Ima System: Other Honda Insight ZE2 рестайлинг

Disconnecting the motor power cable connector from the motor stator

Turn the ignition switch to LOCK (0). Turn the battery module switch OFF.

Slide the protector (A) in the direction of the arrow. Push the tab (B), then raise the lever (C). Remove the IMA motor power cable (D) from the motor stator.

Note. If the outside of the IMA motor power cable connector is dirty, clean it before you disconnect it. Cover the disconnected connector (E) with a plastic bag (F), and wrap the IMA motor power cable terminals with insulating tape (G). If the IMA motor power cable is wet, dry them with a clean shop towel. Do not use compressed air.

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.

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1. Turn the ignition switch to LOCK (0), then remove the key from the ignition switch.
2. Remove the cargo floor lid, the cargo floor box, and the spare tire (see «TRIM REMOVAL/INSTALLATION - CARGO AREAS»(ref-513199-S36077582502012110700000) ).
3. Loosen the bolt (A), and remove the 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 the bolt (B) is showing.
6. Wait at least 5 minutes to allow the PDU capacitors to discharge.
7. Remove the IPU cover (see «IPU COVER REMOVAL/INSTALLATION»(ref-513150-S10286247142012110700000) ).
8. Measure the voltage at the IMA battery module terminals (A). There should be less than 30 V. If the voltage is more than 30 V, there is a problem in the system; check for IMA DTCs before continuing.
9. After service or repairs are completed: Make sure all high voltage circuits are connected properly. Install the IPU cover (see «IPU COVER REMOVAL/INSTALLATION»(ref-513150-S10286247142012110700000) ).
10. Push the button (A), and turn the battery module switch ON.
11. Reinstall all remaining removed parts.

Intermittent Failures

The term intermittent failure means a system may have had a failure, but it is OK now. If the IMA system indicator on the dash does not come on, check for poor connections or loose terminals at all connectors related to the circuit you are troubleshooting. If the IMA system indicator was on but then went off, the original problem may have been intermittent.

Opens and Shorts

Open and short are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental connection of a wire to ground or to another wire. In simple electronics, this usually means something won't work at all. With complex electronics such as the MCM, this can mean something works, but not the way it's supposed to.

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1. Start the engine, and check the IMA system indicator (A).
2. If the IMA system indicator stays on, turn the ignition switch to LOCK (0), then connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
3. Turn the ignition switch to ON (II).
4. Make sure the HDS communicates with the vehicle and the MCM (IMA system). If it doesn't, troubleshoot the DLC circuit (see «DLC CIRCUIT TROUBLESHOOTING»(ref-513150-S05348875882012110700000) ).
5. Select IMA SYSTEM on the HDS.
6. Check the diagnostic trouble code (DTC) and note it. Also check the freeze data and the on-board snapshot. Refer to the «DTC Troubleshooting»(ref-513150-S14068378132012110700000) and begin the appropriate troubleshooting procedure. NOTE: For specific operations, refer to the user's manual that came with the HDS.

If you can't duplicate the DTC

Some of the troubleshooting requires you to reset the MCM, and try to duplicate the DTC. If the problem is intermittent and you can't duplicate the DTC, do not continue the procedure. To do so will only result in confusion and, possibly, needlessly replaced parts.

Substituting the MCM

Special Tools Required

1. Honda Diagnostic System (HDS) tablet tester
2. Honda Interface Module (HIM) and an iN workstation with the latest HDS software version
3. HDS pocket tester
4. GNA600 and an iN workstation with the latest HDS software version
5. MVCI unit with the latest control module (CM) update software installed

Any one of the above updating tools can be used.

Use this procedure when you have to substitute a known-good MCM during a troubleshooting procedure.

1. Remove the MCM (see «MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION»(ref-513150-S37622565542012110700000) ).
2. Install a known-good MCM.
3. Do the MOTOR ROTOR POSITION CALIBRATION in the ADJUSTMENT MENU with the HDS.

OBD Status

The OBD status shows the current system status of each DTC and all of the parameters. This function is used to see if the repair was successfully finished. The results of diagnostic tests for the DTC are displayed as

1. PASSED: The on-board diagnosis is successfully finished.
2. FAILED: The on-board diagnosis has finished but failed.
3. NOT COMPLETED: The on-board diagnosis was running, but it is out of the enable conditions of the DTC.

