The Check Engine Light Came On On My 2000 Accord At 51,000 Miles. The Diognositc Said To Change The Egr Valve And Reset The Light. I Did That And It Came Back With The Same Trouble Code. Is This A Common Thing? I Checked All The Wires From The Valve To The Computer And They Were Fine.

I bet your egr ports are clogged. I'm pretty sure it's an emmision recall which the dealership should do at no charge. The bulletin# is 99-085 i can post the content tomorrow.

thanks i appreciate it!!!!!!!

Here is the first page of 3, i can email you the other 2 if your car isn't under the 8yr/80K warranty. It does involve drilling the intake manifold.


2000 Honda Accord EX Coupe V6-3.OL

Vehicle: All Technical Service Bulletins
Recall - DTC P0401 EGR Flow/EGR Port Clogging

99-085

October 26, 2001
* Applies to:
1998-00 Accord V6 - ALL,
2001 Accord V6 - 4-door from VIN I HGCG I ... I AOOOOO I thru I HGC(I I ... IA058564 2-door from VIN I I-IGCG2... I AOOOOO I thru I HGCG2... IA023388

Updated information is shown by black bars and asterisks.
Accord Warranty Extension: EGR Port Clogging
(Supersedes 99-085, Product Update Campaign: PCV Hose Routing, dated March 21, 2000)
BACKGROUND
In some areas of the (U.S., certain basic chemical properties of gasoline (regardless of brand) may cause the intake manifold EGR port to clog or the EGR valve to tail. If this happens, the MIL comes on with a DTC P0401 (insufficient EGR flow) or P 1491 (insufficient EGR lift) stored.

* WARRANTY EXTENSION INFORMATION

This warranty extension cancels the PCV hose routing Product Update Campaign. You should no longer install the PCV hose routing kit.

American Honda is extending the warranty on EGR system problems in the affected vehicles to 8 years or 80,000 miles, whichever comes first. To be eligible for coverage under this extended warranty, the MIL, must be on with one of the above DTCs stored. Install the EGR pipe kit, and file a claim using the information in this service bulletin.

CUSTOMER NOTIFICATION

1998-99 vehicles - Owners of vehicles that were subject to the PUD will be mailed a letter explaining that the PUD has been cancelled, and detailing the 8 year, 80,000 mile warranty extension covering EGR system clogging.

1999-01 vehicles - The original PUD applied to V6 Accords through the first part of the 1999 model year. This warranty extension adds the remainder of the 1999 model year, all of 2000, and part of the 2001 model year. Owners of vehicles that were not involved in the original PUD will be mailed a letter detailing the 8 year, 80,000 mile warranty extension covering EGR system clogging.
Examples of the customer notifications are at the end of this service bulletin.
CORRECTIVE ACTION
Clean the EGR port, and install the EGR pipe kit.
PARTS INFORMATION
EGR Pipe Kit: P/N 06175-P8C-AOO, H/C 6912125
TOOL. INFORMATION
EGR Pipe Installation Kit: T/N 07ZAD-P8AAOOO

Kit contents:
EGR pipe installation tool T/N07ZAD-P8AA100
Drill Bit T/N 07ZAH-P8AA100
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies
OUT of warranty

thanks, but the car isnt under Warranty any more, i bought it from a private seller, but if i can get the directions i can do it myself...

It doesn't matter if you bought the car from a private seller, auto auction, dealer, won the car, etc. it still has the warranty extension for 8yrs or 80,000 miles which ever comes first.

If you still need the other 2 pages send me a PM with your email address, or I can just post it here since it will be helpful to MANY people. Drilling the intake could be a bad thing for some people in which case they should take to some one. In case any problems there is some one to blame and to cover the costs of extra repairs.

I will post it or email it tonight when I get home.

2000 Honda Accord EX Coupe V6-3.OL Page 2

Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office e.
You must request consideration, and get a decision, before starting work.

REPAIR PROCEDURE

1. Remove the throttle body cover, intake manifold covers, ignition wire holder, and ignition wire cover.

2. Disconnect the brake booster vacuum hose and the vacuum hose from the intake manifold.

3. 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.

4. Remove the PCV valve from the cylinder head cover. Remove the intake manifold (three nuts and six bolts).

5. Remove the intake manifold chamber, IAT sensor, boost plate, and PCV hose from the intake manifold.

6. Cover the six ports on the bottom of the manifold with duct tape.

7. 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.

8. 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.

9. 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 oil the drill. Make sure the port is drilled through completely.

10. Clean up the aluminum chips from drilling, then remove the duct tape.

11. 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 IO 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.
12. Place the EGR pipe from the kit into the EGR port.

13. 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.

14. Install the intake manifold chamber; torque the nuts and bolts to 12 Nm (8.7 lb-ft). Install the IAT sensor; torque it to 18 Nm. (13 lb-ft). Install the boost plate; torque the bolts to 12 Nm (8.7 lb-ft). Install the PCV hose.

15. Inspect the EGR port in the front of the injector base on the engine. If it is partially or fully clogged, clean the port.

16. Disconnect the 6P connector from the EGR valve. Remove the EGR valve.

17. Install the new EGR valve with a new gasket. Torque the mounting nuts to 22 Nm (I 6 lb-ft). Reconnect the 6P connector.

18. Install the intake manifold with the original gasket. Torque the mounting nuts and bolts to 22 Nm (I 6 lb-ft) sequentially in two or three steps. Route the PCV hose so it is not pinched under the intake manifold.

19. Install the PCV valve in the cylinder head cover.

20. Install the throttle body with a new gasket. Torque the mounting nuts and bolts to 22 Nm (I 6 lb-ft).

2000 Honda Accord EX Coupe V6-3.OL Page 3


21. Reinstall the brake booster vacuum hose, vacuum hose, ignition wire holder, and all of the covers.
22. Connect the PGM Tester (loaded with SN200 or later software). Clear any DTCS.
23. Use the PGM tester to override two-trip error detection.
^ From the PGM tester menu, select 1. Honda Systems.
^ Then select 2. SCS.
24. Test-drive the vehicle to make sure no new DTC’s are set.

Just got a used 1999 Accord and am having the P0401 code thrown. The previous owner had similar issues, but just ignored it after replacing the EGR valve a couple of times.

I am going to install the EGR pipe kit per the recall/warranty extension item listed above. However, the Honda dealership want's $90.00 for the install kit which consists of a special drill bit and a driver tool for the EGR pipe. They won't rent me the tools. The service manager said that his service guys just use regular carbide drill bits.

Anyone know if it can be done without that kit and if so, what size is the drill bit? Alternatively, I'd appreicate a cheaper source for the install kit.

Thanks much!

standard bits will work just keep it lubed to prevent galling, then drive the s/s sleve into place. Pathetic fix I must say.

I ended up buying the kit for $85.00 then sold it for $65.00. The guy that bought it has used it and is now selling it. I have his contact info if anyone wants it.

You **could** do it with a standard bit if you can find the exact size AND you are comfortable drilling aluminum freehand with a steel bit. I was not. It doesn't take much of an error to ruin aluminum or get the hole started off center.

To each his own...I'm out $20.00 for the use of the tool and it helped tremendously.