Pgm-Fi System: Removal & Installation Honda Insight ZE2

A/F Sensor Replacement

Special Tools Required

O2 Sensor Wrench, Snap-on S6176 or equivalent, commercially available

Scheme 315

Scheme 316

1. Remove the cowl cover and the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-360286-S15719891662010042800000) ).
2. Disconnect the A/F sensor connector (A).
3. Remove the A/F sensor (A).
4. Install the parts in the reverse order of removal.

Secondary HO2S Replacement

Special Tools Required

O2 Sensor Wrench, Snap-on S6176 or equivalent, commercially available

Scheme 317

Scheme 318

1. Remove the cowl cover and the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-360286-S15719891662010042800000) ).
2. Disconnect the secondary HO2S connector (A).
3. Raise the vehicle on a lift.
4. Remove the wire clips (A), then remove the secondary HO2S (B).
5. Install the parts in the reverse order of removal.

Scheme 319

1. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
2. Remove the cowl cover and the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-360286-S15719891662010042800000) ).
3. Disconnect the CMP sensor 3P connector (A.
4. Remove the CMP sensor (B).
5. Install the sensor in the reverse order of removal with a new O-ring (C).

Scheme 320

Scheme 321

1. Raise the vehicle on a lift. NOTE: Make sure the vehicle is level, because engine oil will drip out when you remove the sensor.
2. Remove the engine undercover (see «SPLASH SHIELD REPLACEMENT»(ref-360308-S41260454582010042800000) ).
3. Remove the CKP sensor cover (A).
4. Disconnect the CKP sensor connector (A).
5. Remove the CKP sensor (B).
6. Install the parts in the reverse order of removal with a new O-ring (C).
7. Do the CKP pattern clear/CKP pattern learn procedure (see «CKP PATTERN CLEAR/CKP PATTERN LEARN»(ref-360279-S39336907372010042800000) ).
8. Check the engine oil level, and add more oil if needed.

Scheme 322

1. Remove the engine oil dipstick.
2. Disconnect the knock sensor 1P connector (A).
3. Remove the knock sensor (B).
4. Install the parts in the reverse order of removal.

Scheme 323

1. Remove the cowl cover and the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-360286-S15719891662010042800000) ).
2. Disconnect the MAP sensor 3P connector (A).
3. Remove the MAP sensor (B).
4. Install the parts in the reverse order of removal with a new O-ring (C).

Scheme 324

1. Disconnect the MAF sensor/IAT sensor 5P connector (A).
2. Remove the screws (B).
3. Remove the MAF sensor/IAT sensor (C).
4. Install the parts in the reverse order of removal with a new gasket (D).

Scheme 325

1. Drain the engine coolant (see «COOLANT CHECK»(ref-360270-S28078969742010042800000) ).
2. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-360274-S09784809262010042800000) ).
3. Disconnect the ECT sensor 1 connector (A).
4. Remove ECT sensor 1 (B).
5. Install the parts in the reverse order of removal with a new O-ring (C), then refill the radiator with engine coolant (see «COOLANT CHECK»(ref-360270-S28078969742010042800000) ).

Scheme 326

1. Drain the engine coolant (see «COOLANT CHECK»(ref-360270-S28078969742010042800000) ).
2. Raise the vehicle on a lift.
3. Disconnect the ECT sensor 2 connector (A), then remove ECT sensor 2 (B).
4. Install the parts in the reverse order of removal with a new O-ring (C), then refill the radiator with engine coolant (see «COOLANT CHECK»(ref-360270-S28078969742010042800000) ).

Scheme 327

Scheme 328

1. Remove the under-dash fuse/relay box (see «REMOVAL AND INSTALLATION»(ref-360306-S00499054042010042800000) ).
2. Remove the fuse (A).
3. Remove the joint bar (B).
4. Turn over the under-dash fuse/relay box, then remove the ELD (A).
5. Install the parts in the reverse order of removal.

PCM Replacement

Special Tools Required

1. Honda Diagnostic System (HDS) tablet tester
2. Honda Interface Module (HIM) and an iN workstation with the latest HDS software version
3. HDS pocket tester
4. GNA600 and an iN workstation with the latest HDS software version

Any one of the above updating tools can be used.

