Engine Assembly: Removal & Installation Honda Insight ZE2

Engine Removal

Special Tools Required

1. Universal Lifting Eyelet 07AAK-SNAA120
2. Engine Support Hanger, A and Reds AAR-T1256*

*Available through the Honda Tool and Equipment Program 888-424-6857

Note. IMA components are located in this area. The IMA is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precaution before doing repairs or service (see SERVICE PRECAUTIONS ). Use fender covers to avoid damaging painted surfaces. To avoid damaging the wiring and terminals, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

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1. Turn the battery module switch OFF (see «DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR»(ref-360262-S00529659112010042800000) ).
2. Before removing the engine/transmission , read the Service Precautions for the IMA System (see «SERVICE PRECAUTIONS»(ref-360262-S24025229172010042800000) ).
3. Remove the hood support rod, then use it as shown to prop the hood in the wide-open position.
4. Relieve fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-360273-S39576641402010042800000) ).
5. Do the 12 volt battery removal procedure (see «12 VOLT BATTERY REMOVAL AND INSTALLATION»(ref-360280-S00647822892010042800000) ).
6. Remove the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-360286-S15719891662010042800000) ).
7. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
8. Disconnect the battery cables (A) from the battery terminal fuse box.
9. Remove the harness clamps (B).
10. Remove the harness clamp (A).
11. Remove the two bolts (B) and loosen the two bolts (C), then remove the, battery base (D).
12. Remove the powertrain control module (PCM) cover.
13. Disconnect the PCM connectors (A) and the engine wire harness connector (B).
14. Remove the harness clamp (C) and the harness holder (D), then remove the PCM (E).
15. Disconnect the evaporative emission (EVAP) canister hose (A) and the brake booster vacuum hose (B).
16. Remove the fuel feed hose clamp bracket (A) and the quick-connect fitting cover (B), then disconnect the fuel feed hose (C) (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(ref-360273-S13389400172010042800000) ).
17. Disconnect the secondary heated oxygen sensor (secondary HO2S) connector (A), then remove the secondary HO2S harness from the clamps (B).
18. Remove the steering joint cover (see step 6 under «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-360267-S20727019192010042800000) ).
19. Install the steering wheel holder tool (see step 10 under «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-360267-S20727019192010042800000) ).
20. Remove the steering joint from the steering gearbox pinion shaft (see step 11 under «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-360267-S20727019192010042800000) ).
21. Remove the radiator cap.
22. Raise the vehicle on the lift to full height.
23. Remove the front wheels.
24. Remove the splash shields.
25. Remove the drive belt (see «DRIVE BELT INSPECTION»(ref-360270-S17077343672010042800000) ).
26. Loosen the drain plug in the radiator, and drain the engine coolant (see «COOLANT CHECK»(ref-360270-S28078969742010042800000) ).
27. Drain the engine oil (see «ENGINE OIL REPLACEMENT»(ref-360265-S13171749412010042800000) ).
28. Drain the transmission fluid (see «CVT FLUID REPLACEMENT»(ref-360271-S23012508582010042800000) ).
29. Remove the harness clamp (A).
30. Remove the under-floor three way catalytic converter (under-floor TWC).
31. Remove the stabilizer links from the stabilizer (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-360293-S21966217862010042800000) ).
32. Separate the knuckles from the lower arms (see step 4 under «LOWER ARM REMOVAL/INSTALLATION»(ref-360293-S05750906342010042800000) ).
33. Separate the tie-rod end ball joint from the knuckles (see step 9 under «KNUCKLE/HUB/WHEEL BEARING REPLACEMENT»(ref-360293-S15870797262010042800000) ).
34. Disconnect the EPS motor connector and the torque sensor connector (see step 20 under «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-360267-S20727019192010042800000) ).
35. Remove the driveshaft heat shield.
36. Remove the driveshafts (see «DRIVESHAFT INSPECTION»(ref-360269-S37216526322010042800000) ). Coat all precision-finished surfaces with clean engine oil. Tie a plastic bags over the driveshaft ends.
37. Remove the A/C compressor without disconnecting the A/C hoses. Do not bend A/C hoses excessively.
38. Lower the vehicle on the lift.
39. Remove the radiator (see «RADIATOR REPLACEMENT»(ref-360270-S28613610992010042800000) ).
40. Disconnect the heater hoses.
41. Disconnect the IMA power cable connector and the harness clamp. NOTE: If the IMA power cable connector is dirty, clean it before removal. Cover the disconnected connector with plastic bag, and wrap the IMA power cable terminal with tape. If the IMA power cable is wet, wait until it dry.
42. Remove the shift cable (see «SHIFT CABLE REPLACEMENT»(ref-360271-S22639156422010042800000) ).
43. Remove the canister purge hose (A).
44. Install the universal lifting eyelet to the air cleaner bracket hole (B) with a bolt (C) and a nut (D).
45. Remove the harness clamp (A) from its clamp bracket (B) located in front of the damper top.
46. Set up the engine support hanger (AAR-T1256). Carefully position the engine support hanger to the vehicle; position both cross-arm foot bases (C) over the harness clamp brackets on both sides, and position both fronts stands on the front bulkhead. Attach the hook to the slotted hole in the universal eyelet, tighten the wing nut by hand, and lift and support the engine/IMA motor/transmission. NOTE: Be careful when working around the windshield.
47. Raise the vehicle on the lift to full height.
48. Support the transmission with a jack and wood block under the transmission.
49. Remove the torque rod (A).
50. Remove the jack and wood block from under transmission.
51. Support the front subframe with a transmission jack and wood block under the front subframe.
52. Remove the front subframe bolts.
53. Lower front subframe and steering gearbox as an assembly by lowering the jack slowly, then remove the assembly from under the vehicle.
54. Lower the vehicle on the lift.
55. Install the universal lifting eyelet to cam chain case.
56. Attach the chain hoist to the universal lifting eyelet (A) and the transmission hook (B). Lift the engine/IMA motor/transmission until it is securely supported by the chain hoist, then remove the engine support hanger. NOTE: Wrap the VSA modulator-control unit with the clean shop towel.
57. Remove the harness holder mounting bolt (A) and the ground cable (B), then remove the harness holder (C).
58. Remove the transmission mount bracket (D).
59. Remove the ground cable (A), then remove the side engine mount/bracket assembly (B).
60. Check that the engine/IMA motor/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
61. Slowly lower the engine/IMA motor/transmission about 150 mm (6 in). Check once again that all hoses and electrical wiring are disconnected and free from the engine/IMA motor/transmission, then lower it all the way.
62. Disconnect the chain hoist from the engine/IMA motor/transmission.
63. Raise the vehicle, and remove the engine/IMA motor/transmission from under the vehicle.