When the battery module charge is at or above a specific value

When the SOC of the battery module is at or above a specific value, the generation amount is restricted to prevent overcharging. Since regenerative braking force is insufficient at this time, the PCM cancels full cylinder deactivation and increases engine braking power.

When the battery module charge is at or below a specific value

When the SOC of the battery module drops, idle speed is increased in each shift position to charge the battery module. When the battery module SOC value is low, selecting the I range mode gives priority to battery module charging by lowering the IMA motor assist level, increasing the idle speed, and increasing the regeneration amount (see ELECTRONIC CONTROL SYSTEM ). Charge priority control is canceled when the battery module state-of-charge reaches about 40 percent.

When the engine cannot be started with the IMA motor

Based on signals from the MCM, when the SOC value drops, when the temperature is low, or when there is a problem with the IMA system, the PCM judges that the engine cannot be started by the IMA, so it is started by the starter motor.

Auto Idle Stop System

To reduce fuel use and to minimize tailpipe emissions, auto idle stop system shuts off the engine by stopping fuel injection when the vehicle comes to a stop.

Based on inputs from various sensors and control units, the PCM may or may not allow auto idle stop under different operating conditions.

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Auto Stop Indicator

When auto idle stop is operating, the auto stop indicator blinks, If the driver's door is opened during auto idle stop, the auto stop indicator blinks and a warning buzzer sounds to remind the driver that auto idle stop is in operation.

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Auto Idle Stop Conditions

Note. Each of the conditions below must be met before the engine goes into auto idle stop. The engine may not go into auto idle stop if DTCs in any of these systems are stored: PGM-FI, IMA, CVT, or climate control.

Engine Restart Conditions

Note. The engine restarts when one or more of the conditions below are met.

ECT/IAT Auto idle Stop Conditions

Auto idle stop is disabled by the PCM when the engine coolant and the outside air temperatures are in the range shown below. The thresholds vary, depending on whether ECON ON or ECON OFF is selected.

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1. ECON ON: The PCM determines a minimum coolant temperature, based on the outside air temperature.
2. ECON OFF: The PCM determines a minimum coolant temperature and a minimum/maximum outside air temperature.
3. Cooling System Monitoring: Auto idle stop is disabled while the PCM monitors the cooling system for failures, Monitoring occurs during cold engine warm up.

Brake Booster Vacuum Auto Idle Stop Conditions

Auto idle stop is disabled when there is not enough vacuum in the brake booster. The amount of needed vacuum depends on the barometric pressure.

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SOC/Battery Temperature Auto idle Stop Conditions

Auto idle stop is disabled when the IMA battery module state-of-charge (SOC) becomes too low, or the battery temperature becomes too hot or too cold.

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In-Vehicle Humidity Auto Idle Stop Conditions

Auto idle stop is disabled when the climate control unit anticipates windshield fogging. The threshold depends on outside air temperature, the in-vehicle temperature, and the in-vehicle humidity. To determine the approximate auto idle stop threshold for the ambient conditions of the vehicle, use the instructions and the graph below

Note. Make a copy of this Note to record your results on the graph.

1. Using the climate control sensor input display mode of the HDS, record the outside air temperature (SENSOR 3), the in-vehicle temperature (SENSOR 2), and the in-vehicle humidity (SENSOR A).
2. Draw a vertical line from the outside temperature value to the 80 percent relative humidity curve.
3. Draw a horizontal line from the 80 percent intersection to the right side of the graph.
4. Draw a vertical line from the in-vehicle temperature value to the top to the graph.

1. The auto idle stop humidity threshold is where the lines cross. Auto idle stop is disabled when the in-vehicle humidity is above this point, and it is enabled when the humidity is below this point.
2. In the example below, auto stop is disabled when the in-vehicle humidity exceeds about 30 percent This is determined by an outside temperature of 45°F (7°C) and an in-vehicle temperature of 72°F (22°C).

The auto idle stop enable time depends on how close the in-vehicle humidity is to the calculated humidity threshold. The closer the in-vehicle value is to the threshold, the shorter the auto idle stop enable time will be. Auto idle stop may not occur if the values are too close.

