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I will run down what worked for me and how to diagnose it yourself in a 2nd Gen Honda Insight (2010-2014) since I looked everywhere and the information was not easy to find.

1. A/C Clutch Relay: The quick and easy fix, it is Denso Part #: 156700-2680 or Mitsuba 7001-71-8927 or Omron Part #: G8HL-H71


It is located in your engine compartment on the driver side in front of the battery and has a cover to protect the relays. Just remove the cover and replace the relay highlighted in yellow.

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This worked great for a lot of people and you can get a relay from Amazon for < $10.00

This worked for me for about 6 weeks but then the issue came back.

2. Ambient Temperature Switch: This time I noticed my ambient temperature was also not accurate. I was told that that could be the issue so I purchased a replacement from Honda Part #: 80525-S30-941

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It is located on the passenger side behind the front bumper. It can be accessed from above by removing the cover above the grill just remove the 7 clips and pull up and back and should come right out. reach down until you can grab the sensor I looked through the front until I grabbed it. You can just slide it off it's bracket by pulling it toward the drivers side and then pressing the clip and installing a new one.

[Make sure to not turn on the vehicle without the switch or you will have to disconnect the battery to get it to work properly.]

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This fixed my temperature reading issue but the intermittent A/C issue persisted. So I went on to the next possible problem.

3. A/C Clutch: issue. I removed the passenger side front tire and removed the plastic panel that covers the A/C unit as show below. There is one in the back I couldn't catch in the photo, the arrow points to the general area.

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One removed you will have access to the A/C Clutch Assembly:

First check the clearance. It should be within .014" - .026" to be within spec. I used Craftsman Leaf Gap Gauge Part # 40811 to check. Mine was at .035" which was out of spec.

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I then removed the 12mm bolt at the center of the A/C Clutch plate with an impact wrench as noted below.

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Once removed you can pull off the A/C Clutch plate. I had to give it a little nudge with a screw driver. I took out the spacer in between the clutch plate and clutch assembly and measure it with the Leaf Gap Gauge and noted it was .020" as noted below.

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doing the math removing the shim would give me clearance within spec. so I proceed to clean the A/C Clutch plate with a little carb cleaner and a wire brush and reinstalled the A/C Clutch Plate without the shim and rechecked the clearance .015" exactly.

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Before putting everything back I turned on the car and turned the A/C on and off a few times and the A/C Clutch engaged and disengaged perfectly.

Now this is a temporary fix as obviously eventually the clutch plate with be worn down to the point that it will need to be replaced but this should take a while.

Hope this helped save you some money and stay cool.
 
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