Repair Procedure

1. Drive the vehicle onto a hoist, but don't raise it yet.

2. Make sure you have the anti-theft code for the radio, then write down the radio station presets.

3. Disconnect the negative cable from the battery.

4. Raise the vehicle.

5. Remove the splash shield.

6. Open the coolant drain, and drain out the coolant into a clean container.





7. Remove the bolts from the exhaust pipe to the catalytic converter and from the brace.





8. Remove the bolt from the lower center radiator support.

9. Lower the vehicle.

10. Remove the two nuts and one bolt from the engine cover, and remove the cover.





11. Disconnect the two oxygen sensor connectors.

12. Remove the three nuts mounting the catalytic converter to the cylinder head. Remove the catalytic converter.





13. Insert an air nozzle into the exhaust port. Seal the nozzle to the port as much as possible with a shop towel. Do not turn on the nozzle.

14. Remove the bolt, then remove the intake air duct from the air cleaner housing.





15. Remove the PCV hose from the cylinder head cover.

16. Remove the vacuum line from the fuel pressure regulator.

17. Remove the throttle cable from its bracket.

18. Remove the intake air pipe from the throttle body.





19. Remove the A/C condenser fan shroud.

20. Remove the breather pipe from the air cleaner housing.





21. Remove the bolts and nuts holding the intake manifold. Leave the manifold in place for now.

22. Remove the two mounting bolts, then remove the harness bracket from the upper water pipe.

23. Remove the two mounting bolts, then remove the upper water pipe.

24. Remove the EGR valve connector.

25. Remove the two EGR valve mounting nuts, then remove the EGR valve.

26. Remove the water pipe and the air hose from the intake manifold.





27. Secure the intake manifold out of the way on top of the cylinder head cover.





28. Remove the driver's side EGR valve mounting stud.





29. Remove the four radiator support bolts.

30. Unclip all harnesses connected to the radiator support.





31. Move aside the radiator support.





32. Lift up the radiator slightly, and then slide it down until it is below the top of the AC condenser.





33. Apply brightly colored tape 120 mm from the tip of a 3/8 inch drill bit that is at least 7 inches long.

34. Apply oil to the drill bit up to the tape.

35. Place a shop towel underneath the EGR port to catch the aluminum chips from the drilling process.

NOTE:
Be sure to wear proper eye protection when performing this procedure.





36. Insert the drill bit into the EGR port. Run the drill motor at 250 rpm while applying moderate pressure. Drill approximately 2 mm, then remove the drill from the port, and remove the chips from the bit.

37. Re-apply oil to the drill bit, and repeat step 36 until the depth of the hole is almost to the 120 mm tape line.

38. Have an assistant apply 50 to 60 psi air pressure to the exhaust port while you continue drilling until the bit goes through. DO NOT drill any farther.

39. Remove the drill bit from the hole. Have the assistant continue to apply air pressure to the exhaust port for 15 seconds.

40. Insert the nozzle on a can of brake cleaner into the EGR port. Place a shop towel around it and squirt brake cleaner into the port for 2 seconds while continuing to apply air pressure to the exhaust port.

41. Continue applying air pressure to the exhaust port for 15 seconds after you stop spraying the brake cleaner.

42. Check the EGR port with a light to confirm it is clean and drilled completely thru. Repeat steps 40 and 41 if needed.

43. Reinstall all removed parts.

44. Refill the coolant.

^ Refer to page 10-11 of the 2000-2006 Insight Service Manual, or

^ Online, enter keyword COOLANT, and select Coolant Replacement from the list.

45. Enter the radio anti-theft code, and then enter the radio station presets. Set the clock.

46. Do the idle learn procedure.

^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off.

^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice).

^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes.