Product Update: IMA Controller Modification (01-102)

PRODUCT UPDATE: IMA CONTROLLER MODIFICATION

TECHNICAL SERVICE BULLETIN

BACKGROUND

The IMA (Integrated Motor Assist) system supplies power to various 12-volt loads on the vehicle (lights, radio, windows, etc.) and assists the engine to improve vehicle performance. In very cold weather, power demands on the IMA battery module can exceed output, causing permanent damage to the battery module.

VEHICLES AFFECTED

Not all 2000-01 Insights with M/T are affected by this product update. Only vehicles that are registered and normally driven in cold weather areas are affected. Before you begin, verify that the vehicle is registered in one of the states affected by the update (see the map on page 4). Then check for vehicle eligibility by doing one of the following.

• Verify that the customer has a notification letter.
• Check the vehicle's VIN on your campaign responsibility report.
• Do a VIN status inquiry on DCS.

CUSTOMER NOTIFICATION

All owners of affected vehicles will be sent a notification of this product update. An example of the customer notification is in EXAMPLE OF CUSTOMER LETTER  section.

CORRECTIVE ACTION

Replace the battery condition monitor (BCM) module and the motor control module (MCM).

PARTS INFORMATION

ECU Module Kit: P/N 06060-PHM-305, H/C 6912901

WARRANTY CLAIM INFORMATION

Operation Number: 118121

Flat Rate Time: 0.8 hour

Failed Part: P/N 1K100-PHM-010, H/C 6377170

Defect Code: 5AG

Contention Code: L43

Template ID: 01-102A

Skill Level: Repair Technician

REPAIR PROCEDURE

1. Write down the radio station presets.
2. Make sure the ignition switch is off, then disconnect the negative cable from the under-hood 12 V battery.
3. Remove the cargo floor mat and the cargo box (see page 20-43 of the 2000 Insight Service Manual).
4. Remove the battery module switch cover, then remove the locking cover from the switch. See Fig 1 .
5. Turn off the battery module switch. Reinstall the locking cover on the switch, and remove the 5 mm bolt on the side of the switch.
6. Wait at least 5 minutes for the capacitors in the system to discharge.
7. Remove the rear clips from the middle bulkhead carpet. See Fig 2 .
8. Remove the under-cover (two bolts, two clips, and three screw clips). See Fig 3 .
9. Remove the intelligent power unit (IPU) lid (six Torx bolts and 17 hex bolts). See Fig 4 .
10. Measure the voltage between the junction board terminals. There should be 10 V or less.
    • If you have more than 10 V, there's a problem in the IMA system. Look for and troubleshoot any DTCs before continuing.
    • If you have 10 V or less, continue to step 11.

    Refer to Fig 5 .

11. Lift out the battery module foam insert. See Fig 6 .
12. Remove the mounting bolts for the battery condition monitor (BCM) module and the motor control module (MCM). Disconnect the electrical connectors, then remove the modules. See Fig 7 .
13. Install the new BCM and MCM. Make sure all module connectors are secure.
14. Install the IPU lid.
15. Remove the locking cover from the battery module switch, install the 5 mm bolt, turn the switch on, reinstall the locking cover, and install the battery module switch cover.
16. Install the remaining parts in the reverse order of removal.
17. Reconnect the negative cable to the under-hood 12 V battery.
18. Remove the EPS fuse from the under-hood fuse/relay box. See Fig 8 .
19. With the transmission in neutral and the clutch released, run the engine at 3,500 rpm until the battery level indicator shows at least 50 percent charge.
20. Turn off the engine, then install the EPS fuse.
21. Enter the radio station presets, and set the clock.
22. Center-punch a completion mark above the sixth character of the engine compartment VIN. Refer to Fig 9 .

EXAMPLE OF CUSTOMER LETTER

December, 2001

Product Update: Insight IMA Battery Module 

Dear Insight Owner:

We have sent this letter to inform you of a potential problem with your 2000 or 2001 Insight.