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Climate Control Unit Auto Idle Stop Conditions

The climate control unit calculates a maximum time for auto idle stop. This time depends on whether ECON ON or ECON OFF is selected.

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1. ECON ON: In this mode, the climate control unit prioritizes fuel consumption and calculates the longest time possible before the windshield may fog. The engine restarts when the time expires.
2. ECON OFF: In this mode, the climate control unit prioritizes passenger comfort and calculates the time before the in vehicle temperature would become uncomfortable. The engine restarts when the time expires. This time is typically shorter than when ECON ON is selected.

Intelligent Power Unit (IPU)

The IPU consists of the power control unit (PCU), the battery module, and the junction board. The IPU is located under the cargo compartment to lower the center of gravity of the vehicle and to increase space in the vehicle interior.

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Power Control Unit (PCU)

The PCU consists of the motor control module (MCM), the DC-DC converter, the motor power inverter (MPI) module, and the phase motor current sensor.

The MCM controls the IMA motor and monitors the condition of the battery module.

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Motor Control Module (MCM)

The MCM calculates the battery module SOC and controls the IPU module fan. The SOC is calculated using voltage, temperature, input current, and output current readings of the battery module.

The MCM controls the DC/AC conversion between the battery module 100 V DC to the 3-phase AC IMA motor.

The MCM also controls the IMA motor assist and regeneration.

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Motor Power Inverter (MPI) Module

The MPI module converts 100 V DC power into 3-phase AC power to run the electric motor during assist.

During regeneration, the MPI module converts AC voltage to DC.

The MPI module is air cooled. The heat from the heat sink is exhausted to the cargo area by the IPU module fan.

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DC-DC Converter

Instead of using an alternator to maintain the 12 V battery, the electrical system uses a DC-DC converter. The converter converts high voltage direct current into low voltage direct current with little energy loss.

If a problem is detected in the 12 V charging system, the DC-DC converter turns on the charging system indicator by sending a signal to the gauge control module via the MCM.

The DC-DC converter has a built-in temperature sensor that sends temperature information the MCM. When the DC-DC converter temperature rises, the MCM drives the IPU module fan. If the DC-DC converter temperature rises abnormally, DC-DC converter output is limited. If the temperature continues to rise, the DC-DC converter output is stopped.

Heat generated by the DC-DC converter is exhausted to the cargo area by the IPU module fan.

IMA Motor

The IMA motor is a synchronous AC type unit that converts electrical energy into kinetic energy and vice versa. It assists the engine during acceleration, runs the vehicle during low speed cruise, and starts the engine.

The IMA motor is located between the engine and the transmission. It consists of a 3-phase coil stator and a permanent magnet rotor that is directly connected to the engine crankshaft. An IMA motor rotor position sensor is mounted on the back of the engine block to detect the position of the rotor.

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Battery Module

A light-weight and compact Ni-MH (nickel-metal hydride) battery supplies energy to the IMA system.

The battery module has seven blocks that are connected in series. Within each block are 12 1.2 V cells. The total battery voltage is a nominal 100 V.

The battery module has three built-in thermistor temperature sensors to monitor battery temperature.

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Junction Board

The junction board is mounted on the battery module, and it distributes high voltage energy within the IMA system. The junction board consists of a high-voltage contactor, a bypass contactor, a bypass resistor, a battery current sensor, a fuse and a battery module switch.

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Battery Module Switch

The battery module switch is connected in series with the battery module fuse. Always turn the battery module switch to the OFF position whenever service or checks are required on or around the high voltage circuits. Follow the service precautions (see SERVICE PRECAUTIONS ).

Battery Current Sensor

The battery current sensor detects the input and output current of the battery module. The current detected by the sensor is used to compute the battery SOC.

IPU Module Fan

The battery module, the MPI module, and the DC-DC converter generate heat during assist/regeneration. The IPU is equipped with a fan to cool these parts, to assure proper battery performance, and to protect the system. The fan has a control circuit and rotation sensor that are controlled by the MCM. When the temperature of the battery module, the MPI module, or the DC-DC converter exceeds the specified value, the MCM operates the IPU module fan. The cooling air is drawn into the battery module from the left side of the rear seat, then it is exhausted into the cargo area through the MPI module heat sink and the DC-DC converter heat sink.

