Honda Insight 2000-2006

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Turn the battery switch OFF and measure the voltage before proceeding.
  4.  
  5. Disconnecting the negative battery cable will clear the radio-s preset buttons. Write down the radio frequencies.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Drain the cooling system.
  10.  
  11. Drain the engine oil.
  12.  
  13. Remove or disconnect the following:

    Both battery cables
     
    Breather pipe brake booster vacuum hose bracket from the air cleaner
     
    Air cleaner/intake air duct assembly
     
    Throttle cover and cable
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) control canister hose
     
    Fuel feed and return hoses
     
    Positive Crankcase Ventilation (PCV) hose
     
    Heater hoses
     

  14.  
  15. Remove the engine wire harness connectors from the cylinder head and intake manifold for the following components:

    Fuel injectors
     
    Ignition coils
     
    Intake Air Temperature (IAT) sensor
     
    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Primary Heated Oxygen Sensor (HO 2 S)
     
    Secondary Heated Oxygen Sensor (HO 2 S)
     
    VTEC solenoid valve
     
    VTEC pressure switch
     
    Top Dead Center (TDC1/TDC2) sensors
     

  16.  
  17. Remove or disconnect the following:

    Intake manifold
     
    Exhaust Gas Recirculation (EGR) plate
     
    Upper radiator hose and connecting pipes
     
    Catalytic converter
     
    Dipstick
     
    Cylinder head cover
     
    Timing chain auto tensioner
     
    Cylinder head plug and hold the camshaft tight while loosening the sprocket mounting bolt
     
    Camshaft sprocket
     
    Engine mount bracket
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Remove the cylinder head plug

     

  18.  

To install:

  1. Clean the mating surface where the head gasket attaches to the engine block.
  2.  
  3. Install or connect the following:

    Dowel pins and a new cylinder head gasket and apply liquid gasket to the cylinder head mating surface
     
    Cylinder head and apply clean engine oil to the threads and under the heads of the cylinder head bolts
     

  4.  
  5. Torque the cylinder head bolts is sequence as follows:
    1. Step 1: 29 ft. lbs. (39 Nm).
    2.  
    3. Step 2: Turn the bolts an additional 90 degrees.
    4.  
    5. Step 3: Torque the 6 mm bolts to 8.7 ft. lbs. (12 Nm).
      NOTE
      If any of the bolts make noise during installation, remove the bolt and retighten it.

    6.  

  6.  
  7. Install or connect the following:

    Camshaft sprocket into the cylinder head
     
    Timing chain on the camshaft sprocket and align the sprocket on the camshaft
     

  8.  
  9. Turn the camshaft sprocket counterclockwise to relieve any timing chain free play. Check the alignment of the TDC mark (A) on the camshaft sprocket with the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence

  10.  
  11. Hold the camshaft in position and torque the mounting bolt to 41 ft. lbs. (56 Nm).
  12.  
  13. Install or connect the following:

    New cylinder head plug. Press the rod to pump any oil from the timing chain auto tensioner
     
    New O-ring (A) into the spacer (B). Align the spacer and new gasket (C) on the auto tensioner (D). Torque the bolts to 8.7 ft. lbs. (12 Nm) while pressing the timing chain auto tensioner against the cylinder head.
     

  14.  
  15. Adjust the valve clearance if necessary

    Cylinder head cover and torque the bolts to 8.7 ft. lbs. (12 Nm)
     
    Catalytic converter with a new gasket and nuts and torque the upper nut to 17 ft. lbs. (24 Nm), the upper bolts to 33 ft. lbs. (44 Nm) and the lower bolt to 16 ft. lbs. (22 Nm).
     
