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Hi, Thanks in advance! 2010 Honda Insight LX

I found a problem in the summer. BOTH the A/C condenser fan and engine cooling (radiator) fans were not working as they should.

Backstory/discovery: I am in Canada, so the amount of time this took to discover was several months. I rarely need A/C, and I it did work a little bit - I assumed that the A/C maybe had leaked, and was not in a rush to have it fixed. Then, one day the engine overheated and stalled on a HOT summer day in heavy traffic (no air blowing over the radiator due to no forward momentum). Also, there is NO engine temperature guage on the dash to indicate the engine was overheating. These issues could have been present for a very long time, even since I bought it used around 2016.

I immediately took the car to a shop to look at the engine stalling issue, and was told both fans needed to be replaced because the blades were broken off the shafts. They had no parts available, I didn't trust the shop, and I needed my car - so I drove away. When I got home, I looked for parts online and, after a few days, I looked under the hood myself. I found that the fan blades on both fan motors were not connected, and it looks like the blades are attached by a (missing) screw, and not actually broken. I asked the shop, but they didn't know if they had disconnected the blades from the shaft.

Questions:

  1. It seems very suspicious to me that both fan motors would have their blades break or separate from the motor shaft. Is this common? Could this be a bad repair or even sabotage from long ago?
  2. Can these blades be re-attached (see picture below for example)? There is some damage to the teeth where the blades atach to the shaft, but nothing major at all.
  3. Perhaps the fan motors are still turning, but not connected to the blades? If I leave the car running, and run the A/C could I test the A/C condenser fan motor easily? Similarly, is there anyway to force the engine cooling fan to run to test that motor? It only runs if the engine temp is high enough.

Thank you!

Picture of one of the fan blades:

Wood Natural material Material property Rim Symmetry
 

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Welcome!

I don't have a Gen2, but this is kinda straightforward.

Search car-part.com, look for "Cooling Fan" under the parts choice list.

The damage suggests that turning motors ripped into the spline after the bolts loosened. I don't have a Gen2 for comparison. Easy enough to test by disconnecting and supplying power.

You could try finding a replacement bolt/washer and reattach, filling with JB-Weld to augment the interface to what's left of the splines and giving it a couple of days before trying it? But then you risk it failing unnoticed until the car is actually damaged by another overheat event. If you go this route, maybe use some thread locker on the bolts (I would use the removable stuff, not the "never take it out again" stuff.)

As to the question of malice, I can think of ways the bolts can loosen. Long ago, a tire shop did an unwanted "brake inspection"; I checked the brakes myself soon after to find that the dust boot around the calipers was displaced. Was the technician checking for a leak around the piston seals and forgot to replace it? or was it sabotage to ensure a speedier return? Who knows, but I do know that most (all?) of the time I was certain that fault fell on others, I eventually discovered (sometimes very uncomfortably) that it fell on me. So... fix it and give it no more thought!

Good luck!
 

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Hello. I just had a similiar issue, the driver's side fan was fallen off from the frame. Honda Insight ZE2 2009 LHD

Original part was out of question in the EU region, the price was overwhelming. I went on an bought these items for the project:
You will also need some cable-ties to fasten the new fan it at the bottom, or you can try and do it the right way with the Mishimoto fasteners, but that will need some more disassembly and maybe you are able to do it from the bottom by removing the plastic under plate. I was in a hurry so sorry for the lack of pictures and the lack of professionality.

INSTALLATION
1.
First you need to remove air intake hose and the top coolant hose. It would be nice if you can somehow plug or squeeze the hose, so that you do not need to add much coolant after. Be sure to add more coolant after this project and run the car hot without the coolant cap on to make sure you bleed all the air out of the system (HONDA TYPE-2 coolant).
(HOX!!! REMOVING THE COOLANT HOSE FASTENER WITHOUT A CORRECT TOOL IS A CHALLENGE, yet can be done with some universal plyers)

2.
Remove the wire at the top of the radiator fan frame, try not to break the plastic fasteners.

3. Remove the radiator fan frame and the coolant container, you need a 10mm socket for this.

4. Cutting the frame. So what I did I cut off the top and bottom part illustrated in this very awesome picture.
Font Wood Metal Grass Pattern


5. Cut the old connector wires and solder those to the new fan. Be sure to check in which way you want the fan to blow [+] and [-] . I soldered the wires the way that it blows to the radiator not away from it. If I remember correctly the Mishimoto black was [+] and mishimoto blue was [-]. Better to test it yourself.

6. I lowered the new fan in and let it sit at the bottom of the radiator. There is 2 places to attach the cable-ties to, the two places where the old fan frame was sitting in. I used cable-ties to attach the two lower fasteners, but leave them somewhat loose for now, because you want to attach the top first!

7. Attach the top part of the fan with the Mishimoto Electric Fan Mounting Kit mount tie kit. I used 2 of these funny looking cable-ties to attach the fan trough the radiator.

8. Tighten the cable-ties at the bottom and check that the new fan is correctly fitted and not wobbling/swinging.

9. Let the lower piece of the old radiator fan frame lie where it belongs, so you can lower the coolant container to that.

10. Attach the top part of the old modified frame back into where it belongs, and attach all the disassembled parts.

11. Be sure to add more coolant and run the car hot without the coolant cap on to make sure you bleed all the air out of the system (HONDA TYPE-2 coolant).

Automotive fuel system Motor vehicle Gas Auto part Automotive exterior


Hopefully this helps someone. It took around hour and a half to do this (mostly because I did not have the right plyers for the top coolant hose) :LOL:

Some crazy stuff this car is making us do.
 

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