Ima System: Removal & Installation Honda Insight ZE2 рестайлинг

IPU Cover Removal/Installation

IMA components are located in this area. The IMA 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 IMA service precautions before doing repairs or service (see SERVICE PRECAUTIONS ).

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1. Remove the cargo floor lid, the IPU duct cover, and the spare tire beam (see «TRIM REMOVAL/INSTALLATION - CARGO AREAS»(ref-513199-S36077582502012110700000) ).
2. Turn the battery module switch OFF (see «TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-513150-S09020884592012110700000) ).
3. Remove the bolts (A, B) and the clips (C).
4. Remove the IPU cover (D).
5. Install the parts in the reverse order of removal. NOTE: Before the battery module switch is turned ON, make sure all the high voltage circuits are connected properly. Then push the button (A), and turn the battery module switch ON.

Motor Control Module (MCM) Removal/Installation

IMA components are located in this area. The IMA 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 IMA service precautions before doing repairs or service (see SERVICE PRECAUTIONS ).

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1. Remove the IPU cover (see «IPU COVER REMOVAL/INSTALLATION»(ref-513150-S10286247142012110700000) ).
2. Remove the bolts (A) and the PCU lid (B).
3. Remove the bolts (A, B) and the PCU busplate (C).
4. Remove the bolts (A) and the PCU cover (B).
5. Disconnect the MCM connectors (A).
6. Remove the bolts (B) and the MCM (C).
7. Install the parts in the reverse order of removal.
8. Do the motor rotor position calibration procedure (see «IMA MOTOR ROTOR POSITION CALIBRATION»(ref-513150-S36031634062012110700000) ).

DC-DC Converter Removal/Installation

IMA components are located in this area. The IMA 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 IMA service precautions before doing repairs or service (see SERVICE PRECAUTIONS ).

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1. Make sure the ignition switch is in LOCK (0).
2. Do the 12 volt battery terminal disconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).
3. Remove the MCM (see «MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION»(ref-513150-S37622565542012110700000) ).
4. Remove the IMA motor power cables (A). NOTE: Check the position of the U phase, the V phase, and the W phase cables before disconnecting them.
5. Remove the DC-DC converter cable (B), and wrap it with insulating tape.
6. Remove the bolts (A) and the terminal cover (B).
7. Disconnect the DC-DC converter connector (A).
8. Remove the bolts (B) and the busbar (C).
9. Remove the bolts (D, E) and the DC-DC converter (F).
10. Install the parts in the reverse order of removal.
11. Do the 12 volt battery terminal reconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).

Motor Power Inverter (MPI) Module Removal/Installation

IMA components are located in this area. The IMA 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 IMA service precautions before doing repairs or service (see SERVICE PRECAUTIONS ).

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1. Remove the MCM (see «MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION»(ref-513150-S37622565542012110700000) ).
2. Remove the DC-DC converter (see «DC-DC CONVERTER REMOVAL/INSTALLATION»(ref-513150-S07743506872012110700000) ).
3. Remove the IMA motor power cables (A). NOTE: Check the position of the U phase, the V phase, and the W phase cables before disconnecting them.
4. Remove the DC-DC converter cable (B), and wrap it with insulating tape.
5. Remove the bolts (A) and the terminal cover (B).
6. Disconnect the phase motor current sensor connector (A).
7. Remove the bolts (B, C) and the phase motor current sensor (D).
8. Remove the bolts (A, B) and the PCU wire harness (C).
9. Remove the bolts (A) and the MPI module (B).
10. Install the parts in the reverse order of removal.
11. Do the motor rotor position calibration procedure (see «IMA MOTOR ROTOR POSITION CALIBRATION»(ref-513150-S36031634062012110700000) ).

IPU Case Removal/Installation

IMA components are located in this area. The IMA 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 IMA service precautions before doing repairs or service.

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1. Make sure the ignition switch to LOCK (0).
2. Do the 12 volt battery terminal disconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).
3. Remove the IPU module air duct (see «IPU MODULE FAN REPLACEMENT»(ref-513150-S19341570812012110700000) ).
4. Remove the IPU cover (see «IPU COVER REMOVAL/INSTALLATION»(ref-513150-S10286247142012110700000) ).
5. Remove the PCU lid (see step 2 ).
6. Remove the IMA motor power cables (A). NOTE: Check the position of the U phase, the V phase, and the W phase cables before disconnecting them.
7. Remove the DC-DC converter cable (B), and wrap it with insulating tape.
8. Disconnect the connector (A).
9. Remove the terminal (B).
10. Remove the bolts (C) and the IPU assembly (D).
11. Remove the clips (A) and the IPU case (B). NOTE: The IPU frame seals (C) must be replaced with new ones when the IPU case is removed.
12. Install the parts in the reverse order of removal.
13. Do the 12 volt battery terminal reconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).

Battery Module Removal/Installation

IMA components are located in this area. The IMA 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 IMA service precautions before doing repairs or service (see SERVICE PRECAUTIONS ).

