• 11/01 - I had the oil changed just after I bought it. Since it had 7800 miles on it and the dealer didn't know if the oil was changed (they didn't change it either) I went ahead and did it anyway. I went ahead and bought a case of Honda's special 0-W20 synthetic oil for the Insight (it only requires 2.5 quarts per oil change!), two filters (OEM), and two oil drain washers from a Honda parts distributor. The shop I used to take my Plymouth Neon and Chevy Beretta to agreed to change the oil on this car. They only charged me $8.50 for their time. The oil, filter and washer runs about $7.00 per change.
• 1/2/2002 - The check engine light came on today. Hopefully it is something simple. The Honda dealer (Fairfield Motors in Muncy, PA) can't put it in the shop to look at it until January 7. It seems to be running fine in the mean time. Many people report faulty oxygen sensors. They cost $241 but Sipper is under warranty. Update I picked my car up on 1/8 from the dealer. The computer reported a P1164 error code - an oxygen sensor. They are ordering the part and will have it in around 1/15.
• 1/17/2002 - Took the Insight to the dealership for replacement of the oxygen sensor. The check engine light came back on while it was on order. They replaced the sensor, took a 6.6 mile, 57.5mpg test drive, and washed the car for free. It snowed the next day and got dirty right away. Let's see how long the light stays off this time.
• 3/5/2002 - The check engine light came on again today. This is the second instance. I suspect another oxygen sensor code. I'm going to stop by the dealership later this week to have it serviced again.
• 3/13/2002 - I took Sipper to the local Honda dealership today. They put it in the shop right away and got the P1164 code again just like the first time (1/2/02). They called Honda for warranty authorization to replace the oxygen sensor and Honda told them to reset the light and send me on my way - they didn't replace the oxygen sensor. The dealer told me that Honda was expecting to have a software fix for the emissions control system in May and that would fix the problem. His indication was that the sensor was activating the P1164 code when the mixture gets too lean.
• 3/25/2002 - Oil change and tire rotation near 15,000 miles. The front tires had more wear than the rear tires before the rotation - this should even it out some. Had to inflate the tires back up to 45 psi after picking it up.
• 5/4/2002 - I'm going to perform the MCM reset as described in the Insight owners group on Yahoo to see if it improves battery charge condition and mileage. UPDATE - no particular increase in mileage or SOC conditioning after one week of observation.
• 5/9/2002 - The check engine light came on today. I've got to get the code reset again for the oxygen sensor - this is the third instance. The MCM reset seemed to have worked in terms of battery charge condition and MPG. The weather has gotten nicer and the MCM reset combined to give me excellent mileage recently.
• 5/11/2002 - The check engine light turned off on its own today. Each previous occurrence it came on and it stayed on until reset by the dealer.
• 8/25/2002 - Started my car for the first time in 78 days since I was on the DiscoveryRide. It had 2/3 charge when I stored it and it still had the 2/3 charge two months later. I experienced my first three battery recalibrations within a week of putting the car back into service. I hope the battery recals stop.
• October 2002 - I have noticed more and more battery recalibrations this fall since letting the car sit for the summer. I happens most when the SOC meter drops below 1/2 charge and when I'm going up long grades.
• 11/4/2002 - Oil and filter change, tires rotated and inspection near 21,000 miles. I completely forgot to have an inspection by the end of September and I was at the scene of an accident as a witness when a state police officer noticed my expired sticker. Oops. Had to inflate the tires back up to 45 psi after picking it up. Battery recals aren't as frequent any more. They usually only happen when I drain the battery really fast and get it below 1/4 to 1/3 charge.
• 11/28/2002 - Battery recalibrations are a rare occurrence now. They only happen when climbing for an extended amount of time and the charge falls below 1/4.
• 2/3/2003 - Check engine light came on. I'll get it reset when I have the ECM replaced this month.
• 2/20/2003 - 26821 miles - I just picked up Sipper from Dix Honda in State College, PA and they did an outstanding job. I am happier with the quality of service they provided than when I took it to Fairfield in Montoursville. I dropped it off on Sunday, February 16 with a laundry list of things to do. The entire service was free since it was covered under warranty and recall notices (Assumed total cost based on Honda parts catalog: $3449.18 plus four hours labor). Here's what was accomplished:

