[tekcajwolley]

2002 Insight Hybrid Hybrid

I installed a ~ 2004 RSX Base k20a3 engine, 2003 Accord 5-sp M/T into a 2002 Honda Insight.



This is not my first rodeo. I have swapped many Hondas:
1. ‘89 integra 1.6l dohc into ‘86 CRX SI.
2. ‘00 1.6l sohc port into a ‘91 Civic 1.5l throttle body.
3. ‘96+ 3-stage VTEC into a ‘93 Civic.
4. ‘96+ b20b into 97 Civic EX.

Every one of these I’m quite proud of. All of them except the ‘93 my daughter wrecked. I guess I kinda like Hondas.

I am not the first to install an Acura engine into a Honda Insight. The project began much differently - I had planned, and attempted, to swap a 2007 Civic r18 in but couldn’t get past immobilizer. So I scrapped that idea and began researching converting it to EV, which I’d wanted an ev project all along. But even back in 2017 battery prices were just too high to make that all practical. I did some good research though.

I didn’t want to make a hot rod as so many Insights had become. I’m just not into racing. But with the wealth of write-ups on this changeover, it was nice to be able to borrow from the work of so many others. And it is appropriate to mention the main benefactors here: Ecky is probably one of the best known and generous with information. Thank you. Mike from Awesome Racing had a great write-up. MakitaDiesel has shared many of his struggles. John Frana. Thanks to all of you and to everyone who contributes to these forums.

Writing has not come easily to me recently as I went thru a dark spell. Part of that has to do with connecting to people. ADHD. Yet I have benefited from the generosity of many on these forums. But a difficult project like this has been good.

I have always liked the ideas I’ve found reading various articles in the Temple of VTEC over the years. I watched the development of the K and R series engines. I liked the R series because of the Atkinson Cycle design, the ceramic cylinders, and electronic throttle. This is why I thought it’d be a great candidate for “hybridizing” the Insight. It was so disappointing that immobilizer couldn’t be hacked though.

So reluctantly I chose the k20a3 after many failures elsewhere. But it has such great aftermarket support. And this vast wealth of information made my swap much easier. Why re-invent that wheel? I chose the a3 because I figured it was the most efficient of the series. It is essentially VTEC-e with cam phasing.



I installed the 3.4:1 ratio final drive into a 2003 Accord 5-sp M/T, using the accord shifter and cables, and all new bearings and synchros. I followed the example of Mike at Awsome Racing with his ball joint bushing upgrade that allows ~ 2000 Civic spindles and brakes. Glad I didn’t have to engineer that. Braking under high speed downhill, they have worked very well, shutting it right down.
I used 2000 Civic SI 15” wheels with the tallest profile tires that would fit reasonably well in the wheel holes. I can easily drive 70 MPH at very low engine speed. ( can’t remember the specifics here as the car has been in storage a while - more on that later.). But I was interested in low r’s at highway speed. One reason I chose the RSX a3 is for the dual plane intake - the long runners enable higher torque at low speeds. And its low end torque I was after.

This is a very fun car to drive. One night on Donner pass….. ��



The a3 is a rough engine. I’ve read complaints in the RSX forums. The left and rear mount are stock Insight CVT. The right is from Ktuner, I believe. I’m 67, OK? The brackets are all mine though. I built a special wood stand, sat the engine/trans on it, leveled it all up, made templates, then cut out and welded everything up right there. Good ol’fashioned farmer engineering. Seriously, they are very good brackets.






To try to minimize cabin noise I stuck 2 layers of that stick-on black foam insulation on the floors and firewall, one layer in other places such as the door panels, roof and tank bulkhead. I sprayed some rigid foam in some of the remote crevices and railings. In the back I put down 1 1/2” rigid foam under the new plywood floor, and between the floor and lower fairings. It helps a lot but we have to face it, this was never intended to be soft. This is as raw a car as I’ve driven. But very rewarding.



Glad to answer almost any questions.

I’ve recently moved from western Colorado to western Nevada, and that first night driving it out here along I70 thru Utah and highway 50 thru Nevada at some high speeds, that engine just wanted to wind out. Amazing cars to drive! At speeds well above 65 �� !!! (Across 2 states) I still got 41 mpg that night! That’s only possible having access to the fuel maps with certain aftermarket ECU mods.

Throughout the build I have stayed close to industry standards, including trying to be faithful to federal EPA emission standards. The car has a federal EPA emission sticker so I tried to do everything I could to at least have the option to pass inspection at some point.

Now I’m considering a move to California. I understand I can take with me my federal EPA certified Nissan Frontier and license it there with federal emissions (After a visit to the smog referee). I have been reading the California BAR SmogCheck manual regarding swaps (engine changes) and it seems that because I built this car in Colorado years ago as a 49 state emissions qualifier, I should be able to take it into the state under the same circumstances as my Frontier. I can document everything, but after some initial calls to the referee’s office, I’m not so sure.

I realize there are people that concoct ways and means to circumvent emissions (and others) laws. I felt as though I was guilty by association because I mentioned “engine change”. I try to put myself into the shoes of the person (s) appointed to enforce the laws, but I really felt battered after the 2nd call. I’m sure many who do swaps have little intention of obeying even the spirit of the law. But I do. Psychs say one should not carry old baggage from one relationship into the next, and I got the distinct impression I was a nail addressing a very big hammer.

But I took decisive and expensive steps to make this car conform to federal laws from the start. But it’s feeling like an uphill climb every time I talk to these folks. Just not feeling good about this.

It seems my options are these:
1. Do whatever is necessary to pass smog in California (legally) at whatever expense. There are some things need fixed (Stock ECU, EVAP, VTEC switch, rear O2, etc). I’m 67, and don’t have access to a shop anymore. Just a driveway in a respectable neighborhood.
2. Continue the registration in Nevada while living in California. Probably not a good idea. I really don’t want to be looking over my shoulder.
3. Keep it in storage and some day electrify it. Go EV. Expensive and extensive. (Although I do see potential ways to make it a short range grocery getter.)
4. Sell it at whatever loss and make someone a great deal on a really great rare fun car. There’s someone out there contemplating something like this. PM me! ��
5. Part it out.
6. Give it to my ex. ��

I can tell you there is absolutely no better commuter car, ever. If you live out in more rural areas, driving somewhere to work, this IS the car I would want. NO ONE rolls coal on this car! 50+ MPG.

Please, please offer me some feedback here.

Sorry about the pics not showing.