Repair Procedures A and B
REPAIR PROCEDURE A: EGR VALVE REPLACEMENTNOTE:
This procedure is for 1999-01 Odysseys thru VIN 2HKRL18..1H586575 already repaired according to S/B 00-009, and all other vehicles within the affected VIN ranges.
1. Remove the intake manifold cover.
2. Remove the EGR valve and gasket.
3. Install the new gasket and EGR valve. Torque the nuts to 22 Nm (16 lb-ft). Reconnect the EGR valve connector, and install the intake manifold cover.
REPAIR PROCEDURE B: EGR PORT CLEANING AND INSTALLATION OF EGR PIPE KIT
NOTE:
This procedure is only for 1999-01 Odysseys thru VIN 2HKRL18..1H586575 not yet repaired according to S/B 00-009.
1. Verify that the HDS has software version 1.017.006 or later installed. Previous versions will not do this diagnosis.
2. Connect the HDS to the vehicle's 16P data link connector (DLC).
3. Turn the ignition switch to ON (II). Turn on the HDS.
4. At the screen prompts, enter the VIN and the odometer reading, and then verify the correct date/time.
5. Select the Mode Menu. Then select Honda Systems.
6. From the System Selection Menu screen, select PGM FI.
7. From the Mode Menu screen, select DTCs/Freeze Data, then clear any DTCs.
8. Remove the intake manifold cover. Unplug the ignition coil 3P connectors on the rear bank, then remove the rear ignition coil cover.
9. Disconnect the brake booster vacuum hose and the vacuum hose from the intake manifold.
10. Remove the throttle body from the intake manifold (two nuts and two bolts). Leave all hoses, cables, and electrical connectors connected to the throttle body. Discard the throttle body gasket.
11. Remove the PCV valve from the cylinder head cover. Remove the intake manifold (three nuts and six bolts).
12. Remove the end plates, the IAT sensor, and the boost plate from the intake manifold. If the PCV hose connects to the intake manifold instead of the end plate, remove the hose.
13. Cover the six ports on the bottom of the manifold with duct tape.
14. Use an 8 mm drill bit and carburetor cleaner to clean the EGR port in the intake manifold. Turn the drill bit only by hand. Do not use a power drill.
15. Put the special drill bit from the EGR pipe installation kit in your power drill. Coat the drill bit completely with clean engine oil.
NOTE:
The oil coating is critical to drilling the hole accurately, and it contributes to drill bit life.
16. Insert the guide part of the drill bit into the EGR port. Make sure it is inserted fully. Then drill out the EGR port using steady pressure on the drill. Make sure the port is drilled through completely.
17. Clean up the aluminum chips from drilling, then remove the duct tape.
18. Put the manifold in a parts washer (solvent or soap and water) and clean it thoroughly.
^ Flush out the EGR port for 20 seconds.
^ Flush out the manifold from the throttle body opening. Run cleaner down each side for 20 seconds.
^ Flush each intake runner for 10 seconds. Start at the throttle body end and work towards the back.
^ Turn the manifold so the throttle body opening is facing down. Flush each main runner for 20 seconds.
^ Dry the manifold with compressed air and clean shop towels.
19. Place the EGR pipe from the kit into the EGR port.
20. Use the installation tool and a small hammer to drive the EGR pipe into the port until it is flush with the port. Make sure the pipe will not contact the gasket after installation.
21. Install the end plates; torque the nuts to 12 Nm (8.7 lb-ft). Install the IAT sensor with the original 0-ring; torque it to 18 Nm (13 lb-ft). Install the boost plate with the original gasket; torque the bolts to 12 Nm (8.7 lb-ft). If necessary, install the PCV hose.
22. Inspect the EGR port in the front of the injector base on the engine. If it is partially or fully clogged, clean the port.
23. Disconnect the 6P connector from the EGR valve. Remove the EGR valve.
24. Install the new EGR valve with a new gasket. Torque the mounting nuts to 22 Nm (16 lb-ft). Reconnect the 6P connector.
25. Install the intake manifold with the original gasket. Torque the mounting nuts and bolts to 22 Nm (16 lb-ft) sequentially in two or three steps. Route the PCV hose so it does not get pinched under the intake manifold.
26. Install the PCV valve in the cylinder head cover.
27. Install the throttle body with a new gasket. Torque the mounting nuts and bolts to 22 Nm (16 lb-ft).
28. Reinstall the brake booster vacuum hose and the vacuum hose. Connect the 3P ignition coil connectors, and install the covers.