Honda Insight w/Acura TSX engine - Ecomodding

[Ecky]

Wow, that's quite a wide range of oils!

[19bonestock88]

Yeah, makers usually spec a summer weight and a winter weight if they spec more than just one at all...

[Ecky]

For those part of the K24 Insight group, Brian Gilispie (owner? at Hasport) posted a video last night showing his completed prototype Insight mounts:

https://www.facebook.com/groups/1890...group_activity

I'd also like to share the most recent email I sent to the shop I'm working with:

Originally Posted by ecky

Here's a consolidation of the previous emails we exchanged:

You ordered:
-TSX transmission
-03-07 Accord throttle body
-02-05 Civic front lower control arm ball joint adapters
-Rywire or Wireworx or CJs harness adapters
-Clutch
-TSX long block (alternator, I/H/E)
-Flywheel
-RSX-S engine harness
-RSX-S ECU

I ordered:
-2012 Civic Si 6th gear (?)
-50 degree VTC gear + limiting pin
-3.4 final drive
-OEM Civic Si LSD
-Replacement front springs with higher spring rate

Still need:
-Kpro for RSX-S: https://www.hondata.com/kpro/kpro-product

-RSX-S wideband O2 sensor - https://www.amazon.com/dp/B000C5UFVM..._t1_B001F7GJNE

-Downstream O2 sensor - https://www.amazon.com/Denso-234-412...n+sensor+denso

-EM2 or EP3 spindles (4 lug EP3 is 2002-2003)

EP3 passenger: https://www.ebay.com/itm/2002-HONDA-...US!-1#viTabs_0

EP3 driver: https://www.ebay.com/itm/2002-HONDA-...ry!05446!US!-1

new bearings and hubs (pick out a good one): https://www.rockauto.com/en/catalog/...+assembly,1636

-02-05 Civic calipers (pick one out that's powdercoated please): https://www.rockauto.com/en/catalog/...b,caliper,1704
It looks like Power Stop has red powdercoated, and Beck/Arnley and ACDELCO both have black powdercoated. I'm not picky about color, but the rust protection is nice.


-02-05 Civic rotors: https://www.rockauto.com/en/catalog/...hub,rotor,1896
Pick out something coated. Bosch Quietcast are coated, looks like there are good options from Wagner, Power Stop and ACDELCO too.

-02-05 Civic brake pads (your choice, something good): https://www.rockauto.com/en/catalog/...brake+pad,1684


-A/C compressor - I checked and the Accord and TSX A/C compressors aren't cross compatible. Here's the correct one for the TSX:
https://www.rockauto.com/en/catalog/...ompressor,6628

RockAuto has the receiver/drier for the Insight for $8: https://www.rockauto.com/en/catalog/...cumulator,6972
$13 for one on Amazon: https://www.amazon.com/s/ref=nb_sb_n...+SEASONS+33595

-Swivel thermostat housing: https://www.ebay.com/itm/K-MOTOR-Swi...MAAOSwDZ1bEYWx

Tensioner bracket, pulley, belt (hydro PS delete): https://www.rockauto.com/en/catalog/...nent+kit,10660

Engine rear main seal: https://www.g1parts.com/oem-parts/ho...ZC1tYW51YWw%3D

Engine front main seal (behind pulley): https://www.g1parts.com/oem-parts/ho...1hbnVhbA%3D%3D

Transmission rebuild kit (seals, synchros, bearings):
https://www.heeltoeauto.com/drivetra...sk-syn11..html
^ The transmission is from a 2004 TSX with triple cone 1-2 and dual 3-4-5-6

-The Insight's shift box won't clear for reverse, needs one of the rods cut, shortened (?) to move all of the gears slightly to the left. Either cut and weld, or perhaps just cut and thread the rod, and get a double threaded nut

-Charging harness (TSX or RSX) (may or may not have come with engine harness)

-Might also need an aftermarket fan switch? not sure yet

-Hasport mount kit if it's available yet, otherwise fab up custom mounts. I need you to figure this one out. The Innovative mounts not only are garbage in how they fit, but they also don't last, so please use a proper rubber mount as a base. RockAuto has a lot of inexpensive choices to choose from.

-axles will be specific to engine placement, will only know after the engine is mounted

-64mm / 2.5" exhaust, stainless or aluminum if not too expensive
-catalytic converter - whatever fits, either behind the engine or in the exhaust tunnel

-resonator/muffler, make it as quiet as you can, I'd strongly prefer "OEM quiet"


Would be nice:
-stainless steel brake lines

~
Some useful threads on how to do the swap:


K20 powertrain change - narrative documentary: https://www.insightcentral.net/forum...cumentary.html

Attempting to build the Ultimate Insight......Lets see what happens:
https://www.insightcentral.net/forum...t-happens.html

I have a very good map which should work well as a base map for the engine once you get the KPro in.

Let me know if you have any questions, or feel I'm missing something.

[Stacygifford]

The TSX and accord ac compressors may not be cross compatible, but the accord compressor definitely bolts up to the the TSX engine no problem. As far as lines go, not sure. With the accord compressor, only one line (the shortest one) has to be modified.

I do have to ask about the 2nd o2 sensor though. Why run it? It doesn't effect how the computer works and only monitors the function of the cat. And you can easily disable it on kpro.

Seems like extra work/cost with no benefit. I could be missing something though.

[Ecky]

Maybe I'll pass on the 2nd O2 then. Vermont's state inspections aren't so thorough that they'd notice, but it might be nice to have in case I move somewhere that will.

[Ecky]

Spent some time agonizing over where to mechanically limit VTC advance (variable exhaust cam timing). Supposedly a full 50 degrees of advance is safe, but barely, on the 06-08 K24A2 (which came from the factory with only 25 degrees of adjustment). The 04-05 K24A2 motor actually has slightly less aggressive cams, but the pistons' relief for the valves is smaller and it's possible under some circumstances, such as catastrophic oil pressure failure, or mis-shifting and over-revving the motor, where a full 50 degrees of potential advance might cause the valves and pistons to collide. 45 degrees is supposed to be safe, but I couldn't find any hard data, so I opted to limit it to 40 degrees.




Supposedly allowing another ~15-20 degrees of cam advance is good for 20 ft-lbs of torque across the rev range.

[lennyspecv]

Where do get the VTC kit that has a limiting pin?

[Ecky]

I bought mine on eBay:

https://www.ebay.com/itm/Honda-Acura...72.m2749.l2649

The gear itself I got on Facebook, a guy one one of the K20 groups tears apart junkyard cars and has a whole bucket full of them.

[lennyspecv]

Thank you. I didn’t know their was an issue with full 50-degree advance on the k24. Glad I read this thread.
Do you mind sharing the name of the K20 group or his name so I can a gear too? Hopefully a better deal than new.

[Ecky]

I'm a member of:

K series For Sale and Discussion SoCal
Honda SFWD
K series Insight Group K20/K24