    Heater hoses and connecting pipes with new O-rings and torque the bolts to 8.7 ft. lbs. (12 Nm)
     
    Upper radiator hose
     
    EGR plate and intake manifold with a new gasket and torque the bolts to 16 ft. lbs. (22 Nm)
     
    PCV hose
     
    Fuel feed and return hoses. Torque the return hose bracket bolt to 8.7 ft. lbs. (12 Nm) and the feed hose fastener to 16 ft. lbs. (22 Nm)
     
    Brake booster vacuum hose
     
    EVAP hoses and water bypass hoses
     

  16.  
  17. Install the engine wire harness connectors to the following components:

    TDC1 and TDC2 sensors
     
    VTEC solenoid and pressure switch
     
    Primary and secondary HO 2 S
     
    ECT sensor
     
    MAP sensor
     
    TP sensor
     
    IAC valve
     
    IAT sensor
     
    Ignition coils
     
    Fuel injectors
     

  18.  
  19. Install or connect the following:

    Air cleaner and intake air duct assembly then torque the bolts to 8.7 ft. lbs. (12 Nm)
     
    Throttle cable and adjust as necessary
     
    Engine cover and torque the bolts to 8.7 ft. lbs. (12 Nm)
     
    Both battery cables
     

  20.  
  21. Allow the engine to sit for approximately 30 minutes before refilling any fluids.
  22.  
  23. Fill the engine with clean oil.
  24.  
  25. Fill the cooling system.
  26.  
  27. Turn the ignition switch to the ON position and allow the fuel pump to run for a few seconds to pressurize the fuel system.
  28.  
  29. Enter the preset radio frequencies.
  30.  
  31. Start the vehicle and check for leaks, repair if necessary.
  32.  

  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Drain the cooling system and engine oil.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative and then positive battery cables
     
    Accessory drive belt
     
    Engine appearance cover
     
    Breather pipe and brake booster vacuum line
     
    Air cleaner and intake air duct
     
    Throttle cable linkage
     
    Brake booster vacuum hose
     
    EVAP canister hose
     
    Heater hoses
     
    Engine wire harness connectors and clamps from the cylinder head and intake manifold
     
    PCV valve
     
    Fuel lines
     
    Cylinder head cover
     
    Intake manifold
     
    Radiator hoses
     
    Catalytic converter
     
    Dipstick
     
    Cam chain tensioner by loosening the bolt in sequence one turn at a time.
     
    Cylinder head plug
     
    Timing chain
     

  8.  
  9. Hold the camshaft with an open end wrench, then remove the camshaft sprocket bolt.
  10.  
  11. Remove the camshaft sprocket.
  12.  
  13. Remove the engine mount bracket bolt on the cylinder head side.
  14.  
  15. Loosen the cylinder head bolts in sequence and 1 / 3 turns until all bolts are loose.
  16.  
  17. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Insight

  18.  

To install:

  1. Clean the cylinder head and block mating surfaces.
  2.  
  3. Ensure the crankshaft pulley is at TDC.
  4.  
  5. Apply liquid gasket to the areas of the engine block as shown.

    Click image to see an enlarged view

    Fig. Engine block sealant application areas-Insight



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Insight

  6.  
  7. Install the cylinder head.
  8.  
  9. Coat the cylinder head bolt threads with clean engine oil.
  10.  
  11. Tighten the cylinder head bolts in the sequence shown to 29 ft. lbs. (39 Nm), plus an additional 90 degrees.
  12.  
  13. Tighten the 6 mm bolts (A) to 105 inch lbs. (12 Nm).
  14.  
  15. Install the timing chain on the camshaft sprocket and place the sprocket on the camshaft.
  16.  
  17. Turn the camshaft sprocket counterclockwise to relieve the free play and check that the TDC mark on the sprocket lines up with the cylinder head surface.
  18.  
  19. If the mark is not aligned correctly, remove the sprocket from the camshaft and reposition the timing chain until the mark is aligned.
  20.  
  21. Hold the camshaft with an open end wrench and tighten the sprocket bolt to 41 ft. lbs. (56 Nm).
  22.  
  23. Install a new cylinder head plug.
  24.  
  25. Press the rod to pump the oil out of the timing chain tensioner.
  26.  
  27. Install a new o-ring to the tensioner spacer and a new gasket on the tensioner and then tighten the bolts and nuts equally to 105 inch lbs. (12 Nm), while pressing the tensioner against the head.
  28.  
  29. Adjust the valve clearance.
  30.  
  31. The remainder of the installation is the reverse of the removal procedure.
  32.  
  33. Start the engine and hold at 3500 rpm with no load for 10 minutes.
  34.  
  35. Check that the IMA battery level indicator reads full.
  36.  
  37. Check the engine idle.
  38.  

 
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