Kswapping ZE1 Honda Insights

I had been driving the 2000 Insight from Texas Daily for monthes, Learning everything about the Honda IMA system, the 1.0 ECA1 3cylinder engine, and Hybrid technology in general; I was in love! Yes the car was slow, its looks were… questionable… but it was Fully Aluminum with Plastic Fenders, had the rear spats, Super light Stock Alloy wheels, the lightest spare tire i had ever seen, a Digital dash that was much like my S2000 (but I actually liked the bolder number font better), and was saving sooo much gas!

the more i learned about these cars, the more i loved them.

Developed in 1999, Honda used race technology to create their first hybrid, with the idea that a race inspired chassis and car that was similar to full race car would make most efficient hyper miler. they banked on the absolute Best Drag Coeffient and lightest chassis, weighing in at 1850lbs stock with AC! they went so far with the aero, that these cars already came with a flat underside thanks to long plastic panels that smoothed out the bottom of the car, and a rear track that was actually 4inchs narrower than the front (an annoying and garish fact that we would fight to correct in the future).
The ZE1 honda insight actually was manufactured at the same Plant as the first generation NSX and the First few years of S2000. It shares the same steering wheel design as the s2000, though made of foam instead of leather wrapped like the s2k, a s2000 steering wheel bolts right on.
the chassis code ZE1 was actually revisited by Honda later for the CRZ, as it bears a striking resemblance to the 2000-2006 Honda insight, but with the CRZ having the chassis code of ZF1; the insight has more in-common with it than the following second generation insight that was built off the honda Fit platform.
The insights also shared alot of similarities with the RSX and EP3, such as Fascia styling cues and struts with intergrated steering arms up front.

eventually i did end up pulling out the Honda insight Engine and meticulously cleaning it out as i replaced the metal on metal clutch which was fried from texas…. i cleaned out the EGR ports and noticed the designs of the engine, with an integrated oil pan made of magnesium that also served to re-enforce half of the engine. the oil pump is on the front, and the first years of the car have the same sandwich oil cooler/heater that the s2000 and RSX type S have. with the electric steering rack mounted on the fire wall and out of the way, and battery mounted over the engine on a removable re-enforcement beam, there was a lot of possibility in the tall stock engine bay, especially with the ECA1 being a timing chain engine much like K-series and having the intake at front of the car, with exhaust by the firewall; the would be no need to dramatically alter Engine Mounts like when K-swapping an Integra or other older Honda

Unfortunately, after fixing the clutch on my insight and enjoying it, the Transmission lost a Gear, due to using the wrong weight oil…. The transmissions in these cars are so squashed to compromise on room, they really arent very good, especially with their long shifter throws, and incredibly long gearing, sometimes needing to downshift even into 1st gear at many times.. But i was able to contact a member of the Insight Central Forums in the next state over in Pennsylvania who had a stock 5 speed for sale, and for a quick $300, were we already picking it up. He was in the process of Kswapping his insight and we quickly became friends, as he liked my style; seeing how i had completed the double din radio head unit using parts from japan and was watching movies on my Kenwood head unit while driving to pick up the transmission.

But later, more misfortune would befall me, as i was was checking my radiator cap; only to be distracted by my exwife who needed her motorcycle mirrors or something adjusted (a hobby she needlessly picked up after i told her not to…) and after that, she immediately needed to attempt going for a ride; which meant she needed my friend Dave to ride the bike for her to a parking lot while she rode passenger with me in the insight there so she could practice when we got there.
now in all that hurried commotion, i had untorqued the radiator cap like a noob and once distracted, had forgotten to tighten it… (tip to everyone, if you ever need to check your coolant level, you only need to lift you overflow tank {if u have one, if not, thats another issue to address on modern cars we have learned} never open ur radiator cap, unless to bleed or emptying/filling a ready to empty or already emptied system)
And i had driven a few days with the radiator half on, until one day on the way home from work, i saw my car overheat… luckily a friend driving the same way was able to get me some water and i filled it back up to get home.
eventually i realized the system was still overheating, and one drive down to valley view in ohio with the exwife, saw the engine massively overheat trying to get back up that lonnng steep hill, so bad in fact that the CEL flashed! I had to pull over a few times to let the car cool down from overheating on that 15min drive home… and I had JUST added a new Aftermarket head Gasket to that engine… i knew it couldnt be blown…
but there were bubbles in the radiator with the cap off, and it kept overheating when idling….