Engine Installation

Special Tools Required

1. Universal Lifting Eyelet 07AAK-SNAA120
2. Engine Support Hanger, A and Reds AAR-T1256*
3. Available through the Honda Tool and Equipment Program 888-424-6857

Note. IMA components are located in this area. The IMA is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precaution before doing repairs or service (see SERVICE PRECAUTIONS ).

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1. Raise the vehicle on the lift, and position the engine/IMA motor/transmission under the vehicle. Lower the vehicle, and attach the chain hoist to the universal lifting eyelet (A) and the transmission hook (B), then lift the engine/IMA motor/transmission into position in the vehicle. NOTE: Attach the first universal lifting eyelet (B) to the cam chain case. See 55 . Reinstall the mounting bolts and support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise and vibration, and reduce engine mount life. Wrap the VSA modulator-control unit with the clean shop towel.
2. Install the side engine mount/bracket assembly (A), then tighten the new side engine mount/bracket assembly mounting bolts (B).
3. Loosely tighten the new side engine mount/bracket assembly mounting nuts (C).
4. Install the ground cable (D).
5. Install the transmission mount bracket (A), and loosely tighten the new transmission mount bracket mounting bolts and nuts (B).
6. Install the harness holder (C) and the ground cable (D).
7. Install the universal lifting eyelet to the air cleaner bracket hole (A) with a bolt (B) and a nut (C).
8. Install the engine support hanger (AAR-T1256), then attach the hook to the slotted hole in the universal eyelet. Tighten the wing nut (A) by hand to lift and support the engine/IMA motor/transmission.
9. Remove the chain hoist from the engine/IMA motor/transmission.
10. Remove the universal lifting eyelet from the cam chain case.
11. Raise the vehicle on the lift to full height.
12. Support the front subframe with a transmission jack and wood block under the front subframe.
13. Install the front subframe, then tighten the new front subframe mounting bolts in the numbered sequence shown. NOTE: Be sure that the pinion shaft grommet is in place securely. Make sure the pinion shaft grommet is not turned up. Incorrect installation can cause leakage of water or mud, and noise. Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
14. Remove the transmission jack and wood block from the front subframe.
15. Support the transmission with a transmission jack and wood block under the transmission.
16. Install the torque rod (A). Install the new bolt with the guide plate (B) on the bolt head aligned with the guide (C) on the front subframe, then loosely tighten the new torque rod mounting bolt and nut (D). NOTE: Be sure to install the torque rod with the "UP" mark facing up.
17. Remove the transmission jack and wood block from under the transmission. Lower the vehicle on the lift.
18. Lower the vehicle on the lift.
19. Remove the engine support hanger, and install the harness clamp in its bracket location in front of the left damper top.
20. Remove the universal lifting eyelet, and install the canister purge hose (A).
21. Tighten the side engine mount/bracket assembly mounting nuts.
22. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown.
23. Raise the vehicle on the lift to full height.
24. Tighten the torque rod mounting bolt and nut in the numbered sequence shown.
25. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring clicks into place in the differential.
26. Install the driveshaft heat shield.
27. Connect the EPS motor connector and torque sensor connector (see step 13 under «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-360267-S20727019192010042800000) ).
