A new contender may soon join the prestigious million-mile club, as the proud owner of a first-generation Honda Insight, currently showing 982,526 miles on the odometer, is eager to push the car over the one-million mark. David Andrew, the new owner, hopes to take his 2002 Honda Insight past this extraordinary milestone after purchasing it from the previous owner on the condition that he would keep it running.
David’s quest to surpass a million miles with the Insight is remarkable for several reasons, one being that the digital readout on the cluster does not accommodate a seventh digit. Additionally, the Insight being a hybrid raises questions, as these vehicles are often perceived as more challenging to maintain due to their combined combustion and electric components.
The Insight’s design incorporates a 1.0-liter inline-three engine paired with a small electric motor, marking Honda’s initial foray into its Integrated Motor Assist hybrid system. Despite the complexities, David intends to demonstrate the reliability of his almost-stock Insight, which he and his wife have cleverly named Miles.
Anyone attempting to achieve one million miles in a vehicle certainly deserves recognition, especially when it’s a 22-year-old Honda hybrid. The Drive interviewed David to learn more about his ambitious journey with the Insight, and here are highlights from our conversation. (The interview has been edited for brevity and clarity.)
The Drive: How did you come to own the Insight?
David Andrew: This is actually my fifth Honda Insight. I previously dismissed hybrid vehicles because they often lack driving excitement. Although slow cars can be enjoyable, the combination of a low-power engine and a continuous variable transmission (CVT) made them seem less engaging.
Once I discovered the Insights were available with a manual transmission, I eagerly searched for one. During the COVID-19 lockdowns, gas prices fell significantly, making these cars temporarily undervalued, so I seized the opportunity to buy one at a bargain price. In May 2020, I purchased a 2001 Insight with a five-speed transmission and 180,000 miles for just $900, and I currently use that car daily.
One day, a friend on Facebook informed me of someone at his dealership completing warranty paperwork. This individual was driving a worn-out Insight nearing a million miles but wished to upgrade to a more reliable vehicle. He wanted to pass the car on to someone who would love it, repair it, and keep using it.
He could no longer manage the downtime caused by seeking hard-to-find parts. The idea of reaching a million miles was becoming impractical for him. Fortunately, I’m in a position to handle that downtime, and I have gained valuable experience from owning and maintaining several of these quirky cars on a budget. After all, it’s just an old Honda.
TD: Have you made any modifications or upgrades to the stock setup?
DA: Other than the quirky fog lights on the bumper, Miles remains entirely stock. The factory headlights were never great and eventually deteriorated, prompting the previous owner to install these LED fogs as a workaround.
While there are aftermarket hybrid battery replacements and upgrades available, including a new lithium battery option that enhances power, they can be quite expensive. Nevertheless, I’ve kept this car in its original state because Honda engineered it well enough that modifications weren’t necessary. Over the years, it’s required three transmissions, two flywheels, and three hybrid batteries, yet it remains on the original engine. Though it’s a CVT model, which seems contradictory to my earlier statements, I made an exception for this car; Miles is special.
TD: What significant repairs have you undertaken? Are there any repairs you are looking forward to, or do you have any reservations?
DA: As expected for an older nickel-metal hybrid, this vehicle has seen three OEM battery replacements from Honda, which is decent lifespan considering they typically last around 300,000 miles. The current battery is reaching its limits, so I’ve installed a grid charger system from my manual Insight, which I believe will help extend this battery’s life until it hits a million miles.
The next big task on my list is possibly rebuilding the engine for the first time. The engine block, pistons, head, valves, and other components are original. The head gasket was replaced at 975,000 miles, but otherwise, everything is still as it was. Currently, it struggles to idle, lacks power even for an Insight, and emits a cloud of oil vapor from the intake.
I plan to conduct a compression test this week to determine if a teardown is necessary. If it is, I will only replace parts that are damaged or worn. I am committed to preserving the original engine as part of the car’s essence. Although I’ve never rebuilt an engine before, I see this challenge as a valuable learning opportunity.
TD: Have you replaced any cells in the battery pack? How challenging were those repairs, given the difficulty in sourcing rare parts?
DA: Although it’s feasible to replace the individual cells in the battery—there are 20 in total—the previous owner opted for a complete new Honda battery as soon as any issues arose, as he couldn’t handle the downtime. Previously, sourcing these batteries from the dealer was easy, but they’re now becoming scarce. There are a few companies offering refurbished and new cells, but he insisted on staying with OEM parts.
TD: How does driving a hybrid vehicle compare to a standard combustion engine model at high mileage?
DA: Over the last 982,000 miles, the Insight has averaged 52.6 miles per gallon. Assuming gas costs an average of $3.50 per gallon, it would have only cost around $65,000 to cover those miles, using nearly 19,000 gallons of fuel. If the mileage were halved to a more typical 26.3 mpg, the total expense would swell to about $130,000. The efficiency gained from driving these high miles highlights how fuel costs significantly impact overall expenses, despite other repair costs.
TD: What do you love most about the Insight, and what do you like the least?
DA: The best aspect of the Insight is its driving experience. Despite its looks, it handles exceptionally well. Its aluminum unibody design offers better stiffness than steel and resists rust, allowing it to go through turns at high speeds, similar to a Miata. The lightweight structure, combined with quick electric steering and instant torque from the hybrid system, makes it a delight to drive. My least favorite thing? That Honda no longer produces this model; it’s evident they created something truly exceptional.
Lastly, I inquired about where David envisions crossing the million-mile finish line. His wife, a photographer based in Pittsburgh, suggested hosting a celebration at a park with a looped path, allowing friends to witness the monumental moment. David plans to invite the car’s former owner to share this special occasion, saying, “He deserves to be part of this journey since he’s driven the car from 11,000 miles back in 2004 to 982,000 last week.”
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