Driving with the Radiator cap half on, had initially blown it off when pressure increased. Upon finding the cap in the engine bay, i should have checked it, because it had broken the spring under the cap and was no longer working properly; which caused the radiator to not hold pressure, and the insights are set to run at high coolant temps, fan coming on at 215f
Add to that fact that Aftermarket Headgaskets are NOT as strong as OEM Honda head gaskets..

The Engine had a blown headgasket

So i was able to source another 5speed honda insight from Poughkeepsie New York, a 2001 in New Formula red, which i Immediately stole the stock ECA1 and 5speed engine from to put into my Silverstone 00 insight which matched my s2000; Leaving that Red insight empty and parked on the side of my garage for monthes…
until
I saw that my insight central friend in PA had recently got his Kswapped silverstone insight Rear-ended and totaled…. But, it still ran and he was selling it for $3500 with a salvage title, so i paid him in full and he delievered the car in a snowstorm during winter on the back of a trailer with his honda ridgeline.

I broke down the silverstone insight, piece by piece, and saved as many parts as i could and scrapped the rest of the aluminum for $200 in scrap, cut up enough to carry in pieces in the back of my volvo 740 wagon. The engine, EP3 coilovers, and Knuckles were ready to put into my Red car that was just waiting for it.

And in 2015, after the passing of my father, i had to accomplish something.. i absolutely HAD to get the swap completed, and was able to finally complete the wiring and get the kswap to start in my red insight.

i daily drove that car right into 2017 when i trained in PDR in Chambersburg PA, until that car got Totaled by an incoherent Audi Driver who made a left hand turn right into the driverside wheel, knocking it off and destroying the hub…
i was able to complete the PDR training and rent a car, keep the car at my trainer’s shop, and come back with my volvo and pick it up after buying it back from insurance. I towed it home, got the kswap out and copied it and the wiring exactly, learning how to understand the hardest part about K-swapping an insight, Removing knuckle Ball joint to allow the insight A-arm which has a Ball Joint to mount to the K-series RSX/EP3/EM2 knuckle since they all already come with a pressed in Ball Joint; but the insight knuckles dont, because the insight Ball joint is on the A-Arm instead. Since u cant have 2 Male Ball Joint assemblies, one has to go, and by removing the one from the K-series knuckle, you can cut apart the insight knuckle to get the bushing and weld it into the K-series knuckle so that it will properly hold the insight Ball Joint on the A-Arm.

that was the biggest thing stumping most ppl from K-swapping an insight back in the day. ‘how to do the knuckles’, and i had it fully written up and posted on my instagram @tigerroadperformance

it would be years before the swap got popular enough for me to no longer have to prove to ppl at carshows that it was possible. now days everyone comes to expect it, but back then, it was fun blowing ppl’s minds.

my best and cleanest kswap got an article on Jalopnik and millions of views, it had custom Tigerroad V3 Switchback DRL and LED turn signals, an F1 rear brakelight to keep the tiny car seen, and a Custom stock Dash Shift light that told u exactly when to shift as the Tach did not fully show revs after VTEC. It had a double din radio, and i had learned how to deal with the innacurate speedo by correcting it with a Yellow Jacket calibrator. It had a back up camera, and my other (less clean) Ksight even had a front camera, wing, and mustang louvers.

By 2019 i had K-swapped 3 honda inisghts