1. Diagnosed CEL and it was P1164 again (air fuel ratio error fault). The PCM recall is designed to alleviate that problem.
2. Performed the ECM recall (02-081). Replaced ECM with updated controller, programmed four keys, performed idle learn procedure, test drove car. Cost to Honda: $669.58 for ECM plus labor.
3. Performed IMA controller recall (I assume they replaced both the Motor Control Module (MCM) and Battery Condition Module (BCM) (recall number 01-102) Cost to Honda: $792.33 for MCM $1745.80 for the BCM plus labor.
4. Installed updated window regulator and motor assembly as per service bulletin. They lubricated the window run tracks with silicone spray which they recommend twice a year for best performance. Cost to Honda: $241.48 for regulator plus labor.
5. Checked shifting performance. They indicated that a sticky shifter is typical during cold weather since transmission fluid is cold.

• After the 2/20 work was done I noticed that the transition from lean burn to normal burn mode is more gradual and smooth than before. The IMA also force charges the battery much earlier than before. Force charging usually only took place below 1/2 charge but it did it today above 3/4 charge and the BCM filled up quickly. The transition from IMA to non-IMA operation is also smoother. I used to be able to feel when the car went in and out of lean burn and assist but now it is absolutely seamless! Read other owners' experiences with ECM, widow, and wiper recalls. I also bought an S2000 antenna which I installed and it looks really nice! They also made me another key. Each cost around $20. On my way home the rear attachment bolt on the driver's side wheel skirt came off and I arrived home with the skirt dangling. I zip tied it back on and need to work on a replacement bolt. I might begin to use a zip tie on each wheel skirt anyway since the cost to replace the skirt is very expensive ($209.65).
• 6/15/03 - Changed the cabin air filter, washed the car thoroughly, and gave it the first wax since I've owned it. It looks like a million dollars. The air filter was very dirty and - that is why the A/C hasn't been blowing very cold or with much air volume.
• 8/12/03 - The SOC seems to be low all the time so I did an MCM reset. Problem solved. Much better IMA performance.
• 9/2/03 - The SOC meter is not responding but the IMA system seems to be working alright. It assists and charges but the SOC just doesn't move from four bars. Reset the MCM and that did the trick.
• 9/8/03 - (35801 miles) Had the parking brake recall performed at Fairfield Honda in Montoursville, PA. They have a brand new building and the service was very good. I had them order the parts about a week in advance and they were able to do the work immediately and even washed the car for me free of charge. I have had a blown left front strut for a few thousand miles and they diagnosed the problem and ordered a new strut to be replaced under warranty in a week or two.
• 11/5/03 - Ordered a replacement clutch switch from the company I bought the cruise from. It should be here soon.
• 11/14/03 - (37800 miles) Had the front left shock replaced, inspection, and oil & filter change.
• 2/04 - (39100 miles) Our neighbor hit my car. The driver door is busted up. I'll have to get that fixed.
• 4/18/04 - (43544 miles) Changed the oil, oil filter and air filter myself. I suspect that the last time the oil was changed at Fairfield Honda they did not use 0W-20 oil since the engine has run rough since and I got terrible mileage for the last 6000 miles. I'm sending the oil to Blackstone for analysis. We'll see what they say. [Blackstone report came back clean - everything is good and they did use 0W-20 oil. I've learned that the EGR valve may be shot - other Insight owners have reported poor mileage and the same hesitation around 1500 to 2000 RPM. They had their EGR valves replaced and it fixed the problem.]
• 5/04 - (44300 miles) Replaced the driver side door today. It went smoothly. Got the door from a junk yard in Florida and they shipped it up here on a pallet.
• 10/12/2004 - (47180 miles) Got my car back today after three weeks at Fairfield Honda (I drove Jen's old Laser in the mean time). I took it there because the headlight switch finally bit it. I was driving home one evening and had no headlights. Luckily it was just about dusk so my fog lights made me visible to some degree. Anyway, they replaced the light switch, red/white wire in the harness and the 16P headlight harness connector. No charge for that since it was under Recall 04-015. They did the emissions and safety inspection - everything went well there except I needed new front brakes and rotors. That set me back a bit. I also reported the herky-jerkyness between 1500 and 2000 rpm. They hooked me up with a new EGR valve which cost me the $50 deductible for my Honda Care warranty. That was cheaper than retail. I believe the EGR valve is the culprit for the low mileage I've gotten over the last year or so (around 52 mpg). All told: $416.63.
• 4/8/05. I changed the EGR valve today and it made a world of difference. I should have done this over a year ago! I put about 10000 miles on the car with the bad EGR valve and only got 50 to 60 mpg per tank. Now I'm back up to the 60–70 mpg, the battery stays charged better, acceleration is smoother and there is no surging. It's the magic pill for an ailing Insight!