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1. Make sure the ignition switch is in LOCK (0).
2. Do the 12 volt battery terminal disconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).
3. Remove the IPU case (see «IPU CASE REMOVAL/INSTALLATION»(ref-513150-S04971480222012110700000) ).
4. Remove the IPU module front air duct (A).
5. Remove the bolts (A), the IPU frames (B), and the ground bolt (C).
6. Disconnect the connectors (A, B, C).
7. Remove the IPU wire harness (D).
8. Disconnect MCM connector (A).
9. Remove the bolts (A, B) and the PCU busplate (C).
10. Remove the bolts (A) and the PCU cover (B).
11. Disconnect the MCM connectors (A).
12. Remove the bolts (B) and the MCM (C).
13. Remove the bolts (A) and the terminal cover (B).
14. Disconnect the phase motor current sensor connector (A).
15. Remove the bolts (B, C) and the phase motor current sensor (D).
16. Remove the bolts (A, B) and the PCU wire harness (C).
17. Remove the bolts (A) and the MPI module (B).
18. Install the parts in the reverse order of removal.
19. Do the 12 volt battery terminal reconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).

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1. Remove the right cargo area side trim panel (see «TRIM REMOVAL/INSTALLATION - CARGO AREAS»(ref-513199-S36077582502012110700000) ).
2. Disconnect the IPU module fan connector (A).
3. Remove the bolts (B), the nut (C), and the IPU module fan (D).
4. Install the parts in the reverse order of removal.

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1. Remove the cargo floor lid, the IPU duct cover, and the cargo area side trim panel (see «TRIM REMOVAL/INSTALLATION - CARGO AREAS»(ref-513199-S36077582502012110700000) ).
2. Remove the clips (A, B) and the IPU module air duct (C).
3. Install the parts in the reverse order of removal.

IMA Motor Power Cable Removal/Installation

IMA components are located in this area. The IMA 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 IMA service precautions before doing repairs or service (see SERVICE PRECAUTIONS ).

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1. Make sure the ignition switch is in LOCK (0).
2. Do the 12 volt battery terminal disconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).
3. Remove the IPU cover (see «IPU COVER REMOVAL/INSTALLATION»(ref-513150-S10286247142012110700000) ).
4. Remove the bolts (A) and the PCU lid (B).
5. Remove the IMA motor power cables (A). NOTE: Check the position of the U phase, the V phase, and the W phase cables before disconnecting them.
6. Remove the DC-DC converter cable (B), and wrap it with insulating tape.
7. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-513163-S20686336082012110700000) ).
8. Disconnect the IMA motor power cable connector (A) from the motor stator (B). NOTE: Refer to «DISCONNECTING THE IMA MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR»(ref-513150-S38565231862012110700000) . If the IMA motor power cable terminals are wet, dry them with a clean shop towel. Do not use compressed air.
9. Remove the nut (A), the clamp (B), and the DC-DC converter cable (C) from the battery terminal fuse box.
10. Remove the cowl cover and the under-cowl panel (see «COWL COVER REPLACEMENT»(ref-513174-S22314343132012110700000) ).
11. Remove the IMA motor power cable (A) from the brackets (B).
12. Remove the bolt (C).
13. Remove the fuel tank (see «FUEL TANK REPLACEMENT»(ref-513162-S42580791292012110700000) ).
14. Remove the exhaust pipe and the muffler (see «EXHAUST PIPE AND MUFFLER REPLACEMENT»(ref-513161-S39978018712012110700000) ).
15. Remove the under-floor TWC (see «WARM UP TWC REMOVAL/INSTALLATION»(ref-513182-S30434216862012110700000) ).
16. Remove the heat shield (A).
17. Remove the parking brake cable brackets (A).
18. Remove the bolts (A) and the cover (B).
19. Remove the bolts (A) and the nut (B) then remove the clamps (C). NOTE: Do not reuse the clamps. Replace them with new ones.
20. Install the parts in the reverse order of removal.
21. Do the 12 volt battery terminal reconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).

IMA Motor Rotor Removal/Installation

Special Tools Required

Rotor Puller 07YAC-PHM010C

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 IMA motor rotor.

