)
CompressorField coil resistanceAt 68 °F (20 °C)3.15-3.45 ohms
Pulley-to-armature plate clearance0.35-0.65 mm (0.014-0.026 in)

AIR CONDITIONING SPECIFICATION

ItemMeasurementQualificationSpecification
DIMENSIONOverall length4,377 mm (172.3 in)
Overall width1,695 mm (66.7 in)
Overall height1,427 mm (56.2 in)
Wheelbase2,550 mm (100.4 in)
TrackFront1,492 mm (58.7 in)
Rear1,475 mm (58.1 in)
Seating capacityFive (5)
WEIGHTGross Vehicle Weight Rating (GVWR)1,650 kg (3,638 lbs)
ENGINETypeWater-cooled, 4-stroke SOHC i-VTEC gasoline engine
Cylinder arrangementInline 4-cylinder, transverse
Bore and stroke73x80 mm (2.87x3.15 in)
Displacement1,339 cm 3 (82 cu in)
Compression ratio10.8
Valve trainChain drive, SOHC i-VTEC 2 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pump
Fuel requiredRegular UNLEADED gasoline with 87 Pump Octane Number or higher
STARTERTypeGear reduction
Normal output1.0 kW
Hour rating30 seconds
Rotation directionCounterclockwise as viewed from drive end
IMA MOTORTypeDC brushless-3 phases
BATTERY MODULEType7.2VNi-MH
Number14
Output100 V
CVTTypeElectronically-controlled continuously variable transmission, multi plates wet sump, hydraulic
Primary reductionDirect 1:1
Gear ratioLow-High2.526-0.421
Reverse4.508-1.874
Final reductionTypeSingle helical gear
Gear ratio4.200
STEERINGTypeElectrical power-assisted rack and pinion
Overall ratio16.09
Turns, lock-to-lock3.29
Steering wheel diameter370 mm (14.6 in)
SUSPENSIONTypeFrontIndependent strut with stabilizer, coil spring
RearTorsion beam, coil spring
Shock absorberFront and rearTelescopic, hydraulic, nitrogen gas-filled
TIRESSizeFront and rear175/65R15 84S
SpareT135/80D15 99M
WHEEL ALIGNMENTCamberFront0°00'
Rear1°00'
CasterFront3° 20'
Total toe-inFront0 mm (0 in)
Rear2.5 mm (0.10 in)
Front wheel turning angleInward38° 28'
Outward (reference)32° 21'
BRAKESType of service brakeFrontPower-assisted self-adjusting ventilated disc
RearPower-assisted self-adjusting drum
Type of parking brakeMechanical actuating, rear wheels
Pad friction surface area (swept area)Front43.7 cm 2 (6.77 sq in) x 2
Shoe friction surface areaRear57.6 cm 2 (8.93 sq in) x 2
AIR CONDITIONINGCompressorTypeScroll
Capacity77.1 mL (4.7 cu in)/rev.
Maximum speed10,000 rpm
Lubricant capacity80 mL (2 2/3 fl.oz)
Lubricant typeSP-10
CondenserTypeCorrugated fin
EvaporatorTypeCorrugated fin
BlowerTypeRadial
Motor type220W/12V
Speed controlInfinitely variable
Maximum capacity400 m 3 (14,126 cu ft)/h
Temperature controlAir-mix type
Compressor clutchTypeDry, single plate, Poly V-belt drive
Electrical power consumption at 68 °F (20 °C)42 W maximum at 12 V
RefrigerantTypeHFC-134a (R-134a)
Capacity450-500 g (15.8-17.6 oz)
ELECTRICAL RATINGSBattery12 V-35 Ah/20 HR (12 V-28 Ah/5 HR)
FusesBattery terminal fuse box100 A, 60 A, 20 A
Under-dash fuse/relay box50 A, 40 A, 30 A, 20 A, 15 A, 10 A, 7.5 A
Light bulbsHeadlight high beam12 V-60W
Headlight low beam12 V-55W
Front turn signal lights12 V-21 W
Front side marker lights12 V-5 W
Front parking lights12 V-5 W
Side turn signal lightsLED
Rear turn signal lights12 V-21 W
Rear side marker lights12 V-3.8 W
Brake/taillightsLED
High mount brake lightLED
Back-up lights12 V-16 W
License plate lights12 V-5 W
Ceiling lights12 V-8 W
Cargo area light12 V-5 W
Front individual map lights12 V-8 W
Glove box light12 V-3.4 W
Gauge lightsLED
Indicator lightsLED
Washer reservoirCapacity (USA models)2.5 L (2.6 US qt)
Capacity (Canada models)4.85 L (5.1 US qt)

DESIGN SPECIFICATIONS

Scheme 1

Scheme 1: Body Specifications