Engine Block: Other Honda Insight ZE2

Main Bearing Selection

Crankshaft Bore Code Location

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1. Letters have been stamped on the end of the engine block as a code for the size of each of the five main journal bores. Write down the crank bore codes. If you can't read the codes because of accumulated dirt and oil, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Main Journal Code Location
2. The main journal codes are stamped on the crankshaft.
3. Use the crank bore codes and the crank journal codes to select the appropriate replacement bearings from the following table. NOTE: Color code is on the edge of the bearing.

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1. To check rod bearing-to-journal oil clearance, remove the bearing cap bridge (see «CRANKSHAFT AND PISTON REMOVAL»(ref-360295-S38251644852010042800000) ).
2. Remove the connecting rod cap and the bearing half.
3. Clean the crankshaft rod journal and the bearing half with a clean shop towel.
4. Place plastigage across the rod journal.
5. Reinstall the bearing half and connecting rod cap, and torque the bolts to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) +90 °. NOTE: Apply new engine oil to the bolt threads and flanges. Do not rotate the crankshaft during inspection.
6. Remove the connecting rod cap and bearing half, and measure the widest part of the plastigage. Connecting Rod Bearing-to-Journal Oil Clearance Standard (New): 0.026-0.044 mm (0.0010-0.0017 in) Service Limit: 0.050 mm (0.0020 in)
7. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance.
8. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearing, replace the crankshaft (see «CRANKSHAFT AND PISTON REMOVAL»(ref-360295-S38251644852010042800000) ) and start over.

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1. Inspect each connecting rod for cracks and heat damage. Connecting Rod Big End Bore Code Locations
2. Each connecting rod falls into one of four tolerance ranges (from 0 to 0.024 mm (0.0009 in), in 0.006 mm (0.0002 in) increments) depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3, or 4) indicating the range. You may find any combination of 1, 2, 3, or 4 in any engine. If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Normal Bore Size: 43.0 mm (1.69 in) Connecting Rod Journal Code Location
3. The connecting rod journal codes are stamped on the crankshaft.
4. Use the big end bore codes and the 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. If the engine is already out of the vehicle, go to step 7 .
2. Remove the splash shields (see «ENGINE REMOVAL»(ref-360292-S12679607972010042800000) ).
3. Drain the engine oil (see «ENGINE OIL REPLACEMENT»(ref-360265-S13171749412010042800000) ).
4. Remove the drive belt (see «DRIVE BELT INSPECTION»(ref-360270-S17077343672010042800000) ).
5. Remove the driveshaft heat shield (see step 32 «ENGINE REMOVAL»(ref-360292-S12679607972010042800000) ).
6. Remove the A/C compressor without disconnecting the A/C hoses (see step 34 «ENGINE REMOVAL»(ref-360292-S12679607972010042800000) ).
7. Remove the dipstick, then remove the dipstick tube.
8. Remove the crankshaft position (CKP) sensor cover (A), then disconnect the CKP sensor connector (B).
9. Remove the transmission mounting bolts.
10. Remove the oil pan bolts. Note the bolt locations by their size.
11. Insert a flat blade screwdriver where shown, and separate the oil pan from the engine block.
12. Remove the oil pan. NOTE: Lower the oil pan carefully not to damage the IMA motor rotor position sensor.

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1. Remove the engine/IMA motor/transmission assembly (see «ENGINE REMOVAL»(ref-360292-S12679607972010042800000) ).
2. Remove the transmission (see «TRANSMISSION REMOVAL»(ref-360271-S32365248072010042800000) ).
3. Remove the IMA motor housing (see «DRAIN COVER REMOVAL/INSTALLATION»(ref-360262-S39142099352010042800000) ).
4. Remove the crankshaft position (CKP) sensor cover (A), then disconnect the CKP sensor connector (B).
5. Remove the harness cover (C).
6. Remove the oil pan (see «OIL PAN REMOVAL»(ref-360295-S34464411812010042800000) ).
7. Remove the oil pump (see «REMOVAL»(ref-360265-S12238473842010042800000) ).
8. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(ref-360277-S00097021702010042800000) ).
9. Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
10. Remove the bearing cap bridge.
11. Remove the connecting rod caps/bearings. Keep all caps/bearings in order.
12. Lift crankshaft (A) out of the engine block, being careful not to damage the journals and the CKP pulse plate (B).
13. Remove the CKP pulse plate.
14. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
15. 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 pistons as they are pushed out.
16. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B). Take care not to damage the cylinder with the connecting rod.
17. Reinstall the bearing cap bridge and bearings on the engine block.
18. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
19. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reused in original order. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.

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-360295-S35505710562010042800000) ). If the engine block is to be reused, hone the cylinders and remeasure the bores.
2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern (A). 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. NOTE: 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 the engine block 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.