Note. Make sure the HDS/iN workstation has the latest HDS software version. The lifetime points of the ECO guide cannot be carried over to the replacement PCM.

Scheme 329

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Scheme 331

Scheme 332

1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the PCM and all other vehicle systems. If it doesn't, go to the DLC circuit troubleshooting (see «DLC CIRCUIT TROUBLESHOOTING»(ref-360284-S14481644492010042800000) ). If you are returning from the DLC circuit troubleshooting, skip steps 4 through 7,17 through 19, and 20 through 23, and do these procedures after replacing the PCM: Replace the engine oil and the engine oil filter (see «ENGINE OIL FILTER REPLACEMENT»(ref-360265-S13867516412010042800000) ). Clean the throttle body (see «THROTTLE BODY CLEANING»(ref-360274-S32947855962010042800000) ).
4. Select the PGM-FI system with the HDS.
5. Select the INSPECTION MENU with the HDS.
6. Select the ETCS TEST, then select the TP POSITION CHECK, and follow the screen prompts. NOTE: If the TP POSITION CHECK indicates FAILED, continue with this procedure.
7. Select the REPLACE PCM MENU, then select READ DATA, and follow the screen prompts. NOTE: Doing this step copies (READS) the engine oil life data from the original PCM so you can later download (WRITES) it into the new PCM. If the READ DATA indicates FAILED, continue with this procedure.
8. Jump the SCS line with the HDS.
9. Turn the ignition switch to LOCK (0).
10. Remove the PCM cover (A), then go to step 11 (KC model) or to step 12 (except KC model).
11. Remove the bracket (A).
12. Remove the bolts (D).
13. Disconnect PCM connectors A, B, and C, then remove the PCM (E). NOTE: PCM connectors A, B, and C have symbols (A=[], B= , C=o) embossed on them for identification.
14. Install all parts in the reverse order of removal. NOTE: If the IMA battery level indicator displays no level, start the engine, and hold it between 3,500 and 4,000 rpm without load (in P or N) until the level in the indicator is half full.
15. Turn the ignition switch to ON (II).
16. Manually input the VIN to the PCM with the HDS. NOTE: DTC P0630 VIN Not Programmed or Mismatch may be stored because the VIN has not been programmed into the PCM; ignore it, and continue this procedure.
17. If the READ DATA (engine oil life) failed in step 7, go to step 18.
18. Select the PGM-FI system with the HDS.
19. Select the REPLACE PCM MENU, then select WRITE DATA, and follow the screen prompts. NOTE: If the WRITE DATA indicates FAILED, continue with this procedure.
20. Select the IMMOBI system with the HDS.
21. Enter the immobilizer PCM code that you got from the iN, and use the PCM replacement procedure in the IMMOBI MENU of the HDS; it allows you to start the engine.
22. If the TP POSITION CHECK failed in step 6, clean the throttle body (see «THROTTLE BODY CLEANING»(ref-360274-S32947855962010042800000) ), then go to step 23.
23. If the READ DATA failed in step 7 or the WRITE DATA failed in step 19, replace the engine oil (see «ENGINE OIL REPLACEMENT»(ref-360265-S13171749412010042800000) ), and the engine oil filter (see «ENGINE OIL FILTER REPLACEMENT»(ref-360265-S13867516412010042800000) ), then go to step 24.
24. Select the PGM-FI system, and reset the PCM with the HDS.
25. Update the PCM if it does not have the latest software.
26. Do the PCM idle learn procedure (see «PCM IDLE LEARN PROCEDURE»(ref-360285-S23715037572010042800000) ).
27. Do the CKP pattern clear/CKP pattern learn procedure (see «CKP PATTERN CLEAR/CKP PATTERN LEARN»(ref-360279-S39336907372010042800000) ).
28. Do the start clutch control calibration procedure (see «START CLUTCH PRESSURE CONTROL CALIBRATION PROCEDURES»(ref-360271-S04238261862010042800000) ).