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Power Cables

The IMA motor power cables connect the IMA motor to the MPI module. The cables feed through an aluminum tube for damage protection and to prevent electrical noise. The DC-DC converter cable is also contained inside the aluminum tube. The tube is attached to the underside of the vehicle by orange clamps.

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Charging system indicator stays on, no DTCs set

Note. If the 12 V battery voltage is too low to operate the starter motor, the charging system indicator may come on.

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1. Turn the ignition switch to ON (II).
2. Check the DC-DC CONVERTER TEMPERATURE in the DATA LIST with the HDS. Is there 201-257°F (94-125°C) indicated? YES -The system is OK at this time. The charging system indicator will go off when the DC-DC converter temperature decreases. If the temperature does not decrease even though time has passed, replace the DC-DC converter (see «DC-DC CONVERTER REMOVAL/INSTALLATION»(ref-513150-S07743506872012110700000) ). NO -Go to step 3.
3. Do the gauge self-diagnostic function (see «SELF-DIAGNOSTIC FUNCTION»(ref-513176-S11328941922012110700000) ). Does the charging system indicator flash? YES -Go to step 4. NO -Substitute a known-good gauge control module, and recheck. If the charging system indicator circuit is OK, replace the original gauge control module.
4. Turn the ignition switch to LOCK (0).
5. Turn the battery module switch OFF (see «TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-513150-S09020884592012110700000) ).
6. Remove the IPU cover (see «IPU COVER REMOVAL/INSTALLATION»(ref-513150-S10286247142012110700000) ).
7. Remove the PCU lid, the PCU busplate, and the PCU cover (see «MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION»(ref-513150-S37622565542012110700000) ).
8. Check the connections at the high voltage terminals (A, B) on the DC-DC converter (C). Are the connections OK? YES -Replace the DC-DC converter (see «DC-DC CONVERTER REMOVAL/INSTALLATION»(ref-513150-S07743506872012110700000) ). NO -Repair the connections.

Charging system indicator blinks, no DTCs set

1. This indicator may blink after you start the vehicle in extremely cold weather -22°F (-30°C) or blow. It stops blinking when the battery module warms up.

Charging system indicator never comes on, no DTCs set

1. Turn the ignition switch to LOCK (0).
2. Connect the HDS to the DLC.
3. Turn the ignition switch to ON (II), and select the IMA SYSTEM. Does the HDS communicate with the IMA system? YES -Go to step 4. NO -Do the DLC circuit troubleshooting.
4. Do the gauge self-diagnostic function. Does the charging system indicator flash? YES -The system is OK at this time. NO -Substitute a known-good gauge control module, and recheck. If the charging system indicator circuit is OK, replace the original gauge control module.

Motor Control Module (MCM) Update

Special Tools Required

1. Honda Diagnostic System (HDS) tablet tester
2. Honda Interface Module (HIM) and an iN workstation with the latest HDS software version
3. HDS pocket tester
4. GNA600 and an iN workstation with the latest HDS software version
5. MVCI unit with the latest control module (CM) update software installed

Any one of the above updating tools can be used.

IMA Motor/IMA Battery Update

The MCM contains the software programs for the IMA motor control and the battery module condition monitor.

Note. Make sure the updating tool has the latest HDS software version. To ensure the latest programs are installed, do an MCM update whenever the MCM is substituted or replaced. If you are using the HIM, select the IMA motor and/or the battery module in the HIM MCM update menu. You can not update an MCM with the program it already has. It will only accept a new program. Before you update the MCM, make sure the vehicle's 12 V battery is fully charged. Do not turn the ignition switch to ACCESSORY (I) or to LOCK (0) while updating the MCM. If you do, the MCM can be damaged. To prevent MCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, door locks, etc.) during the update. If you need to diagnose the Honda interface module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in ON (II) when you disconnect the HIM from the data link connector (DLC). This will prevent MCM damage.

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1. Turn the ignition switch to ON (II). Do not start the engine.
2. Connect the updating tool to the data link connector (DLC) (A) located under the driver's side of dashboard.
3. Make sure the updating tool communicates with the vehicle and the MCM. If it doesn't, troubleshoot the DLC circuit (see «DLC CIRCUIT TROUBLESHOOTING»(ref-513150-S05348875882012110700000) ).
4. Do the MCM update procedure as described on the HIM label and in the MCM update system.