28. Connect the tie-rod end ball joints to the knuckles (see «KNUCKLE/HUB/WHEEL BEARING REPLACEMENT»(ref-360293-S15870797262010042800000) ).
29. Connect the lower arms to the knuckles (see step 7 under «LOWER ARM REMOVAL/INSTALLATION»(ref-360293-S05750906342010042800000) ).
30. Install the stabilizer links to the stabilizer (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-360293-S21966217862010042800000) ).
31. Install the A/C compressor.
32. Install the under-floor three way catalytic converter (under-floor TWC) (A). Use new gaskets (B) and new self-locking nuts (C).
33. Install the splash shields.
34. Lower the vehicle on the lift.
35. Connect the IMA power cable connector and harness clamp.
36. Install the shift cable (see «SHIFT CABLE REPLACEMENT»(ref-360271-S22639156422010042800000) ).
37. Install the heater hoses.
38. Install the drive belt (see «DRIVE BELT INSPECTION»(ref-360270-S17077343672010042800000) ).
39. Install the radiator (see «RADIATOR REPLACEMENT»(ref-360270-S28613610992010042800000) ).
40. Install the steering joint to the steering gearbox pinion shaft (see «INSTALLATION»(ref-360267-S30274839572010042800000) ).
41. Remove the steering wheel holder tool.
42. Install the steering joint cover (see step 27 under «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-360267-S20727019192010042800000) ).
43. Connect the secondary heated oxygen sensor (secondary HO2S) connector (A), then install the secondary HO2S harness to the clamps (B).
44. Connect the fuel feed hose (A) (see «FUEL LINE/QUICK-CONNECT FITTING INSTALLATION»(ref-360273-S33469807112010042800000) ), then install the quick-connect fitting cover (B) and the fuel feed hose clamp bracket (C).
45. Install the evaporative emission (EVAP) canister hose (A) and the brake booster vacuum hose (B).
46. Install the powertrain control module (PCM) (A), then install the harness holder (B) and the harness clamp (C).
47. Connect the engine wire harness connector (D) and the PCM connectors (E).
48. Install the PCM cover.
49. Install the battery base (A), then install the harness clamp (B).
50. Connect the battery cables (A) to the battery terminal fuse box.
51. Install the harness clamps (B).
52. Install the front wheels.
53. Install the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-360286-S15719891662010042800000) ).
54. Do the 12 volt battery installation procedure (see «12 VOLT BATTERY REMOVAL AND INSTALLATION»(ref-360280-S00647822892010042800000) ).
55. Turn the battery module switch ON (see «DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR»(ref-360262-S00529659112010042800000) ).
56. Refill the transmission with CVT fluid (CVTF) (see «CVT FLUID REPLACEMENT»(ref-360271-S23012508582010042800000) ).
57. Install the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
58. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
59. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point in the fuel line.
60. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see step 9 under «COOLANT REPLACEMENT»(ref-360270-S24697686892010042800000) ).
61. Refill the engine with engine oil (see step 6 under «ENGINE OIL REPLACEMENT»(ref-360265-S13171749412010042800000) ).
62. Do the PCM reset procedure (see «HDS CLEAR COMMAND»(ref-360279-S22973070982010042800000) ).
63. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see «CKP PATTERN CLEAR/CKP PATTERN LEARN»(ref-360279-S39336907372010042800000) ).
64. Inspect the idle speed (see «IDLE SPEED INSPECTION»(ref-360285-S18029534852010042800000) ).
65. Inspect the ignition timing (see «IGNITION TIMING INSPECTION»(ref-360276-S15076727832010042800000) ).

