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Discussion Starter · #1 ·
Well, yesterday I spent about 8 hours working on the Insight and I took a few pics along the way. Just thought I would share some of them.

First is the dreaded EGR plate and EGR valve modification.
Here it is all set up and ready to go. After some reading, I decided to off shoot the center of the hole to get a better blast of the cleaner.
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Here is the place where I drilled the hole and sprayed the solution in. On a side note, BE VERY CAREFUL IF YOU DO THIS!!! IT IS VERY EASY TO PUNCH THRU LIKE I DID!!!! I thought I broke my EGR valve, but after a 20 minute test drive, no problems and the herky jerk is gone!
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As for my EGR plate, after having nearly 80,000 miles on it since new from the factory, it was not as bad as some of the photos i have seen on here. here is a cleaned version.
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As you see the HondaBond in the picture was because of this, I reused the original OEM EGR gasket since it looked very good and I just smeared some Honda Bond on it. I stand by this stuff!! I've used it on all my motors and it is great!
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Discussion Starter · #2 ·
Now for the sparkplugs!!

I've read plenty of the threads about the indexing of the plugs and I just wanted to try something a little different. I used the Denso Iridium IKH20 plugs and I marked my plugs prior to their removal with red paint. All my plugs were the B- indexed plugs.

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Each one of these plugs I marked the best I could with my paint pen. The mark was facing towards the firewall so I could see which way the open end of the plug faced towards the engine. They all faced in the general same direction. My mark on the plug is the 12 noon position, the open end of the plug faced the 1600 (4pm to you civilians out there) mark on the clock. All were exactly the same.

Plug 1
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Plug 2
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Plug 3
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Discussion Starter · #3 ·
More spark plug pics!

Here are some new versus old sparkplug pics...

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And here is a close up pics of the electrodes themselves. My car had nearly 80k this weekend and the plugs had never been changed in this 11 year old car.

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Don't forget your anti-seize!!
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Discussion Starter · #4 ·
New brakes and bleeding them...

Here are the new Autozone rotors and pads that I installed. Not bad for only $70 in total for parts and brake fluid. After I bedded in the pads, the brakes are 100% better than the tired OEM rotors and pads which still had a little life left in them, but I didn't want to take any chances.

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Plus you can see how dirty the brake fluid was, bleeding the brakes by yourself sucks.

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I also bled the clutch and changed the oil and filter also. I don't think I will do my valves till I hit 100k.
 

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Hmmmmm.

I would be concerned about the different electrode reach. Are those cooler plugs than stock? The heat range looks perfect on the plugs that came out. Hopefully you don't have carbon fouling problems.

Or other problems. I'll be interested to see how this works out. It looks like the electrode on the stock plugs is a good 2-3mm longer than your replacements?
 

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Discussion Starter · #6 ·
Denso IR vs OEM IR

I noticed that too but I am not too concerned. Oscar Jackson did a similar experiment on the Honda Fit with Denso IR spark plugs. The OEM iridium plugs are longer but the Denso performed better and actually increased HP and fuel efficiency on a completely stock Fit L15 motor.

As far as my test drive went, it "seemed" to be (placebo effect probably) stronger and my fuel efficiency did not seem to change at all, but got a little better. I have a 400 mile trip coming up soon so I did all this maintenance to see if it actually changes anything.
 

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Sounds good!

I wish I had access to a dyno. It's so hard to quantify such small changes without being able to measure precisely. A slight environmental change could completely muddy any dis/advantages the plugs provide.

Did you index them, or just stick them in?
 

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Discussion Starter · #9 ·
Just an update so far on the new plugs. Drove about 60 miles yesterday, mostly freeway and averaged 56 MPG while driving around 68 to 73 MPH. It seems to have a noticeable pick up on the freeway, seems much smoother.

:D
 

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With the difference in the electrode reach (center section), all you are doing is putting the initial "explosion" in a different location in the combustion chamber. The center "ceramic" size will determine heat range. Most plugs today are gapped at 47-52 thousands, mainly because of the better ignition sytems installed.
My opinion.

Willie
 

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Discussion Starter · #12 ·
Congrats on finally getting the plate work done :) I need to do my valves/egr valve sparks soon as well as I do have the stuff, just need to mess with them some more ;)
Thanks bud, just let me know if you need a helping hand for your Insight. I have yet to talk to another San Diegan with an Insight.
 

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vmirjamali:
Location should be Poway, not San Diego......We're "country".

Willie
 

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With the difference in the electrode reach (center section), all you are doing is putting the initial "explosion" in a different location in the combustion chamber. The center "ceramic" size will determine heat range. Most plugs today are gapped at 47-52 thousands, mainly because of the better ignition sytems installed.
My opinion.

Willie
Yes, I'm aware of this.

Putting the initial spark in a different position in the combustion chamber could have a big impact on things. Hence our plugs being indexed in the first place.

Wish we could see the combustion chamber side of the head to see how they look. IIRC, the electode doesn't really protrude much with the stock plugs.
 

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from this picture that was posted earlier from an ebay auction, it seems that the new plug would screw in at the same location, but the electrode will sit a little more tucked in. As it is, the original plug doesnt really stick out that much. But I think that small difference probably doesnt do anything

 

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All of this guessing really bothers me....

I wish I had access to a dyno. We need to definitively test these things. Even if our assumptions are educated guesses, there is a lot of room for error. None of us are thermodynamics engineers, as far as I know. The level of R&D that Honda put into this car is obviously quite astounding, so I tend to question every alteration to that said engineering.

If the new plugs produce even 1% less power, that would be impossible to detect by MPG alone. It would even be hard to test with a dyno. But 1% is 1%, and if there's a minus sign infront of it, that would obviously be undesirable. There's just no way to tell......

I wish we could get one of the Honda engineers that worked on our engine to answer some questions. What are the chances of that? Someone out there could answer all of our questions and them some, if we could just get in touch with them, and they are willing.
 
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