Engine Block: Removal & Installation Honda Insight ZE2

Piston, Pin, and Connecting Rod Replacement

Special Tools Required

1. Piston Base Head 07PAF-0010400
2. Piston Base Head Insert 07PAF-0010500
3. Insert Pin 07PAF-0010700
4. Pilot Pin 070AF-PWC0110
5. Insert Adjust 070AF-PWC0120
6. Pilot Collar, O.D. 18 mm 070AF-PWC0130
7. Piston Base 07973-6570500
8. Piston Base Spring 07973-6570600

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1. Assemble the piston base (A), piston base spring (B), pilot pin (C), and piston base head (D) as shown.
2. Temporarily install the pilot collar over the pilot pin (A), and adjust the piston base head inserts as shown, then tighten the screws (B). Remove the pilot collar.
3. Assemble and adjust the length of the piston pin driver head and shaft to 57 mm (2.2 in).
4. With the arrow on top of the piston pointing up, place the piston assembly (A) on the piston base (B). Be sure you position the recessed fiat area of the piston against the piston base head inserts (C) as shown.
5. Press the pin (D) out with the piston pin driver (E), the pilot collar (F), and a hydraulic press.

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1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 17.996-18.000 mm (0.7085-0.7087 in)
2. Zero the dial indicator to the piston pin diameter.
3. Check the difference the piston pin diameter and the piston pin hole diameter in the piston. Piston Pin-to-Piston Clearance Standard (New): 0.010-0.017 mm (0.0004-0.0007 in)
4. Check the difference between the piston pin diameter and the connecting rod small end diameter. Piston Pin-to-Connecting Rod Interference Standard (New): 0.019-0.036 mm (0.0007-0.0014 in)

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1. Assemble the piston with the arrow (A) pointing up and the connecting rod with the embossed mark (B) on the same side.
2. Insert the pilot collar (A) into the piston and the connecting rod.
3. With the arrow on top of the piston and the embossed mark on the connecting rod facing up, place the piston assembly (B) on the piston base (C). Be sure you position the recessed flat area of the piston against the piston base head inserts (D) as shown.
4. Press the pin (E) in with the piston pin driver (F) and a hydraulic press.

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1. Remove the piston from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-360295-S38251644852010042800000) ).
2. Using a ring expander (A), remove the old piston rings (B).
3. Clean all the ring grooves thoroughly with a squared-off broken ring, or a ring groove cleaner with a blade to fit the piston grooves. File down the blade, if necessary. The top and second ring grooves are 1.0 mm (0.04 in) wide, and the oil ring groove is 2.0 mm (0.08 in) wide. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tool. NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.
4. Using a piston, push a new ring (A) into the cylinder bore 15-20 mm (0.6-0.8 in) from the bottom.
5. Measure the piston ring end-gap (B) with a feeler gauge: If the gap is too small, check to see if you have the proper rings for your engine. If the gap is too large, recheck the cylinder bore diameter against the wear limits (see «BLOCK AND PISTON INSPECTION»(ref-360295-S35505710562010042800000) ). If the bore is over the service limit, the engine block must be rebored. Piston Ring End-Gap Top Ring: Standard (New): 0.15-0.30 mm (0.006-0.012 in) Service Limit: 0.60 mm (0.024 in) Second Ring: Standard (New): 0.30-0.42 mm (0.012-0.017 in) Service Limit: 0.65 mm (0.026 in) Oil Ring: Standard (New): 0.20-0.70 mm (0.008-0.028 in) Service Limit: 0.80 mm (0.031 in)
6. Install the rings as shown. The top ring (A) has a R mark, and the second ring (B) has a 2R mark. The manufacturing marks (C) must face upward.
7. Rotate the rings in their grooves to make sure they do not bind.
8. Position the ring end gaps as shown
9. After installing a new set of rings, measure the ring-to-groove clearances: Top Ring Clearance Standard (New): 0.065-0.090 mm (0.0026-0.0035 in) Service Limit: 0.15 mm (0.006 in) Second Ring Clearance Standard (New): 0.030-0.055 mm (0.0012-0.0022 in) Service Limit: 0.12 mm (0.005 in)

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1. Set the crankshaft to bottom dead center (BDC) for each cylinder.
2. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore.
3. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
4. Position the piston/connecting rod assembly with the arrow (A) facing the cam chain side of the engine.
5. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
6. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
7. Check the connecting rod bearing clearance with plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-360295-S14900502612010042800000) ).
8. Inspect the connecting rod bolts (see «IF THE CRANKSHAFT IS NOT INSTALLED»(ref-360295-S13776865782010042800000) ).
9. Apply new engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft).
10. 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 8 of the procedure. Do not loosen it back to the specified angle.