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1. Support the engine with a jack and a wood block under the oil pan.
2. Remove the ground cable (A), then remove the side engine mount/bracket assembly (B).
3. Install the side engine mount/bracket assembly, then tighten the new side engine mount/bracket assembly mounting bolts (C).
4. Loosely tighten the new side engine mount/bracket assembly mounting nuts (D), and install the ground cable.
5. Remove the jack and wood block from under the oil pan.
6. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
7. Loosen the transmission mount bracket mounting bolts and nuts (A).
8. Raise the vehicle on the lift to full height.
9. Loosen the torque rod mounting bolt and nut (A).
10. Lower the vehicle on the lift.
11. Tighten the side engine mount/bracket assembly mounting nuts.
12. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown.
13. Raise the vehicle on the lift to full height.
14. Tighten the torque rod mounting bolt and nut in the numbered sequence shown.
15. Lower the vehicle on the lift.
16. Install the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).

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1. Remove the 12 volt battery (see «12 VOLT BATTERY REMOVAL AND INSTALLATION»(ref-360280-S00647822892010042800000) ).
2. Turn the battery module switch OFF (see «DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR»(ref-360262-S00529659112010042800000) ).
3. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
4. Disconnect the battery cables (A) from the battery terminal fuse box.
5. Remove the harness clamps (B).
6. Remove the harness clamp (A). Remove the two bolts (B) and loosen the two bolts (C), then remove the battery base (D).
7. Remove the powertrain control module (PCM) (see «PCM REPLACEMENT»(ref-360284-S39322714792010042800000) ).
8. Disconnect the IMA power cable connector and the harness clamp (see step 41 ).
9. Support the transmission with a jack and a wood block under the transmission.
10. Remove the harness holder mounting bolt (A) and the ground cable (B), then remove the harness holder (C).
11. Remove the transmission mount bracket (D).
12. Remove the transmission mount.
13. Install the transmission mount, and loosely tighten the new transmission mount mounting bolts, then tighten the transmission mount mounting bolts in the numbered sequence shown.
14. Install the transmission mount bracket (A), and loosely tighten the new transmission mount bracket mounting bolts and nuts (B).
15. Install the harness holder (C) and the ground cable (D).
16. Remove the jack and wood block from under the transmission.
17. Raise the vehicle on the lift to full height.
18. Loosen the torque rod mounting bolt and nut (A).
19. Lower the vehicle on the lift.
20. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown.
21. Raise the vehicle on the lift to full height.
22. Tighten the torque rod mounting bolt and nut in the numbered sequence shown.
23. Install the battery base (A), then install the harness clamp (B).
24. Connect the battery cables (A) to the battery terminal fuse box.
25. Install the harness clamps (B).
26. Install the PCM (see «PCM REPLACEMENT»(ref-360284-S39322714792010042800000) ).
27. Connect the IMA power cable connector and the harness clamp (see step 31 under «Engine Installation»(ref-360292-S34867356662010042800000) ).
28. Turn the battery module switch ON (see «DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR»(ref-360262-S00529659112010042800000) ).
29. Install the 12 volt battery (see «12 VOLT BATTERY REMOVAL AND INSTALLATION»(ref-360280-S00647822892010042800000) ).
30. Install the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).

