Honda Insight 2000-2006

Timing Chain, Oil Pan & Oil Pump

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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. Disconnect the negative battery cable.
  4.  
  5. Remove the engine.
  6.  
  7. Remove the cylinder head.
  8.  
  9. Remove the idler pulley bracket mounting bolt.
  10.  
  11. Remove the water pump.
  12.  
  13. Remove the crankshaft pulley.
  14.  
  15. On 2000-03 models, remove the engine oil cooler bypass hoses.
  16.  
  17. Remove the oil pan.
  18.  
  19. Remove the oil screen and oil pump assembly.
  20.  
  21. Remove the timing chain.
  22.  
  23. Remove the crankshaft sprocket.
  24.  
  25. Remove the timing chain tensioning arm and chain guide.
  26.  
  27. Remove the Crankshaft Position Sensor (CKP) pulser plate.

    Click image to see an enlarged view

    Fig. Exploded view of the timing chain components-Insight

  28.  

To install:

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Fig. Aligning the crankshaft sprocket timing marks-Insight



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Fig. Aligning the timing chain link with the crankshaft sprocket timing mark-Insight

  1. Install the CKP sensor plate.
  2.  
  3. Install the timing chain guide and tighten the bolt to 105 inch lbs. (12 Nm).
  4.  
  5. Install the timing chain tensioning arm and tighten the bolts to 16 ft. lbs. (22 Nm).
  6.  
  7. Set the crankshaft sprocket so no. 1 piston is at TDC. Align the TDC mark (A) on the crankshaft pulser with the pointer (B) on the block.
  8.  
  9. Align the timing chain colored link (A) with the punch mark (B) on the crankshaft sprocket.
  10.  
  11. Clean and dry the oil pump mating surfaces.
  12.  
  13. Apply liquid gasket to the oil pump mating surface on the cylinder block and the bolt holes as shown.

    Click image to see an enlarged view

    Fig. Oil pump sealant application areas on cylinder block-Insight

  14.  
  15. Install the dowel pins (A) and align the inner rotor with the crankshaft and install the oil pump (B) using new o-rings (C).
  16.  
  17. Install the oil screen (D) using a new gasket (E).

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump installation-Insight

  18.  
  19. Clean and dry the oil pan mating surfaces.
  20.  
  21. Apply liquid gasket to the oil pan mating surface on the cylinder block and the bolt holes as shown.
  22.  
  23. Using new gaskets and o-rings, install the oil pan. Tighten the bolts in sequence as shown. Tighten M8 bolts to 16 ft. lbs. (22 Nm). Tighten the M6 bolts to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Oil pan sealant application areas on cylinder block-Insight



    Click image to see an enlarged view

    Fig. Exploded view of the oil pan installation-Insight



    Click image to see an enlarged view

    Fig. Oil pan tightening sequence-Insight

  24.  
  25. Lubricate the crankshaft pulley bolt with clean engine oil and install the pulley. Tighten the bolt to 14 ft. lbs. (20 Nm), plus an additional 90°.
  26.  
  27. Install or connect the following:

    On 2000-03 models, the engine oil cooler bypass hoses
     
    Crankshaft pulley
     
    Water pump
     
    Idler pulley bracket bolt
     
    Cylinder head
     
    Engine
     
    Connect the negative battery cable.
     
    Check the engine operation and road test.
     

  28.