Campaign - Premature IMA Battery Module Failures: Overview
06-026February 5, 2008
Applies To:
2000-04 Insight - See VEHICLES AFFECTED
Product Update: Premature IMA Battery Module Failure
(Supersedes 06-026, dated May 13, 2006)
Updated information is shown with black bars in the images and asterisks in the text.
BACKGROUND
*NOTE:
Because of a class action settlement, the warranty coverage for the IMA battery on 2002-04 Insights purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension:
Vehicle Warranty Mileage.*
American Honda is announcing a product update to replace certain IMA components to help prevent IMA battery deterioration. This product update applies only in states where there is an abnormally high replacement rate for IMA batteries.
The IMA battery control module(s) allows the battery to overcharge. Occasional overcharging is a desirable function, but too many frequently repeated cycles of overcharge can damage the IMA battery. This damage is the result of excessive current and heat build up. Unique local topographical and ambient conditions in affected states, combined with a driving cycle that typically keeps the IMA battery fully charged, create this potential problem.
VEHICLES AFFECTED
This product update affects all 2000-04 Insights registered in the states of Arizona, California, Colorado, Florida, Hawaii, Nevada, and Texas, the shaded states on this map) as shown.
To verify vehicle eligibility, check for at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition to these verification items, check for a punch mark above the 14th character of the engine compartment VIN. A punch mark in that location means the product update has already been completed.
CUSTOMER NOTIFICATION
Owners of affected vehicles within the seven states have received a notification of this product update. An example of the notification is shown in this service bulletin.
CORRECTIVE ACTION
Based on the model and/or model year, install the appropriate IMA repair kit or part.
WARRANTY CLAIM INFORMATION
REPAIR PROCEDURE
1. Turn the ignition switch to the LOCK (0 position).
2. Remove cargo floor mat:
^ Refer to page 20-44 of the 2000-2006 Insight Service Manual, or
^ Online, enter keywords FLOOR MAT, then select Interior Trim Removal/Installation - Cargo Area from the list.
3. Remove the battery module switch cover (two bolts), then remove the locking cover from the switch.
4. Flip the battery module switch to OFF, then reinstall the locking cover.
5. Wait at least 5 minutes for the capacitors in the system to discharge.
6. Remove the rear clips from the middle bulkhead carpet.
7. Remove the under-cover (two bolts, two clips, and three screw clips).
8. Remove the IPU (intelligent power unit) lid (six Torx bolts and 17 hex bolts).
9. Measure voltage at the junction board terminals.
^ If the reading is 30 V or less, the capacitors are discharged enough for you to continue; go to step 10.
^ If the reading is more than 30 V, there is a problem with the IMA system. Troubleshoot the system using the IMA section of the service manual, then continue with this procedure.
10. Lift out the battery module foam insert.
11. Replace the BCM (2002-04 Insights) or the BCM and the MCM (2000-01 Insights):
^ Remove the mounting bolts.
^ Disconnect the connectors: The BCM has three; the MCM has five.
^ Remove the module(s).
^ Install the new module(s) in the reverse order of removal, and torque the mounting bolts to 9.8 Nm (7.2 lb-ft).
12. Reinstall the foam insert.
13. Reinstall the IPU lid. Torque the bolts to 9.8 Nm (7.2 lb-ft).
14. Reinstall the trunk right side shelf support. Torque the bolts to 9.8 Nm (7.2 lb-ft).
15. Remove the battery module switch locking cover, flip the switch to ON, then reinstall the locking cover.
16. Reinstall the battery module switch cover.
17. Reinstall the rear clips on the middle bulkhead carpet.
18. Reinstall the cargo floor mat.
19. Check for and clear any DTCs with the HDS.
20. Remove the No. 15 (40A) fuse (EPS control unit) from the under-hood fuse/relay box.
21. With the transmission in neutral (M/T) or Park (CVT), and the clutch released (M/T), start the engine. Hold the engine speed at 3,500 rpm until the IMA battery level indicator shows at least 50 percent charge.
22. Turn off the engine, and reinstall the No. 15 fuse.
23. Center-punch a completion mark above the 14th character of the engine compartment VIN.
Disclaimer