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1. Remove the transmission (see «TRANSMISSION REMOVAL»(ref-513160-S19092007002012110700000) ).
2. Remove the support (A).
3. Remove the drive plate (A).
4. Turn the ignition switch to LOCK (0). Turn the battery module switch OFF (see «TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-513150-S09020884592012110700000) ). 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 IMA motor power cable connector is dirty, clean it before removal. Cover the disconnected connector (E) with a plastic bag (F), and wrap IMA motor power cable terminals with insulating tape (G). If the IMA motor power cable is wet, dry it with a clean shop towel before you wrap it with tape. Do not use compressed air.
5. Install a plastic film (A) between the IMA motor rotor (B) and the motor stator (C).
6. Remove three of the six bolts (A) as shown.
7. Install the rotor puller guide pins, then remove the remaining three bolts (A).
8. Attach the rotor puller with its supplied bolts. NOTE: When installing the rotor puller, position the puller to fit over the guide pins (A).
9. Remove the IMA motor rotor (A).
10. To prevent damage to the rotor magnets while working on the stator, place the rotor, with puller attached, into the puller case.
11. Install the parts in the reverse order of removal. NOTE: When installing the rotor, install the special tool to the rotor and set the rotor with the tool tip stretched out. 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.
12. Remove the plastic film.
13. Reconnect the IMA motor power cable to the motor stator.
14. Reinstall the drive plate.
15. Reinstall the support.
16. Install the transmission (see «TRANSMISSION INSTALLATION»(ref-513160-S29137252232012110700000) ).
17. Do the motor rotor position calibration procedure (see «IMA MOTOR ROTOR POSITION CALIBRATION»(ref-513150-S36031634062012110700000) ).

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1. Remove the splash shields.
2. Remove the drain cover (A).
3. Install the parts in the reverse order of removal.

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1. Remove the IMA motor rotor (see «IMA MOTOR ROTOR REMOVAL/INSTALLATION»(ref-513150-S28757816692012110700000) ).
2. Remove the connector (A) and the bracket (B).
3. Remove the bolt (C) and the IMA motor housing (D). NOTE: Set the dowel pins (E) in the IMA motor housing before installing the motor stator on the engine.
4. Install the parts in the reverse order of removal.
5. Install the IMA motor rotor (see «IMA MOTOR ROTOR REMOVAL/INSTALLATION»(ref-513150-S28757816692012110700000) ).
6. Do the motor rotor position calibration procedure (see «IMA MOTOR ROTOR POSITION CALIBRATION»(ref-513150-S36031634062012110700000) ).

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1. Remove the IMA motor housing (see «IMA MOTOR HOUSING REMOVAL/INSTALLATION»(ref-513150-S22101359612012110700000) ).
2. Remove the bolts (A, B) and the IMA motor rotor position sensor (C).
3. Install the parts in the reverse order of removal. NOTE: Tighten the bolts (A) first, then tighten the bolts (B).
4. Do the motor rotor position calibration procedure (see «IMA MOTOR ROTOR POSITION CALIBRATION»(ref-513150-S36031634062012110700000) ).

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1. Check the idle stop switch adjustment (see «IDLE STOP SWITCH REPLACEMENT»(ref-513150-S06387860532012110700000) ). Is the adjustment OK? YES -Go to step 2. NO -Adjust the idle stop switch (see «IDLE STOP SWITCH REPLACEMENT»(ref-513150-S06387860532012110700000) ).
2. Jump the SCS with the HDS.
3. Disconnect PCM connector A (49P).
4. Turn the ignition switch to ON (II).
5. Release the brake pedal.
6. Measure the voltage between PCM connector terminal A15 and body ground. Is there battery voltage? YES -Go to step 7. NO -Go to step 9 .
7. Press the brake pedal.
8. Measure the voltage between PCM connector terminal A15 and body ground. Is there 0 V? YES -The idle stop switch signal is OK. NO -Go to step 17 .
9. Turn the ignition switch to LOCK (0).
10. Check the No. 12 IMA (10A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES -Go to step 11. NO -Repair a short in the wire between the No. 12 IMA (10A) fuse, the idle stop switch 2P connector, and the PCM (A15), then replace the No. 12 IMA (10A) fuse.
11. Disconnect the idle stop switch 2P connector.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between idle stop switch 2P connector terminal No. 2 and body ground. Is there battery voltage? YES -Go to step 14. NO -Repair an open in the wire between the No. 12 IMA (10A) fuse and the idle stop switch 2P connector.
14. Turn the ignition switch to LOCK (0).
15. Release the brake pedal.
16. Check for continuity between idle stop switch 2P connector terminals No. 1 and No. 2. Is there continuity? YES -Repair an open in the wire between the PCM (A15) and the idle stop switch. NO -Replace the idle stop switch (see «IDLE STOP SWITCH REPLACEMENT»(ref-513150-S06387860532012110700000) ).
17. Turn the ignition switch to LOCK (0).
18. Disconnect the idle stop switch 2P connector.
19. Press the brake pedal.
20. Check for continuity between idle stop switch 2P connector terminals No. 1 and No. 2. Is there continuity? YES -Replace the idle stop switch (see «IDLE STOP SWITCH REPLACEMENT»(ref-513150-S06387860532012110700000) ). NO -Repair a short to power in the wire between the idle stop switch 2P connector and the PCM (A15).

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1. Remove the driver's dashboard undercover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-513196-S07201669662012110700000) ).
2. Disconnect the idle stop switch connector (A).
3. Loosen the locknut (B), and remove the idle stop switch (C).
4. Install the parts in the reverse order of removal.
5. Adjust the idle stop switch (see «IDLE STOP SWITCH REPLACEMENT»(ref-513150-S06387860532012110700000) ).