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1. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore.
2. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
3. Position the piston/connecting rod assembly with the arrow (A) facing the cam chain side of the engine.
4. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
5. Position all pistons at top dead center (TDC).

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1. Measure the diameter of each connecting rod bolt at point A and point B with a micrometer.
2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter: Specification: 0-0.05 mm (0-0.002 in)
3. If the difference in diameter is out of tolerance, replace the connecting rod bolt.

Crankshaft Installation

Special Tools Required

1. Driver Handle, 15 x 135L 07749-0010000
2. Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100

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1. Check the connecting rod bearing clearance with plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-360295-S14900502612010042800000) ).
2. Check the main bearing clearance with plastigage (see «CONNECTING ROD AND CRANKSHAFT END PLAY INSPECTION»(ref-360295-S24855965102010042800000) ).
3. Install the bearing halves in the engine block and the connecting rods.
4. Apply new engine oil to the main bearings and the rod bearings.
5. Install the crankshaft position (CKP) pulse plate (A) on the crankshaft (B); face the marked side (C) opposite the crankshaft, and align the tab (D) on the CKP pulse plate with the groove (E) on the crankshaft.
6. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the engine block.
7. Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No. 4 journal of the engine block.
8. Inspect the connecting rod bolts (see «IF THE CRANKSHAFT IS NOT INSTALLED»(ref-360295-S13776865782010042800000) ).
9. Apply new engine oil to the threads of the connecting rod bolts.
10. Seat the rod journals into connecting rod No. 1 and the connecting rod No. 4. Line up the mark (A) on the connecting rod and cap, then install the caps and the bolts finger-tight.
11. Rotate the crankshaft clockwise, and seat the rod journals into connecting rod No. 2 and connecting rod No. 3. Line up the mark on the connecting rod and the cap, then install the caps and the 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 10 of the procedure. Do not loosen it back to the specified angle.
14. Remove all of the old liquid gasket from the bearing cap bridge mating surfaces.
15. Clean and dry the bearing cap bridge mating surfaces.
16. Apply liquid gasket (P/N 08717-0004,08718-0003, or 08718-0009) to the engine block mating surface of the bearing cap bridge. Install the component within 5 minutes of applying the liquid gasket. NOTE: Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A). If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
17. Put the bearing cap bridge on the engine block.
18. Apply new engine oil to the threads of the bearing cap bolts.
19. Tighten the bearing cap bolts is sequence to 25 N.m (2.5 kgf.m, 18 lbf.ft).
20. Tighten the bearing cap bolts an additional 40°.
21. Clean the excess liquid gasket off the engine block.
22. Use the driver handle and oil seal driver attachment to drive a new crankshaft oil seal squarely into the block to the specified installed height. NOTE: Lubricate the inner lips of the mew crankshaft oil seal with new engine oil before installation, but never lubricate the outside diameter of the seal.
23. Measure the distance between the crankshaft (A) and the oil seal (B). Oil Seal Installed Height: 7-8 mm (0.28-0.31 in)
24. Install the cylinder head (see «ROCKER ARM ASSEMBLY INSTALLATION»(ref-360277-S10535355972010042800000) ).
25. Install the oil pump (see «INSTALLATION»(ref-360265-S27006111672010042800000) ).
26. Install the oil pan (see «CKP PULSE PLATE REPLACEMENT»(ref-360295-S37144769832010042800000) ).
27. Install the cam chain (see «CAM CHAIN INSTALLATION»(ref-360277-S40371567552010042800000) ).
28. Connect the CKP sensor connector (A), then install the CKP sensor cover (B).
29. Install the harness cover (C).
30. Install the IMA motor housing (see «DRAIN COVER REMOVAL/INSTALLATION»(ref-360262-S39142099352010042800000) ).
31. Install the transmission (see «TRANSMISSION INSTALLATION»(ref-360271-S39217591732010042800000) ).
32. Install the engine/IMA motor/transmission assembly (see «ENGINE INSTALLATION»(ref-360292-S34867356662010042800000) ). NOTE: When any crankshaft or connecting rod bearing is replaced, run the engine at idle until it reaches normal operating temperature, then continue to running it for about 15 minutes.

