Honda Insight 2000-2006

Engine

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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. Drain the transmission fluid.
  14.  
  15. Remove or disconnect the following:
    CAUTION
    When servicing the Integrated Motor Assisted (IMA) system extreme caution must be observed. Severe personal injury may result.



    Battery and battery box
     
    Engine cover
     
    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
     
    Ground cable
     
    Starter cable and wire harness clamp
     
    Intelligent Power Unit (IPU) lid
     
    Motor power cables
     



    Click image to see an enlarged view

    Fig. Remove the motor power cables



    Engine Control Module (ECM) cover , electrical connectors and the main wire harness connectors
     
    Fuel feed and return hoses
     

  16.  
  17. Loosen the idler pulley center bolt and turn the adjusting bolt clockwise. Turn the adjusting bolt counterclockwise if not equipped with A/C

    A/C compressor/water pump belt
     
    Clutch slave cylinder/line assembly
     
    Shift cables
     
    Motor power cable clamps
     
    Both front wheels
     
    Splash shields and brackets
     
    Lower arm ball joints
     
    Driveshafts
     
    A/C compressor. Do not disconnect the A/C lines
     
    Nitris Oxide (NOX) adsorptive three way catalytic converter
     
    Left side under cover
     
    Grommet mounting bolts and pull the motor power cables out
     
    Motor power cable holder from the underbody
     
    Radiator and heater hoses and attach a chain hoist to the engine
     
    Rear engine mounting bolts
     
    Side mounting bolts
     
    Transmission mount bracket
     
    Lower the engine assembly away from the vehicle
     

  18.  

To install:

  1. Install the engine mount and torque the bolts to 25 ft. lbs. (33 Nm).
  2.  
  3. Install the idler pulley and torque the bolts to 16 ft. lbs. (22 Nm).
  4.  
  5. Position the engine to the vehicle.

    Click image to see an enlarged view

    Fig. Install the transmission mounting bolts and loosen bolt C.

  6.  
  7. Install or connect the following:

    Transmission mount bracket. Torque the bolts to 41 ft. lbs. (56 Nm). Loosen the upper transmission mount bolt.
     
    Side engine mount. Torque the bolts to 38 ft. lbs. (52 Nm). Loosen the side bolt
     
    Rear engine mount. Torque the bolts to 54 ft. lbs. (74 Nm). Loosen the upper bolt. Remove the engine hoist.
     

  8.  
  9. Torque the transmission side engine mount bolts to 40 ft. lbs. (54 Nm) and the rear mount bolt to 66 ft. lbs. (89 Nm).
    CAUTION
    When servicing the IMA system extreme caution must be observed. Severe personal injury may result.



    Motor power cable holder and torque the bolts to 7 ft. lbs. (9.3 Nm)
     
    Motor power cable through the opening and install the grommet. Torque the bolts to 7 ft. lbs. (9.3 Nm)
     
    Left side under cover and torque the bolts to 7 ft. lbs. (9.3 Nm)
     
    Catalytic converter with new gaskets. Torque the 10 x 1.25 mm bolt to 25 ft. lbs. (33 Nm) and the 8 x 1.25 mm bolt to 16 ft. lbs. (22 Nm).
     
    A/C compressor and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Driveshafts with new spring clips
     
    Lower arm ball joints with new cotter pins
     
    Splash shield bracket and torque the bolts to 7 ft. lbs. (9.3 Nm)
     
    Splash shields and torque the bolts to 7 ft. lbs. (9.3 Nm)
     
    Motor power clamps
     
    Shift cables
     
    Clutch slave cylinder
     
    Water pump/A/C compressor belt and adjust as necessary
     
    Radiator and heater hoses
     
    ECM connectors through the bulkhead and install the grommets and harness clamps. Torque the bolts to 7 ft. lbs. (9.3 Nm)
     
    Main wire harness connectors, ECM connectors and the ECM cover. Torque the bolts to 8.7 ft. lbs. (12 Nm)
     
    Fuel feed and return hoses and torque the fasteners to 16 ft. lbs. (22 Nm)
     
    Motor power cables
     



    IPU lid
     
    Starter cable, ground cable and the harness clamp. Torque the 8 x 1.25 mm bolt to 7 ft. lbs. (9.3 Nm) and the 6 x 1.0 mm bolt to 9 ft. lbs. (12 Nm)
     
    EVAP control canister and the brake booster vacuum hose
     
    Throttle cable and adjust as necessary
     
    Air cleaner/intake air duct assembly and breather pipe and bracket and torque the bolts to 8.7 ft. lbs. (12 Nm)
     
    Battery box and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Battery and both cables
     
    Engine cover and torque the bolts to 8.7 ft. lbs. (12 Nm)
     

  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Fill the transmission to the proper level.
  16.  
  17. Enter the preset radio stations.
  18.  
  19. Start the vehicle and check for leaks, repair if necessary.
  20.  


