Bulletins & Advisories Insight ZE2 IMA Battery Replacement

Discussion in '2nd Generation (2009)' started by Service News, Friday 24th Jul, 2009.

  1. Service News Staff Managed Dealer Information

    Honda issued this TSB# SJ-10-009-01 dated 24-7-2009 for all year models of the second generation ZE2.

    IMA System precautions

    The IMA (integrated motor assisted) system uses high (100V) voltage circuits. Be sure to shut off the electrical circuits and isolate the IMA system and related parts before servicing the IMA system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precautions in the Shop Manual before doing any repairs to the IMA system. The high voltage cables and their covers are identified by orange colouring. Caution labels are attached to high voltage and other related parts. Be careful not to touch these cables and parts without adequate protective
    equipment/insulated tools.

    Wear insulated gloves whenever you inspect or service the IMA system. Be sure to check the gloves for pin holes, tears or other damage.

    The INSIGHT IMA battery when ordered for replacement does not come with the Junction Board/Main switch attached. Because of this, connections between the Junction board and battery which will remain live have to be disconnected with insulated tools to protect you from electrical shocks.

    Servicing, disassembling, or replacing items marked with high voltage symbol in Shop Manual procedures requires insulated tools.
    A special insulated tool kit (Tool No. 07000-INS-000) has been prepared for battery replacement and is available in the Special Tools Loan Programme. It should always be used when carrying out IMA battery replacement on INSIGHT and junction board/battery work on other hybrid models.


    NOTE: Gloves are shown in the above illustration but ARE NOT SUUPLIED IN THE KIT. If this special tool is required please use locally sourced insulated gloves.

    Turning OFF power to the high voltage circuit.

    The following procedure should be preformed prior to working on or near high voltage components. Follow the procedure exactly. Otherwise, you may be injured or may damage equipment.
    1. Turn the Ignition switch to LOCK (0).
    2. Remove the trunk floor lid.
    3. Loosen the bolt (A) and remove bolt (B)

    4. Remove the battery module switch lid (C) from the IPU cover.
    5. Turn the battery module switch (A) OFF, then check that bolt (B) is showing
    6. Wait at least 5 minutes to allow the PDU capacitors to discharge.
    7. Remove the IPU cover.
    8. Measure the voltage at the battery module terminals (A). There should be lower than 30 V. If the voltage is more than 30 V at present, there is a problem in the system; do the DTC troubleshooting first.

    Turning On power to the high voltage circuit.
    1. After service or repairs are completed, make sure all the high voltage circuits are connected properly.
    2. Install the IPU cover
    3. Push the button (A) and turn the battery module switch ON.
    Battery Module Removal / Installation
    1. Do the battery terminal disconnection procedure.
    2. Remove the IPU case
    3. Remove the IPU module front air duct (A)
    4. Remove the bolts (A) and the IPU frames (B)
    5. Using insulated tools remove the bolts (A, B) and the PCU busplate (C)

    6. Disconnect MCM connector (A)


    7. Remove the clips (B, C)
    8. Disconnect the connectors (A, B)
    9. Remove the covers (C)
    10. Using insulated tools remove bolts (A, B) and the junction board (C) from the battery module (D)

    11. Disconnect the connectors (A, B, C).

    12. Remove the IPU harness (D).
    13. Remove the bolts (A) and PCU assembly (B)
    14. Install the parts in the reverse order of removal, observing the cautions for electrical shocks using insulated gloves/tools.
    15. Do the battery terminal reconnection procedure.
  2. Ichiban Founder Staff Team

    England CJ Leeds