2004 Honda Insight Service and Repair Manual

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Fits the 2004 Insight — Base Hatchback 2-Door ·
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2004 Honda Insight service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Base Hatchback 2-Door

Engines covered

  • 1.0L 995CC 61Cu. In. l3 FULL HYBRID EV-GAS (FHEV) SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
No active recalls The 2004 Honda Insight has no recalls on file with NHTSA.
TSB #10186009

"Service Bulletin - There are several A/C leak detection tools available. -Refrigerant Gas Leak Detector -Ultrasonic Leak Detector -Leak Dye"

TSB #10107371

SERVICE NEWS ARTICLE - PLANNING ON USING A LEAK CHECK DYE TO HELP FIND A LEAK? HERES THE CURRENT LIST OF VEHICLES THAT YOU SHOULDNT USE DYE ON.

TSB #10053545

HONDA: TROUBLESHOOTING OF DIAGNOSTIC TROUBLE CODES (DTC) P1456 AND P1457. DEALERS ARE TO RUN EVAP FUNCTION TEST TO FIND IF THERE IS A LEAK SO THE VEHICLE CAN BE REPAIRED. *KB

TSB #10051966

HONDA: PRODUCT UPDATE FOR A MANUFACTURING PROBLEM WITH THE ROOF MOLDING MAY ALLOW THE ROOF MOLDING TO COME LOOSE. *KB

TSB #10045879

HONDA: INFORMATION ON REPLACEMENT AND REMOVAL OF JUNCTION BOARD FROM OLD IMA BATTERY AND NEW BATTERY MOUNTED BEFORE BATTERY IS INSTALLED. MODELS 2003-11 CIVIC HYBRID, 2011-12 CR-Z, 2000-06 INSIGHT, 2010-12 INSIGHT. *PE UPDATED 9/28/12. *PE

TSB #10041726

HONDA: MIL WILL COME IF 3-WAY CATALYTIC CONVERTER OR NOX ADSORPTIVE 3-WAY CATALYST IS DETERIORATED DUE TO SENSOR INPUTS BEING MISINTERPRET BY SOFTWARE. *PE

TSB #10038350

HONDA: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. BATTERY SYSTEM LIGHT COMES ON WITH TROUBLE CODES STORED. *RM MODELS 2000-2004 INSIGHT. UPDTED 5/14/13. *PE

TSB #10032953

HONDA: WARRANTY EXTENSION-VEHICLE WARRANTY MILEAGE. CLASS ACTION LAWSUIT ALLEGING THAT THE ODOMETERS ON CERTAIN 2002-2006 HONDA MODELS WERE OVERSTATING MILEAGE. FEDERAL COURT PROVIDED FINAL APPROVAL OF SETTLEMENT ON 12/29/07. NO MODELS LIST

Showing the 8 most recent of 28 technical service bulletins on file with NHTSA.

20180328Component: ELECTRICAL SYSTEM

WHILE I WAA DRIVING TO WORK SMOKE CAME OUT OF MY STEERING COLUMN AND MY LOW BEAMS STOPPED WORKING. I BELIEVE THE LIGHT SWITCH IS FAULTY AS WAS THE CASE WITH THE RECALL ON 2000-2001 HONDA INSIGHTS.

20180328Component: EXTERIOR LIGHTING

WHILE I WAA DRIVING TO WORK SMOKE CAME OUT OF MY STEERING COLUMN AND MY LOW BEAMS STOPPED WORKING. I BELIEVE THE LIGHT SWITCH IS FAULTY AS WAS THE CASE WITH THE RECALL ON 2000-2001 HONDA INSIGHTS.

20120702Component: SUSPENSION:FRONT:CONTROL ARM

CONTROL ARM CRACKED AND SPLIT WHILE PULLING OUT OF A GAS STATION. THIS VEHICLE DOES NOT HAVE AN UPPER AND LOWER CONTROL ARM, ONLY LOWER (MADE OF ALUMINUM FOR WEIGHT REDUCTION). IF THIS HAPPENED ON T

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