Questions and Answers

Honda Accord EGR Runners II Q. I was reading your article about Honda EGR Runners. I have a 1992 Honda Accord EX with 370,000 kilometres on it and only recently did I experience EGR difficulties. The tech I spoke to wanted more than 2.5 hours to disassemble and clean the EGR ports with a special tool. I know there is a kit available, however when I spoke to their service department, they told me that drilling out the brass plugs would force debris into the intake and create more problems than necessary.

What is the real story here? If my EGR plugs are fouled, then scraping them out would no doubt put small scrapes on their surfaces. The wanted to clean it with brake fluid and this special tool.

Would it cost less to have a new fuel runner purchased and installed, complete with new brass EGR plugs? I would appreciate what insights you may have on this repair, as scraping seems to be the only preferred method.

Thanks...

A. I rechecked the original TSB and, with the exception of some part numbers, it is the same. I included the updated tool and parts lists here.

PARTS INFORMATION:

• O-ring: P/N 16077-PR3-005, H/C 3147568
• O-ring: P/N 91304-PE2-005, H/C 1869460
• Gasket: P/N 36455-PT3-A01, H/C 3583697
• EGR port plugs: P/N 17199-PT3-AHM, H/C 6078596

REQUIRED SPECIAL TOOLS:

EGR Plug Replacement Kit, P/N 07WAZ-001000A, Includes:

• Slide hammer
• 10-24 threaded screw
• No. 25 drill bit
• 10-24 tap
• 30 replacement plugs

This Special Tool kit is available for purchase through the normal parts ordering process. The kit is also available through the American Honda Special Tool Loan Program. For details see Service Bulletin 98-051.

Kit contents:

• Slide hammer (dent puller type) - OTC P/N 898 (Call OTC, [507] 455-1480, for local distributor)
• 10-24 x 3 in. screw - Local purchase
• No. 25 drill bit, 6 inches long) - J & L industrial P/N DAC58125-C (Call J & L Industrial, [800] 521-9520)
• 10-24 tap (6 in. long) - J & L Industrial P/N RNE-38342-E

Unless there has been some radical new procedure for removing blind plugs, drilling and pulling them are the only way to remove them in this case.

The EGR runners are part of the intake manifold so replacing them involves the replacement of the whole intake manifold. I would just follow the procedure as outlined and you will be alright.