I'd try bleeding the cooling system before tearing it apart again. A pocket of air could be blocking the flow of coolant. There should be a bleed screw on the engine, near the upper radiator hose.
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2000 Honda Insight
2000 Honda Insight
2000 Honda Insight
2006 Honda Insight (parts car)
1988 Honda CRXFi
1994 Geo Metro
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