2011 Honda Insight BaseFACTORY OEM SERVICE PROCEDURE

Engine Block

ENGINE BLOCK SPECIFICATION

Item Measurement Qualification Standard or New Service Limit
Block Warpage of deck   0.07 mm (0.003 in)max. 0.10 mm (0.004 in)
Bore diameter   73.000-73.015 mm (2.8740-2.8746 in) 73.065 mm (2.8766 in)
Bore taper Limit: (difference between first and third measurement) - 0.05 mm (0.002 in)
Reboring limit   - 0.25 mm (0.010 in)
Piston Skirt O.D. at 16 mm (0.6 in) from bottom of skirt   72.969-72.979 mm (2.8728-2.8732 in) 72.967 mm (2.8727 in)
Clearance in cylinder   0.021-0.046 mm (0.0008-0.0018 in) 0.05 mm (0.002 in)
Piston ring Ring-to-groove clearance Top 0.065-0.090 mm (0.0026-0.0035 in) 0.15 mm (0.006 in)
Second 0.030-0.055 mm (0.0012-0.0022 in) 0.12 mm (0.005 in)
Ring end gap Top 0.15-0.30 mm (0.006-0.012 in) 0.60 mm (0.024 in)
Second 0.30-0.42 mm (0.012-0.017 in) 0.65 mm (0.026 in)
Oil 0.20-0.70 mm (0.008-0.028 in) 0.80 mm (0.031 in)
Piston pin O.D.   17.996-18.000 mm (0.7085-0.7087 in) -
Pin-to-piston clearance   0.010-0.017 mm (0.0004-0.0007 in) -
Connecting rod Pin-to-rod interference   0.019-0.036 mm (0.0007-0.0014 in) -
Small-end bore diameter   17.964-17.977 mm (0.7072-0.7078 in) -
Large-end bore diameter Normal 43.0 mm (1.69 in) -
End play installed on crankshaft   0.15-0.35 mm (0 006-0 014 in) 0.40 mm (0.016 in)
Crankshaft Main journal diameter   49.976-50.000 mm (1.9676-1.9685 in) -
Rod journal diameter   39.976-40.000 mm (1.5739-1.5748 in) -
Rod/main journal taper   0.005 mm (0.0002 in)max. 0.010 mm (0.0004 in)
Rod/main journal out-of-round   0.005 mm (0.0002 in)max. 0.010 mm (0.0004 in)
End play   0.10-0.35 mm (0.004-0.014 in) 0.45 mm (0.018 in)
Runout   0.030 mm (0.0012 in)max. 0.040 mm (0.0016 in)
Crankshaft bearing Main bearing-to-journal oil clearance   0.018-0.036 mm (0.0007-0.0014 in) 0.050 mm (0.0020 in)
Rod bearing clearance   0.026-0.044 mm (0.0010-0.0017 in) 0.050 mm (0.0020 in)
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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