NOTE
The engine, electric motor and transaxle are removed from the vehicle as a unit.

  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Turn the battery module switch off and measure the voltage.
  4.  
  5. Disable the IMA system.
  6.  
  7. Drain the cooling system, engine oil and transmission fluids.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Disconnect the battery cables and remove the battery.
  12.  
  13. Remove the battery box.
  14.  
  15. Remove the engine appearance cover.
  16.  
  17. Remove the breather pipe and brake booster vacuum line bracket, then remove the air cleaner and intake air duct.
  18.  
  19. Disconnect the throttle cable linkage.
  20.  
  21. Remove or disconnect the following:

    Brake booster vacuum hose
     
    EVAP canister hose
     
    Starter ground and positive cables
     

  22.  
  23. Mark the location and disconnect the U, V and W phase power cables from the electric motor.

    Click image to see an enlarged view

    Fig. Electric motor power cable locations-Insight

  24.  
  25. Remove or disconnect the following:

    Electronic Control Module (ECM) and the main wiring harness connectors
     
    2000-2005 Models: Fuel feed and return lines
     
    2006 Model: Fuel feed line
     
    Accessory drive belts
     
    Clutch slave cylinder, if equipped
     
    Transmission shift cables
     
    Electric motor power cable clamps
     

  26.  
  27. Raise and support the vehicle.
  28.  
  29. Remove or disconnect the following:

    Engine splash shields and brackets
     
    Lower control arm ball joints
     
    Axle halfshafts
     
    A/C compressor without disconnecting refrigerant lines, if equipped
     
    Oxygen sensor and catalytic converter
     
    Motor power cable and cable holder
     
    Radiator and heater hoses
     
    Shift cables
     
    Transmission oil cooler lines, if equipped
     

  30.  
  31. Attach a suitable engine chain hoist device to the engine.
  32.  
  33. Remove the rear and side engine mounting nuts and bolts.
  34.  
  35. Remove the transaxle mount nuts and bolts.
  36.  
  37. Ensure that all vacuum hoses, wiring harnesses and fuel lines are free from interfering with the engine removal.
  38.  
  39. Place a suitable rolling jack under the engine assembly, and lower the chain hoist until the engine assembly is on the jack.
  40.  
  41. Remove the engine/electric motor/transmission from the vehicle.
  42.  

To install:


NOTE
Use new self-locking nuts and color-coded self-locking bolts when installing the engine mounts and suspension components.


NOTE
Do not tighten the engine or transaxle mount fasteners until instructed to do so.

  1. Raise the powertrain into position.
  2.  
  3. Install or connect the following:

    Transaxle mount and bracket. Tighten the bolts and nut to 41 ft. lbs. (64 Nm) on manual transmission, or 76 ft. lbs. (103 Nm) on automatic transmission. Loosen the mount through bolt.
     
    Side engine mount. Tighten the bolt and nuts to 38 ft. lbs. (52 Nm). Loosen the mount through bolt
     
    Upper bracket. Tighten the nuts in sequence to 54 ft. lbs. (74 Nm).
     
    Raise the vehicle
     
    Rear mount. Tighten the bolts to 54 ft. lbs. (74 Nm). Loosen the through bolt.
     
    Lower the vehicle and remove the chain hoist.
     
    Tighten the transaxle mount through bolt to 40 ft. lbs. (54 Nm).
     
    Tighten the side mount through bolt to 40 ft. lbs. (54 Nm).
     
    Tighten the rear mount through bolt to 66 ft. lbs. (89 Nm).
     
    Motor power cable and cable holder
     
    Left engine undercover
     
    Oxygen sensor and catalytic converter
     
    A/C compressor
     
    Axle halfshafts
     
    Lower control arm ball joints
     
    Engine splash shields and brackets
     
    Lower the vehicle
     
    Electric motor power cable clamps
     
    Transmission oil cooler lines
     
    Shift cables
     
    Accessory drive belts
     
    Radiator and heater hoses
     
    ECM and main wiring harness connectors
     
    Motor power cables
     
    2000-2005 Models: Fuel feed and return lines
     
    2006 Model: Fuel feed line
     
    Starter ground and positive cables
     
    EVAP canister hose
     
    Brake booster vacuum hose
     
    Throttle cable linkage
     
    Clutch slave cylinder
     
    Air cleaner and intake duct
     
    Breather pipe and brake booster vacuum line bracket
     
    Battery box
     
    Battery cables
     
    Fill the cooling system, engine oil and transmission fluids
     
    Engine appearance cover
     

  4.  
  5. Check that the IMA battery level indicator reads full.
  6.  
  7. If the battery level indicator displays no segments, start the engine and hold between 3500-4000 rpm with no load until the IMA battery level indicator displays at least three segments.
  8.  
  9. Check the engine idle.
  10.  

 
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