Current maintenance issues (3/15/05)

• Need to replace the clutch switch on my Rostra cruise control. It has squeaked since the day I bought it.
• See about a DC/DC converter recall:
  • In honda-hybrid@yahoogroups.com, Richard A Poedtke <rapoe@c...> wrote: This is the first I have heard on the DC/DC converter recall. Any more information? Dick/Christine It only applied to about a 1000 or so of the Y2K models in the VIN range of about 4144 to 5604. The recall is dated 3/6/2001 I had mine replaced two months after I purchased my car. Apparently a small lot of the DC/DC converters had a defective thermal sensor that would cause them to think they were overheating and shutdown. I do not recall the campaign. They did put a little punch mark above one of the numbers in my VIN to indicate the work was performed. The cost to have a dc/dc converter replaced is $1803.
    
    Robert
    Silver, '00-#4581
• See about adding a grounding subharness to the rear windshield wiper motor under recall.

How to reset the MCM:

"Turn the ignition switch OFF, and remove the No. 18 BACK UP (7.5A) fuse (A) from the under-dash fuse/relay box (B) for 10 seconds.

NOTE: If the MCM has been reset, the IMA battery level indicator (BAT) will not indicate the state of charge when the engine is started. Refer to the 'How to End a Troubleshooting Session' to set the correct state of charge." The section on "How to End a Troubleshooting Session" says:

1. Reset the MCM
2. Turn the ignition switch OFF.
3. Remove the No. 15 EPS (40 A) fuse from the under-hood fuse/relay box.
4. Start the engine, and hold it at 3,500 rpm with no load (in neutral) until the IMA battery level indicator (BAT) on the gauge becomes normal.
5. Reinstall the No.15 EPS (40 A) fuse.

Long term storage for the Insight:

The Honda Insight Technicians Guide states that for long term storage, the IMA battery must be charged periodically. The recommended interval is three months. The procedure outlined is "pull fuse no. 15" and run engine at 3500 rpm for 5-10 minutes until the the gauge shows the desired level of charge.

Adding coolant

From another owner: "It turns out that air gets trapped in the engine unless a bleed bolt is opened while new coolant is added. As I drove the car and the coolant circulated, coolant slowly flowed into the air pockets, thus lowering the level in the reservoir. Overall, this was not a big problem, and the dealer immediately corrected the situation when I notified them of it. I consider this incident another example of technician carelessness, especially since the need for the bleeding the coolant system is clearly explained in the service manual.

Engine error codes

77 - Deteriorating Battery Module
67-1 - Catalyst Deterioration
63 - Battery Charger Controller
P1164 - O2 Sensor
P1468 - Thermostat Malfunction
P1645 - Motor Control Module Signal Malfunction

Maintenance information

• Battery information as it relates to draw and replacement
  • For bad battery call Honda directly at 1-800-999-1009. They will want to confirm condition of battery with the dealer.
• NHTSA Service Bulletin Search
• NHTSA Recall Search