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1. Remove the crankshaft (see «CRANKSHAFT AND PISTON REMOVAL»(ref-360295-S38251644852010042800000) ).
2. Remove the crankshaft position (CKP) pulse plate (A).
3. Install the CKP pulse plate on the crankshaft (B); face the marked side (C) opposite the crankshaft, and align the tab (D) on the CKP pulse plate with the groove (E) on the crankshaft.
4. Install the crankshaft (see «CRANKSHAFT INSTALLATION»(ref-360295-S25371445462010042800000) ).

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1. Remove all of the old liquid gasket from the oil pan mating surfaces, the bolts, and the bolt holes.
2. Clean and dry the oil pan mating surfaces and the O-ring groove.
3. Install the new oil pan gasket (A), the new O-ring (B), and the dowel pins (C) on the oil pan.
4. Apply liquid gasket (P/N 08717-0004,08718-0003, or 08718-0009) to the engine block mating surface of the oil pan and to the inside edge of the bolt holes. Install the component within 5 minutes of applying the liquid gasket. NOTE: Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A). Apply a 5.0 mm (0.20 in) diameter bead of liquid gasket to the shaded area (B). Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket along the broken line (C). If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
5. Install the oil pan. NOTE: Raise the oil pan carefully not to damage IMA motor rotor position sensor. Wait at least 30 minutes before filling the engine with oil. Do not run the engine for at least 3 hours after installing the oil pan. Make sure to install the bolts in the correct locations according to size.
6. Tighten the bolts in three steps. Wipe off the excess liquid gasket on the each side of crankshaft pulley and the drive plate. Specified torque (1): 24 N.m (2.4 kgf.m, 17 lbf.ft) (2)-(13): 12 N.m (1.2 kgf.m, 8.8 lbf.ft)
7. Install the transmission mounting bolts.
8. Connect the CKP sensor connector (A), then install the CKP sensor cover (B).
9. Install the dipstick tube (A) with new O-ring (B), then install the dipstick.
10. If the engine is still in the vehicle, do steps 11 through 15.
11. Install the A/C compressor (see step 27 under «ENGINE INSTALLATION»(ref-360292-S34867356662010042800000) ).
12. Install the driveshaft heat shield (see step 22 under «ENGINE INSTALLATION»(ref-360292-S34867356662010042800000) ).
13. Install the drive belt (see «DRIVE BELT INSPECTION»(ref-360270-S17077343672010042800000) ).
14. Install the splash shields (see step 29 under «ENGINE INSTALLATION»(ref-360292-S34867356662010042800000) ).
15. Refill the engine with engine oil (see step 6 under «ENGINE OIL REPLACEMENT»(ref-360265-S13171749412010042800000) ).

Transmission End Crankshaft Oil Seal Installation - In Car

Special Tools Required

1. Driver Handle, 15 x 135L 07749-0010000
2. Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100

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1. Remove the transmission (see «TRANSMISSION REMOVAL»(ref-360271-S32365248072010042800000) ).
2. Remove the IMA motor housing (see «DRAIN COVER REMOVAL/INSTALLATION»(ref-360262-S39142099352010042800000) ).
3. Clean and dry the crankshaft oil seal housing.
4. Use the driver handle and oil seal driver attachment to drive a new crankshaft oil seal squarely into the block to the specified installed height.
5. Measure the distance between the crankshaft (A) and the oil seal (B). Oil Seal Installed Height: 7-8 mm (0.28-0.31 in)
6. Install the IMA motor housing (see «DRAIN COVER REMOVAL/INSTALLATION»(ref-360262-S39142099352010042800000) ).
7. Install the transmission (see «TRANSMISSION INSTALLATION»(ref-360271-S39217591732010042800000) ).

Drain Bolt/Sealing Bolt Installation

Note. When installing the drain bolt and/or sealing bolt, always use a new washer.

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1. Remove the block cover (A).
2. Install the block cover in the reverse order of removal.