Honda Insight 2000-2006

Starter

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Remove or disconnect the following:

    Negative and then positive battery cable
     
    Engine appearance cover
     
    Breather pipe and brake booster vacuum line
     
    Air cleaner and intake air duct
     
    Starter wiring harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 33 ft. lbs. (44 Nm).
     
    Starter wiring harness connectors
     
    Air cleaner and intake air duct
     
    Breather pipe and brake booster vacuum line
     
    Engine appearance cover
     
    Battery cables
     

  2.  
  3. Remove the No. 15 (40A) fuse from the under hood relay box.
  4.  
  5. Start the engine and run at 3500 rpm for 10 minutes.
  6.  
  7. Check that the battery module indicator reads full.
  8.  
  9. Install the No. 15 fuse.
  10.  

Testing



Starter Performance Test
  1. Disconnect the wire from the S terminal.
  2.  
  3. 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, never leave the battery connected for more than 10 seconds.
  4.  
  5. Connect the battery as shown. If the starter pinion moves out, it is working properly.

    Click image to see an enlarged view

    Fig. 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, never leave the battery connected for more than 10 seconds. Connect the battery as shown. If the starter pinion moves out, it is working properly

  6.  
  7. Disconnect the negative battery terminal from the starter as shown. If the pinion retracts immediately, it is working properly.
  8.  
  9. Clamp the starter firmly in a vise.

    Click image to see an enlarged view

    Fig. Disconnect the negative battery terminal from the starter as shown. If the pinion retracts immediately, it is working properly

  10.  
  11. Connect the starter to the battery as shown, and check that the motor turns and keeps rotating.
  12.  
  13. If the electric current is 80 A or less, and motor speed is 2,600 rpm or more when the battery voltage is at 11.5 V, the starter is working properly.

    Click image to see an enlarged view

    Fig. Connect the starter to the battery as shown, and check that the motor turns and keeps rotating

  14.  

 
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