Honda Seats User manual
2000
-
06 ENGINE
SYMPTOM TROUBLESHOOTING INDEX
2006 Honda Insight
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
2000-06 ENGINE Starting System - Insight
Starting System - Insight
COMPONENT LOCATION INDEX
Fig. 1: Identifying Starting System Component Locations
Courtesy of AMERICAN HONDA MOTOR CO., INC.
TROUBLESHOOTING CHART
).
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
Symptom Diagnostic procedure Also check for
Engine does not start
(does not crank)
1. Check for loose battery
terminals or connections.
2. Test the battery for a low
charge (see 12 VOLT
BATTERY TEST ).
3. Check the starter (see
STARTER CIRCUIT
TROUBLESHOOTING
4. Check the starter cut relay
(see POWER RELAY
TEST ).
Engine cranks, but
does not start
5. Check the transmission
range switch (CVT) (see
TRANSMISSION
RANGE SWITCH
TEST ).
6. Check the clutch pedal
position switch (M/T) (see
FUEL LINE
INSPECTION ).
7. Check the ignition switch
or wire (see IGNITION
KEY SWITCH TEST ).
1. Check for PGM-FI DTCs.
2. Check the fuel pressure:
2000-2003 M/T
models (see 2000-
2003 M/T
MODELS )
2001-2003 CVT
models (see 2001-
ENGINE
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
2003 CVT
MODELS )
2004-2005 M/T
models (see 2001-
2003 CVT
MODELS )
2004-2005 CVT
models (see 2004-
2005 CVT
MODELS ) 2006
model (see 2006
MODEL )
3. Check for a plugged or
damaged fuel line (see
Engine is hard to start
FUEL LINE
INSPECTION ).
4. Check for a plugged fuel
filter (see FUEL FILTER
REPLACEMENT ).
5. Check the throttle body
(see THROTTLE BODY
TEST ).
6. Check for low engine
compression (see
COMPRESSION
INSPECTION ).
7. Check for a damaged or
broken cam chain.
1. Check for PGM-FI DTCs.
2. Check the fuel pressure:
2000-2003 M/T
models (see 2000-
2003 M/T
Check for excessive drag in
Check for excessive drag in
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
MODELS )
2001-2003 CVT
models (see 2001-
2003 CVT
MODELS )
2004-2005 M/T
models (see 2001-
2003 CVT
MODELS )
2004-2005 CVT
models (see 2004-
2005 CVT
MODELS )
2006 model (see 2006
Engine cranks slowly
MODEL )
3. Check for a plugged or
damaged fuel line (see
FUEL LINE
INSPECTION ).
4. Check for a plugged fuel
filter (see FUEL FILTER
REPLACEMENT ).
1. Check for loose battery
terminals or connections.
2. Test the battery for a low
charge (see 12 VOLT
BATTERY TEST ).
3. Check the starter for
binding (see STARTER
OVERHAUL ).
4.
the engine.
5.
CIRCUIT DIAGRAM
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
the transmission (CVT).
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
Fig. 2: Circuit Diagram
Tachometer, 0
-
1,200 RPM
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
Courtesy of AMERICAN HONDA MOTOR CO., INC.
STARTER CIRCUIT TROUBLESHOOTING
NOTE:
Air temperature must be between 59 and 100°F (15 an d
38°C) during this procedure.
After this test, or any subsequent repair, reset the
engine control module (ECM) to clear any DTCs (see
HDS CLEAR COMMAND ).
The battery must be in good condition and fully
charged.
Recommended Procedure
Use a starter system tester.
Connect and operate the equipment in accordance with the manufacturer's
instructions.
ALTERNATE PROCEDURE
1. Hook up the following equipment:
Ammeter, 0-400 A
Voltmeter, 0-20 V (accurate within 0.1 V)
TURNING
).
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
2. Disconnect the three fuel injector connectors.
3. Turn the battery module switch OFF, and measure the voltage (see
OFF POWER TO THE HIGH VOLTAGE CIRCUIT
Fig. 3: Checking Battery Voltage
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If it won't disengage from the flywheel ring gear when you release the
positive terminal to the solenoid terminal.
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
4. With the shift lever in P or N position (CVT) or the clutch pedal pressed
(M/T), turn the ignition switch to START (III).
Does the starter crank the engine normally?
YES -The starting system is OK, go to step 10 .
NO -Go to step 5.
5. Check the battery condition. Check electrical connections at the battery, the
negative battery cable to body, the engine ground cables, and the starter for
looseness and corrosion. Then try starting the engine again.
Does the starter crank the engine?
YES -Repairing the loose connection corrected the problem. The starting
system is OK, go to step 10 .
NO -Check the following:
If the starter will not crank the engine at all, go to step 6.
If it cranks the engine erratically or too slowly, go to step 7 .
key, check the following:
Solenoid plunger and switch malfunction
Dirty drive gear damaged overrunning clutch
6. Make sure the transmission is in Neutral, then disconnect the BLK/WHT wire
from the starter solenoid S terminal. Connect a jumper wire from the battery
Check for an open circuit or loose connections in the BLK/WHT wire
7.
While cranking the engine, check the cranking voltage and the current draw.
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
Fig. 4: Disconnecting BLK/WHT Wire From Starter Solenoid S Terminal
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Does the starter crank the engine?
YES -Check the following items in the order listed until you find the open
circuit:
and connectors between the starter cut relay and the ignition switch,
and between the starter cut relay and the starter.
Check the ignition switch (see IGNITION KEY SWITCH TEST ).
NO -Remove the starter, and repair or replace as necessary.
).
never leave the battery connected for more than 10 seconds.
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
Is the cranking voltage greater than or equal to 8.5 V and the current draw
less than or equal to 350 A?
YES -Go to step 8.
NO -Replace the starter, or remove and disassemble it, and check the
following:
Drag in the starter armature
Shorted armature winding
Excessive drag in the engine
Excessive drag in the transmission (CVT)
8. Check the engine speed while cranking the engine.
Is the engine speed above 100 RPM?
YES -Go to step 9.
NO -Replace the starter, or remove and disassemble it, and check the
following:
Open circuit in starter armature commutator segments
Excessively worn starter brushes
Open circuit in commutator brushes
Dirty or damaged helical spline or drive gear
Faulty drive gear clutch.
9. Remove the starter, and inspect its drive gear and the flywheel ring gear for
damage. Replace any damaged parts.
10. Reset the ECM using the HDS (see HDS CLEAR COMMAND ).
11. Do the ECM idle learn procedure (see ECM IDLE LEARN PROCEDURE
STARTER PERFORMANCE TEST
1. Disconnect the wire from the S terminal.
2. Make the connections as shown using as heavy a wire as possible (preferably
equivalent to the wire used for the vehicle). To avoid damaging the starter,
pinion retracts immediately, it is working properly.
2006 Honda Insight
2000-06 ENGINE Starting System - Insight
3. Connect the battery as shown. If the starter pinion moves out, it is working
properly.
Fig. 5: Connecting Battery Terminal To Starter
Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Disconnect the negative battery terminal from the starter as shown. If the
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