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On the other side of the head, there are three fuel injectors, sandwiched between the fuel rail and the cylinder head. The injectors are controlled by the computer using a duty cycle signal (percentage on-time vs. percentage off-time). When the computer wants to add more fuel, it increases the injector on-time, (also called pulse width). […]

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This is the internal combustion engine block stripped to the casting, crank, rods and pistons. The short block is all aluminum with steel cylinder sleeves. The timing chain guides are made from plastic with a robust aluminum backing. Looks like Honda will avoid all the timing chain troubles motors that the Toyota 22RE encountered. The […]

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This is a rather poor picture of the oil leak under UV light. Dye was added to the motor oil a couple hundred miles before this picture was taken. Our first thought was that the timing chain tensioner o-ring was leaking. It’s a fairly easy repair, so we replaced it and rechecked. Unfortunately, the leak […]

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The Insight uses a conventional belt-driven water pump and a thermostat to control temperature and flow. I suspect there will be electric waterpumps controlled by temperature sensors on future hybrids, which would eliminate the need for a drive belt, thermostat, front crank pully, and front crank seal (assuming the AC compressor is electric as well, […]

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This is the cam and some of the other timing components that had to be removed to reseal the timing cover. Back | Next(23 of 31)Return to Index

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Before doing any service work to any hybrid, the battery must be disconnected. A shock from a battery this size can be fatal, so be sure you know what you are doing and follow the instructions in the factory manual. To disconnect the battery on the Insight, remove the small door on the floor of […]

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Most of the time, the Insight uses the electric motor/generator to start the internal combustion engine, but if the main battery is discharged, or the weather is very cold, there is also an auxiliary starter motor that is powered by the auxiliary 12-volt battery. It’s important to check the auxiliary battery periodically, since you are […]

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Like many Honda’s, the valves on the Insight are screw-and-jamb-nut-style. Up until 1993, most Honda’s had a valve adjustment interval of every 15,000 miles. In 1994, most Honda vehicles switched to intervals of every 30,000 miles. In 2001, despite still using the screw-and-jamb-nut-style valve adjustment, Honda went to a 105,000 mile interval on most of […]

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This is the Insight battery pack with the rear cover removed. The fans and ducting are there to cool the battery, since it will heat up as it is charged and discharged. A high battery temperature will shorten the battery life. There are several battery temperature sensors, and presumably the computer will reduce battery activity […]

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The Insight uses a conventional air conditioning system with a compressor driven off a belt from the gas engine crank pully. This means that the engine must be running when the air conditioning is on. Owners who are accustomed to their hybrid’s gas engine shutting off when they come to stop signs are sometimes concerned […]

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