Engine Block: Other Honda Insight ZE1

Rod Bearing Selection

1. Inspect each connecting rod for cracks and heat damage.

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1. 2. Each rod has a tolerance range from 0 to 0.024 mm (0.0009 in.), and in 0.006 mm (0.0002 in.) increments, depending on the size of its big end bore. It's then stamped with a number (1, 2,3, or 4) indicating the range. You may find any combination of numbers in any engine, (half the number is stamped on the bearing cap, the other half on the rod). If you cannot read the code because of an accumulation of oil and varnish, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

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1. 3. The connecting rod journal codes are stamped on the No. 1 web.
2. 4. Use the big end bore codes and rod journal codes to select appropriate replacement bearings from the following table. NOTE: Color code is on the edge of the bearing.

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1. Raise the vehicle on the hoist to full height.
2. Remove the splash shield (see step 24 on «ENGINE ASSEMBLY»(ref-219281) ).
3. Drain the engine oil (see «ENGINE OIL REPLACEMENT»(ref-219284-S14789033552006021300000) ).
4. With A/C model: Remove the water pump-A/C compressor belt (see step 17 on «ENGINE ASSEMBLY»(ref-219281) ).
5. With A/C model: Remove the A/C compressor without disconnecting the A/C hoses (see step 31 on «ENGINE ASSEMBLY»(ref-219281) ).
6. 2000-2003 models: Remove the engine oil cooler bypass hoses.
7. Remove the oil pan.

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1. Remove the engine assembly (see «ENGINE REMOVAL»(ref-219281-S40897505992006021300000) ).
2. Remove the transmission: Manual transmission (M/T) (see «MANUAL TRANSMISSION»(ref-219299) ) Continuously variable transmission (CVT) (see «TRANSMISSION REMOVAL»(ref-219301-S15672816822006021300000) )
3. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(ref-219282-S32257093762006021300000) ).
4. Remove the cam chain (see «CAM CHAIN REMOVAL»(ref-219282-S33731139012006021300000) ).
5. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the piston as it is pushed out.
6. Remove the main bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
7. Remove the main bearing cap. Keep all bearings in order.
8. Remove the connecting rod bearing caps/bearings. Keep all caps/bearings in order.
9. Lift the crankshaft out of the engine, being careful not to damage the journals.
10. Use the wooden handle of a hammer (A) to drive out the piston (B).
11. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
12. To avoid mix-up on reassembly, mark each piston connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.

Scheme 239

1. Remove the crankshaft from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-219283-S28525440842006021300000) ).
2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
3. Check the keyway and threads.
4. Measure out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round Standard (New): 0.0040 mm (0.00016 in.) max. Service Limit: 0.010 mm (0.0004 in.)
5. Measure taper at the edge of each rod and main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper Standard (New): 0.0025 mm (0.000098 in.) max. Service Limit: 0.006 mm (0.0002 in.)

Scheme 240

1. 6. Place the engine block on the surface plate.
2. 7. Clean and install the bearings on the No. 1 and No. 4 journal of the engine block.
3. 8. Lower the crankshaft into the engine block.
4. 9. Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Runout Standard (New): 0.03 mm (0.001 in.) max. Service Limit: 0.04 mm (0.002 in.)

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1. Remove the piston from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-219283-S28525440842006021300000) ).
2. Check the piston for distortion or cracks.
3. Measure the piston diameter at a point 11 mm (0.4 in.) from the bottom of the skirt. Piston Diameter Standard (New): 71.977-71.995 mm (2.8337-2.8344 in.) Service Limit: 71.97 mm (2.833 in.) Oversize Piston Diameter 0.25: 72.227-72.245 mm (2.8436-2.8443 in.)
4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit, replace the engine block. If the engine block is to be rebored, refer to step 6 after reboring. Cylinder Bore Size Standard (New): 72.000-72.020 mm (2.8346-2.8354 in.) Service Limit: 72.07 mm (2.837 in.) Oversize 0.25: 72.250-72.270 mm (2.8445-2.8453 in.) Reboring Limit: 0.25 mm (0.010 in.) max. Bore Taper Limit: (Difference between first and third measurement) 0.05 mm (0.002 in.)
5. Scored or scratched cylinder bores must be honed.
6. Check the top of the engine block for warpage. Measure along the edges and across the center as shown. Engine Block Warpage Standard (New): 0.07 mm (0.003 in.) max. Service Limit: 0.10 mm (0.004 in.)
7. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and engine block for excessive wear. Piston-to-Cylinder Bore Clearance Standard (New): 0.005-0.043 mm (0.0002-0.0017 in.) Service Limit: 0.05 mm (0.002 in.)

Cylinder Bore Honing

Only a scored or scratched cylinder bore must be honed.

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1. Measure the cylinder bores (see «BLOCK AND PISTON INSPECTION»(ref-219283-S05518374582006021300000) ). If the engine block is to be reused, hone the cylinders and re-measure the bores.
2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern (A). NOTE: Use only a rigid hone with 400 grit or finer stone such as Sunnen, Ammco, or equivalent. Do not use stones that are worn or broken.
3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil them immediately to prevent rusting. Never use solvent, it will only redistribute the grit on the cylinder walls.
4. If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the engine block. Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.

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1. Remove the piston from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-219283-S28525440842006021300000) ).
2. Apply new engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B). NOTE: Take care not to damage the ring grooves.
3. Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection.
4. Heat the piston and connecting rod assembly to about 158°F (70°C), then remove the piston pin.