Ima System: Removal & Installation Honda Insight ZE1

Battery Module Removal/Installation

Special Tools Required

Battery Module Lift (Available for loan from AHM Special Tools) T/N 07YAK-001010A

IMA system components are located in this area. The IMA system is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the Service Precautions before performing repairs or service (see SERVICE PRECAUTIONS ).

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1. Turn the ignition switch OFF.
2. Remove the cargo floor mat (see «TRIM REMOVAL/INSTALLATION - CARGO AREA»(ref-219313-S19796719322006021300000) ).
3. Remove the battery module switch cover (A) from the IPU lid, and remove the locking cover (B).
4. Turn the battery module switch (A) OFF, then install the locking cover (B).
5. Wait for at least 5 minutes to allow the PDU capacitors to discharge.
6. Remove the trunk right side shelf support (A).
7. Remove the mid-frame cover clips and the IPU lid (A).
8. Measure voltage at the junction board terminals (A). There should be 30 V or less. If more than 30 V is present, there is a problem in the circuit; do the DTC troubleshooting before continuing.
9. Remove the foam inserts.
10. Remove the mid-frame (A), then remove the front and rear IPU braces (B) from the junction board.
11. Disconnect the high-voltage cables (C) from the output terminals on the junction board, and wrap them with insulating tape.
12. Remove the battery module air duct mounting bolt (A), then push the duct forward.
13. Remove the mounting bolts (B) from the battery module (C). Disconnect the connectors (D) and Y condenser terminal (E). NOTE: After disconnection, temporarily secure the Y condenser harness on the junction board.
14. Set the battery module lifting tool on the module (A), and install the six knurled bolts (B).
15. With the help of an assistant, lift the battery module out of the vehicle, and carefully set it down on a flat surface.
16. Install the battery module in the reverse order of removal.

Power Control Unit (PCU) Removal/Installation

IMA system components are located in this area. The IMA system is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the Service Precautions before performing repairs or service (see SERVICE PRECAUTIONS ).

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1. Turn the ignition switch OFF.
2. Remove the cargo floor mat (see «TRIM REMOVAL/INSTALLATION - CARGO AREA»(ref-219313-S19796719322006021300000) ).
3. Remove the battery module switch cover (A) from the IPU lid, and remove the locking cover (B).
4. Turn the battery module switch (A) OFF, then install the locking cover (B).
5. Wait for at least 5 minutes to allow the PCU capacitors to discharge.
6. Disconnect the negative cable from the 12 V battery in the engine compartment.
7. Remove the trunk right side shelf support (A).
8. Remove the mid-frame cover clips and the IPU lid (A).
9. Measure voltage at the junction board terminals (A). There should be 30 V or less. If more than 30 V is present, there is a problem in the circuit; do the DTC troubleshooting before continuing.
10. Remove the foam inserts.
11. Remove the mid-frame (A), then remove the front and rear IPU braces (B) from the junction board.
12. Disconnect the high-voltage cables (C) from the output terminals on the junction board, and wrap them with insulating tape.
13. Disconnect the connector (A) from the rear of the cooling fan assembly (B), and remove the harness clip from the fan shroud (C).
14. Remove the four fan bolts (D), and remove the fan bracket (E).
15. Remove the fan duct (F) from the fan (B), and remove the fan.
16. Lift the relay pack (A) from its holder. Disconnect the harness from the resistors (B), and remove the two harness clips from the panel.
17. Disconnect the Y condenser ground (C).
18. Disconnect the connector (D) from the PCU, and disconnect the 12 V battery cables (E).
19. Disconnect the high voltage DC-DC converter 2P connector (F).
20. Pull the intake duct (G) away from the front of the PCU.
21. Remove the PCU terminal cover (H), and remove the clip (I) and three bolts that hold the three-phase cables (J) in place.
22. Remove the four PCU mounting bolts (K).
23. Carefully lift the PCU from the vehicle, and set it on a flat surface.
24. Install the PCU in the reverse order or removal.

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1. Remove the PCU (see «POWER CONTROL UNIT (PCU) REMOVAL/INSTALLATION»(ref-219297-S28585114082006021300000) ).
2. Remove the cover (A).
3. Remove the voltage converter module (A).
4. Remove the motor current sensors (GRAY) (A). NOTE: When reassembling the motor current sensors, align the bus bars so the motor cable connections are properly aligned.
5. Remove the condenser (A) and MPI module (B).
6. Remove the DC-DC converter (A).
7. Install the parts in the reverse order of removal.

IMA Motor Removal/Installation

Special Tools Required

Rotor puller (Available for loan or purchase from AHM Special Tools) 07YAC-PHM010B

The motor rotor contains very strong magnets and should be handled with special care. People with pacemakers or other sensitive medical devices should not handle the motor rotor.

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1. M/T model: Remove the transmission (see «TRANSMISSION REMOVAL»(ref-219299-S16014806222006021300000) ) and the clutch (see «CLUTCH»(ref-219298) ). CVT model: Remove the transmission (see «TRANSMISSION REMOVAL»(ref-219301-S15672816822006021300000) ).
2. Remove the stator cover (A).
3. Remove three of the six bolts (A).
4. Install the guide pins (A), then remove the remaining three bolts (B).
5. Attach the rotor puller with the bolts supplied.
6. Remove the motor rotor (A).
7. Remove the bolts (A).
8. Remove the motor stator (A). NOTE: Clean the mating surfaces of the housing assembly and engine block, and apply liquid gasket, P/N 08718-0009, to the mating surfaces just before installation.
9. Remove the cover (A) and motor power cables (B). NOTE: Check the position of the U phase, V phase, and W phase before disconnecting the motor power cable. Clean the mating surfaces of the housing assembly and cover, and be sure to apply the liquid gasket, P/N 08718-0009, to the mating surfaces just before installation.
10. Remove motor commutation sensors A, B, and C.
11. Install the IMA motor in the reverse order of removal. NOTE: Install the commutation sensors properly. Do not set sensors A, B, and C in the wrong positions. Connect the motor power cable with the U phase, V phase, and W phase set in the correct positions. Clean the surfaces before applying liquid gasket, P/N 08718-0009. Set the rotor on the special tool, and install the rotor with the end of the special tool extended. Turn the handle of the special tool slowly when inserting the rotor into the stator. The rotor is drawn into the stator by magnetic force.