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1. Raise the vehicle on the lift to full height.
2. Support the transmission with a jack and a wood block under the transmission.
3. Remove the torque rod (A). NOTE: Make sure the tab (B) on the bolt head aligned with the guide (C) on the front subframe.
4. Install the torque rod (A). NOTE: Be sure to install the torque rod with the "UP" mark facing up.
5. Install the bolt with the tab (B) on the bolt head aligned with the guide (C) on the front subframe, then tighten the new torque rod mounting bolt and nut in the numbered sequence shown.
6. Remove the transmission jack and wood block from under the transmission.
7. Lower the vehicle on the lift.

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1. Remove the 12 volt battery (see «12 VOLT BATTERY REMOVAL AND INSTALLATION»(ref-360280-S00647822892010042800000) ).
2. Turn the battery module switch OFF (see «DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR»(ref-360262-S00529659112010042800000) ).
3. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
4. Disconnect the battery cables (A) from the battery terminal fuse box.
5. Remove the harness clamps (B).
6. Remove the harness clamp (A). Remove the two bolts (B) and loosen the two bolts (C), then remove the battery base (D).
7. Remove the powertrain control module (PCM) (see «PCM REPLACEMENT»(ref-360284-S39322714792010042800000) ).
8. Disconnect the IMA power cable and the harness clamp (see step 41 ).
9. Support the transmission with a jack and a wood block under the transmission.
10. Remove the harness holder mounting bolt and the ground cable (A), then remove the harness holder (B).
11. Remove the transmission mount bolts and nuts, then remove the transmission mount bracket (C).
12. Install the transmission mount bracket, and loosely tighten the new transmission mount bracket mounting bolts and nuts.
13. Install the harness holder and the ground cable.
14. Remove the jack and wood block from under the transmission.
15. Raise the vehicle on the lift to full height.
16. Loosen the torque rod mounting bolt and nut (A).
17. Lower the vehicle on the lift.
18. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown.
19. Raise the vehicle on the lift to full height.
20. Tighten the torque rod mounting bolt and nut in the numbered sequence shown.
21. Lower the vehicle on the lift.
22. Install the battery base (A), then install the harness clamp (B).
23. Connect the battery cables (A) to the battery terminal fuse box.
24. Install the harness clamps (B).
25. Install the PCM (see «PCM REPLACEMENT»(ref-360284-S39322714792010042800000) ).
26. Connect the IMA power cable and the harness clamp (see step 31 under «Engine Installation»(ref-360292-S34867356662010042800000) ).
27. Turn the battery module switch ON (see «DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR»(ref-360262-S00529659112010042800000) ).
28. Do the 12 volt battery installation procedure (see «12 VOLT BATTERY REMOVAL AND INSTALLATION»(ref-360280-S00647822892010042800000) ).
29. Install the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).

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1. Raise the vehicle on the lift to full height.
2. Support the transmission with a jack and a wood block under the transmission.
3. Remove the torque rod (A).
4. Remove the torque rod bracket (A).
5. Install the torque rod bracket.
6. Install the torque rod (A). NOTE: Be sure to install the torque rod with the "UP" mark facing up.
7. Install the bolt with the tab (B) on the bolt head aligned with the guide (C) on the front subframe, then tighten the new torque rod mounting bolt and nut in the numbered sequence shown.
8. Remove the transmission jack and wood block from under the transmission.
9. Lower the vehicle on the lift.