Body and Frame: Description and Operation

Integrated Motor Assist (IMA) System

General Information

The IMA system uses 144 V high voltage circuits and an organic solution (lithium-ion) contained IMA battery module. Improper handling may cause serious injury such as electrocution. When working on or around the IMA system, pay attention to the following precautions.

Preparation Items

- Protective items (insulated gloves or rubber gloves, protective goggles, protective shoes)
- ABC fire extinguisher (available for both oil fires and electric fires)
- Shop towels (for wiping off the electrolyte)
- Insulating tape
- Voltmeter

Precautions when Working on High Voltage Area

CAUTION: Be careful not to let the electrolyte get into your eyes or contact your skin. Doing so may cause loss of your eyesight or skin damage. If it electrolyte gets into your eyes or comes into contact with your skin, immediately flush with a large amount of water and seek medical attention.

- Wear insulated gloves or rubber gloves, protective goggles, and protective shoes whenever you inspect or service the IMA system.
- Check the gloves for pin holes, tears, or other damage.
- As a safety warning, attach a sign saying, WORKING ON HIGH VOLTAGE PARTS. DO NOT TOUCH to the steering wheel.
- The high voltage cables and their covers are identified by orange coloring. The caution labels are attached to high voltage and other related parts. When the system is energized, be careful not to touch these cables and parts without adequate protective gear.
- Be sure to shut off the electrical circuits and isolate the IMA system and related parts before servicing the IMA system. (See "Turning Off and ON Power to the High Voltage Circuit" below)
- Always use insulated tools when servicing, disassembling, or replacing items marked with in each procedure even if the IMA module switch is OFF.
- Do not disassemble the IMA battery module when doing the repair or replacement procedure.
- After disconnecting the high voltage terminals, busbars, etc., insulate the parts with insulating tape.
- Do not touch bare wires that could carry a high voltage. If you must touch them, put on insulated gloves, and measure the voltage between the body ground. If the voltage is above the 12 V battery voltage, insulate the part with insulating tape before doing any operation since to prevent shorting the IMA battery (144 V).
- When insulating a high voltage area with insulating tape, be sure to cover it thoroughly.
- Check around the battery module for leaks of the organic solution. If you find a leak, avoid touching it, but if you must touch it, put on rubber gloves and protective goggles.
- Keep sparks and flames away from the IMA battery, since the organic solution is flammable.
- Seal the replaced IMA battery in a P.P. (Polypropylene) bag, and keep it in a well-ventilated area away from sparks and flames.

Precautions when Working on High Magnetic Area

WARNING: If the rotor is installed by hand, it may suddenly be pulled toward the stator with great force, causing serious hand or finger injury. Always use the special tool (rotor puller) to remove or install the rotor assembly.

- The rotor assembly contains very strong magnets and should be handled with special care. People with pacemakers or other magnetically sensitive medical devices should not handle the rotor assembly.
- Use the special tool (rotor puller) to remove or install the rotor assembly.
- Keep the rotor assembly away from magnetically sensitive devices.

Handling of a Vehicle Damaged in a Collision

CAUTION: Be careful not to let the electrolyte get into your eyes or contact your skin. Doing so may cause loss of your eyesight or skin damage. If it electrolyte gets into your eyes or comes into contact with your skin, immediately flush with a large amount of water and seek medical attention.

- Wear insulated gloves or rubber gloves, protective goggles, and protective shoes whenever you inspect or service the IMA system.
- Do not touch bare wires that could carry a high voltage. If you must touch them, put on insulated gloves, and measure the voltage between the body ground. If the voltage is above the 12 V battery voltage, insulate the part with insulating tape before doing any operation since to prevent shorting the IMA battery (144 V).
- When insulating a high voltage area with insulating tape, be sure to cover it thoroughly.
- If fire breaks out in the vehicle, extinguish it with an ABC fire extinguisher. Extinguishing fire with a small amount of water may be dangerous. Discharge a large amount of water from a hydrant or wait for firefighters.
- If the vehicle is soaked in water, you may risk getting an electric shock. Do not touch the parts and the wires of the high voltage system. Extract the vehicle from the water completely before doing any operation.
- Check around the battery module for leaks of the organic solution. If you find a leak, avoid touching it, but if you must touch it, put on rubber gloves and protective goggles.
- Keep sparks and flames away from the IMA battery, since the organic solution is flammable.
- Seal the replaced IMA battery in a P.P. (Polypropylene) bag, and keep it in a well-ventilated area away from sparks and flames.

Other Precautions

- When the vehicle is left for a long time, it badly impacts on lifetime of the IMA battery. If a new vehicle has been stored for a long time, at least every 12 months no-load charging should be conducted under the following conditions: Start the engine, and hold the engine speed between 3,500-4,000 rpm without load (in P or N) until the IMA battery level indicator displays at least half charged level.

NOTE: Once a vehicle has been put into service (sold), the customer is advised to drive the vehicle at least once a month for at least 30 minutes to maintain the IMA battery.

- High temperature may damage the IMA battery. When drying paint in a heated paint booth, make sure the temperature does not exceed 150 °F (65 °C).
- If the 12 V battery is discharged, its cables have been disconnected, or the MCM has been reset, the IMA battery level indicator may not display the State of Charge when the engine is first started. To display the level in the indicator, start the engine, and hold the engine speed between 3,500-4,000 rpm without load (in P or N) until the level gauge displays at least half charged level.

Turning Off and On Power to the High Voltage Circuit

The following procedure should be done before you work on or near any energized high voltage components. Follow the procedure exactly. Otherwise, you may be injured or may damage equipment.

1. Press the engine start/stop button to select the OFF mode.
2. Remove the rear seat-back.
3. Remove the battery module switch lid from the IPU cover.







4. Turn the battery module switch (A) OFF, then check that the bolt (B) is showing.







5. Wait at least 5 minutes to allow the PDU capacitors to discharge.
6. Remove the IPU cover.







7. Measure the voltage at the IMA battery module terminals (A). There should be less than 30 V.







8. After service or repairs are completed:
- Make sure all high voltage circuits are connected properly.
- Install the IPU cover.

9. Push the button (A), and turn the battery module switch ON.







10. Reinstall all remaining removed parts.

Disconnecting the IMA Motor Power Cable Connector from the Motor Stator

1. Press the engine start/stop button to select the OFF mode.
2. Turn the battery module switch OFF.
3. Remove the clamp (A).







4. Slide the protector (B) in the direction of the arrow. Push the tab (C), then raise the lever (D). Remove the IMA motor power cable connector (E) from the motor stator.
- If the outside of the IMA motor power cable connector is dirty, clean it before you disconnect it.
- Cover the disconnected connector (F) with a plastic bag (G), and wrap the IMA motor power cable terminals with tape (H).
- If the IMA motor power cable terminals are wet, dry them with a clean shop towel. Do not use compressed air.