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New door for the Insight! (and other fixings)

If you are familiar with my 2000 Insight you’ll know one of the reasons I got it for a song was that the door had been backed into and the inner structure was mangled, glass missing, regulator bent like a pretzel, and no external door handle. I finally fixed that.

Illustration for article titled New door for the Insight! (and other fixings)
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Video below

I also pulled the primary O2 sensor. Fun fact: it’s wideband due to the 20:1 AF ratio these cars run at when cruising.

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Illustration for article titled New door for the Insight! (and other fixings)

That doesn’t look great. Lots of deposits. A few minutes with a propane torch has it looking MUCH better.

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Note: in most cars this is what an “italian tuneup” does. Heats the primary O2 sensor to the point it’s able to burn off deposits that have built up, which improves accuracy. Insights do not have high enough EGR temperatures to do this.

Illustration for article titled New door for the Insight! (and other fixings)
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Nice. The car runs noticeably smoother now and has enough power at idle to actually run the AC. Imagine that?

Illustration for article titled New door for the Insight! (and other fixings)
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I also cleared my SRS light. Same procedure as any other Honda. Twist spine into a pretzel to unplug a yellow plug from a dummy socket in the fuse box. Jam a wire into it and short out the wires in combination with the light flashing on the dash. Now all that remains is the CEL for my P0420 due to the catalyst not existing.

Illustration for article titled New door for the Insight! (and other fixings)
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Beauty shot.

Check out this video for some context and backstory on this car!

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