Engine Block: Removal & Installation Honda Insight ZE1

Crankshaft Installation

Special Tools Required

1. Driver 07749-0010000
2. Driver attachment 07948-SB00101

Scheme 215

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Scheme 220

1. Check the connecting rod bearing clearance with plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-219283-S34835638222006021300000) ).
2. Check the main bearing clearance with plastigage (see «CRANKSHAFT MAIN BEARING REPLACEMENT»(ref-219283-S29918359622006021300000) ).
3. Install the bearing halves in the engine block and connecting rods.
4. Apply new engine oil to the main bearings and rod bearings.
5. Hold the crankshaft so rod journal No. 1 is straight up, and lower the crankshaft into the engine block.
6. Install the thrust washers (A) on both edges of the No. 3 main bearing recess.
7. Inspect the connecting rod bolts (see «INSPECT THE CONNECTING ROD BOLTS»(ref-219283-S28827604622006021300000) ).
8. Apply new engine oil to the threads of the connecting rod bolts.
9. Seat the rod journal into connecting rod No. 1. Install the connecting rod cap and bolts finger-tight. Install the cap so the bearing recess is on the same side as the recess in the rod.
10. Rotate the crankshaft clockwise, and seat the journal into connecting rod No. 2. Install the connecting rod cap and bolts finger-tight.
11. Rotate the crankshaft clockwise, and seat the journal into connecting rod No. 3. Install the connecting rod cap and bolts finger-tight.
12. Tighten the connecting rod bolts to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft).
13. Tighten the connecting rod bolts an additional 90°. NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 7 of the procedure. Do not loosen it back to the specified angle.
14. Apply liquid gasket, P/N 08717-0004 or 08718-0001, along the broken line. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
15. Put the main bearing cap on the engine block.
16. Apply new engine oil to the threads of the bearing cap bolts.
17. Tighten the bearing cap bolts in sequence to 25 N.m (2.5 kgf.m, 18 lbf.ft). Verify that all the bolts are torqued properly.
18. Tighten the bearing cap bolts an additional 60°.
19. Use the special tools to install a new oil seal. Drive the seal in until the special tool bottoms on the engine block.
20. Install the cam chain (see «CAM CHAIN INSTALLATION»(ref-219282-S10963283072006021300000) ).
21. Install the cylinder head (see «CAMSHAFT AND ROCKER ARM INSTALLATION»(ref-219282-S12210476172006021300000) ).
22. Install the transmission: Manual transmission (M/T) (see «MANUAL TRANSMISSION»(ref-219299) ). Continuously variable transmission (CVT) (see «TRANSMISSION INSTALLATION»(ref-219301-S20070710692006021300000) ).
23. Install the engine assembly (see «ENGINE INSTALLATION»(ref-219281-S41751642692006021300000) ). NOTE: Whenever any crankshaft or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for about 15 minutes.

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1. Clean and dry the oil pan mating surfaces.
2. Apply liquid gasket P/N 08718-0001 to the engine block mating surface of the oil pan (see step 8 on «CYLINDER HEAD»(ref-219282) ). NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
3. Install the new oil pan gaskets (A) and a new O-ring (B) on the oil pan, then install the oil pan (C). Tighten the transmission housing mounting bolts (D).
4. Tighten the bolts and nuts to the specified torque. Specified Torque 8 x 1.25 mm: 22 N.m (2.2 kgf.m, 16 lbf.ft) 6 x 1.0 mm: 12 N.m (1.2 kgf.m, 8.7 lbf.ft)
5. 2000-2003 models: Install the engine oil cooler bypass hose.
6. With A/C model: Install the A/C compressor (see step 17 on «ENGINE ASSEMBLY»(ref-219281) ).
7. With A/C model: Install and adjust the water pump-A/C compressor belt (see «WATER PUMP-A/C COMPRESSOR BELT INSPECTION AND»(ref-219286-S03246618672006021300000) ).
8. Refill the engine with engine oil (see «ENGINE OIL REPLACEMENT»(ref-219284-S14789033552006021300000) ).
9. Install the splash shields (see step 21 on «ENGINE ASSEMBLY»(ref-219281) ).

Pulley End Crankshaft Oil Seal Installation - In Car

Special Tools Required

Driver 40 mm I.D. 07746-0030100

Scheme 224

1. Clean and dry the crankshaft oil seal housing.
2. Apply a light coat of multipurpose grease to the crankshaft and to the lip of the seal.
3. Using the seal driver, drive in the crankshaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.

Transmission End Crankshaft Oil Seal Installation - In Car

Special Tools Required

1. Driver 07749-0010000
2. Driver attachment 07948-SB00101

Scheme 225

1. Clean and dry the crankshaft oil seal housing.
2. Apply a light coat of multipurpose grease to the crankshaft and to the lip of the seal.
3. Using the special tools, drive in the crankshaft oil seal until the driver bottoms against the engine block. When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.

Coolant Drain Bolt Installation

Note. When installing the drain bolt, always use new washer.

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1. Remove the throttle body (see «THROTTLE BODY REMOVAL/INSTALLATION»(ref-219292-S03703405672006021300000) ).
2. Disconnect the knock sensor connector, then remove the knock sensor.
3. Install the knock sensor.
4. Install the throttle body (see «THROTTLE BODY REMOVAL/INSTALLATION»(ref-219292-S03703405672006021300000) ).