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.

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.





8. Remove the under-cover (two bolts, two clips, and three screw clips).





9. Remove the intelligent power unit (I PU) lid (six Torx bolts and 17 hex bolts).





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 MA system. Look for and troubleshoot any DTCs before continuing.

^ If you have 10 V or less, continue to step 11.





11. Lift out the battery module foam insert.





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.

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 fusel relay box.

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.