Campaign - IMA Battery Module Warranty Extension
06-057December 8, 2012
Applies To:
2000-04 Insight - See VEHICLES AFFECTED
Warranty Extension: Insight IMA Battery Module
(Supersedes 06-057, dated March 16, 2011, to revise the information marked by ** (or the black bar in an image).
REVISION SUMMARY
**Under CORRECTIVE ACTION, WARRANTY CLAIM INFORMATION, and REPAIR PROCEDURE, information was added to transfer the junction board from the original battery to the replacement battery.**
BACKGROUND
NOTE:
This service bulletin extends the models covered in Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage. The IMA battery module 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.
To ensure continued reliability with the IMA system, American Honda is announcing an IMA battery module warranty extension for certain 2000-04 Insights. The IMA battery module is now covered for 10 years or 150,000 miles, whichever occurs first. This warranty extension applies to the 43 states not already covered by Service Bulletin 06-027, Warranty Extension: IMA Battery
VEHICLES AFFECTED
This warranty extension affects 2000-04 Insights registered in the shaded states on the map*.
*2000-04 Insights registered in Arizona, California, Colorado, Florida, Hawaii, Nevada, and Texas are covered by Service Bulletin 06-027, Warranty Extension: IMA Battery.
CUSTOMER NOTIFICATION
Owners of affected vehicles within the 43 affected states will receive a notification of this warranty extension. An example of the warranty extension notification is at the end of this service bulletin.
To verify warranty extension eligibility, you must do a VIN status inquiry.
CORRECTIVE ACTION
Replace the IMA battery module if it has failed. In addition, replace the battery condition monitor and the motor control module on 2000-01 models or, on 2002-04 models, replace the battery condition monitor only. **Also transfer/install the junction board. See Service Bulletin 12-048, Junction Board Replacement.**
PARTS INFORMATION
NOTE:
Make sure to order the correct parts for the vehicle you are working on.
WARRANTY CLAIM INFORMATION
NOTE:
The IMA battery module warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law.
REPAIR PROCEDURE
NOTE:
Do this procedure only if troubleshooting indicates a problem with the IMA battery module.
1. Turn the ignition switch to the LOCK (0) position.
2. Remove the 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. Remove the mid-frame, then remove the front and rear IPU braces from the junction board.
12. Disconnect the high-voltage cables from the output terminals on the junction board, and wrap them with insulating tape.
13. Remove the battery module air duct mounting bolt, then push the duct forward.
14. Remove the mounting bolts from the battery module. Disconnect the connectors and the Y condenser terminal.
NOTE:
After disconnection, temporarily secure the Y condenser harness on the junction board.
15. Set the battery module lifting tool on the module, and install the six knurled bolts.
16. With the help of an assistant, lift the battery module out of the vehicle, and carefully set it down on a flat surface.
**17. Transfer the junction board from the original battery to the replacement battery. See Service Bulletin 12-048, Junction Board Replacement.**
18. Install the new battery module in the reverse order of removal (steps 16, 15, 14, 13, 12, and 11).
19. Install a new BCM (2002-04 Insights) ora new BCM and 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 N*m (7.2 lb-ft).
20. Reinstall the foam insert.
21. Reinstall the IPU lid. Torque the bolts to 9.8 N*m (7.2 lb-ft).
22. Reinstall the under-cover (two bolts, two clips, and three screw clips.) Torque the bolts to 9.8 N-m (7.2 lb-ft).
23. Remove the battery module switch locking cover, flip the switch to ON, then reinstall the locking cover.
24. Reinstall the battery module switch cover.
25. Reinstall the rear clips on the middle bulkhead carpet.
26. Reinstall the cargo floor mat.
27. Check for and clear any DTCs with the HDS.
28. Remove the No. 15 (40 A) fuse (EPS control unit) from the under-hood fuse/relay box.
29. With the transmission in neutral (M/T) or Park (CVT), and the clutch released (Mm, start the engine. Hold the engine speed at 3,500 rpm until the IMA battery level indicator shows at least 50 percent charge.
30. Turn off the engine, and reinstall the No. 15 fuse.
Example of Customer Letter
Disclaimer