Engine/Motor Controls - IMA Indicator ON/DTC's Set
02-035July 23, 2002
Applies To:
2000 Insight - ALL
2001 Insight With M/T - From JHMZE13...1T00001 thru JHMZE13...1T01925
IMA Indicator Comes On With DTC 63 or P1448
(Supersedes 02-035, IMA System Stores DTC 63 or P1448, dated June 25, 2002)
Updated information is shown by black bars and asterisks.
SYMPTOM
The IMA (Integrated Motor Assist) system indicator is on and DIG 63 (P1448) is stored in the MCM memory.
PROBABLE CAUSE
The MCM (motor control module) software incorrectly reports an IMA battery cooling problem.
CORRECTIVE ACTION
Replace the battery condition monitor module and the motor control module.
PARTS INFORMATION
ECU Module Kit: P/N 06060-PHM-305
H/C 6912901
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
* Operation Number: 118122 *
Flat Rate Time: 0.8 hour
Failed Part: P/N 1K100-PHM-010
H/C 6377170
Defect Code: 032
Contention Code: C99
Template ID: 02-035A
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
DIAGNOSIS
1. Inspect the cooling air intake behind the passenger seat and the cooling exhaust holes in the IMA case above the spare tire. If either is obstructed, remove the obstruction, and clear the code. Advise the customer that blocking the vents can cause this problem.
2. Remove the IMA cover (steps 3-10 of REPAIR PROCEDURE). Refer to page 12-4 of the 2000 Insight Service Manual.
3. Make sure the cooling fan on the battery pack is operating normally. Use the PGM Tester to run the fan in high and low speed modes.
^ If the fan is OK, check the part number on the battery condition monitor module. If the part number is not 1K100-PHM-030, then the battery condition monitor module and the motor control module need to be replaced. Go to REPAIR PROCEDURE.
^ If the fan is not OK, repair as needed.
REPAIR PROCEDURE
1. Write down the radio station presets.
2. Turn the ignition switch off, then disconnect the negative cable from the 12-volt battery in the engine compartment.
3. Remove the cargo area carpet and the cargo box. (Refer to page 20-43 of the Insight Service Manual).
4. Remove the switch cover from the battery module, then remove the locking cover from the battery module 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 to allow the capacitors to discharge.
7. Remove the three 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 (IPU) lid (six Torx bolts and 17 hex bolts).
10. Measure the voltage between the junction board terminals. There should be 10 volts or less.
^ If you have more than 10 volts, there is a problem in the IMA system. Look for and troubleshoot any DTCs before continuing.
^ If you have 10 volts or less, continue to step 11.
11. Lift the foam insert out of the battery module.
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 two modules.
13. Install the new BCM and the new MCM. Make sure all electrical connectors are secure.
14. Reinstall the IPU lid.
15. Remove the locking cover from the battery module switch, install the 5 mm bolt, turn the switch on, and reinstall the locking cover.
16. Reinstall the remaining parts in the reverse order of removal.
17. Reconnect the negative cable to the 12-volt battery in the engine compartment.
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 shows at least 50 percent charge.
20. Turn off the engine, then reinstall the EPS fuse.
21. Enter the radio station presets, and set the clock.
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