Honda_Element_2003-2006

Honda Insight

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Integrated Motor Assembly



Battery Module & Power Control Unit
Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the IMA system power.
  4.  
  5. Remove the foam inserts.
  6.  
  7. Remove the mid frame (A), the front and rear braces (B) and disconnect the high voltage cables (C).

    Click image to see an enlarged view

    Fig. Removing the battery module braces and high voltage cables-Insight

  8.  
  9. Wrap the cables with insulating tape.
  10.  
  11. Remove the air duct mounting bolt and push the air duct forward.
  12.  
  13. Remove the battery module mounting bolts.
  14.  
  15. Disconnect the 3 connectors at the left side and secure the connectors.
  16.  
  17. Install battery lifting tool 07YAK-001010A on the battery module.
  18.  
  19. With the aid of an assistant, lift the battery module from the vehicle and place on a flat surface.
  20.  
  21. To remove the Power Control Unit (PCU), disconnect the connector (A) from the cooling fan assembly (B) and remove the clip from the fan shroud (C).
  22.  
  23. Remove the 4 fan bolts (D) and remove the fan bracket (E).
  24.  
  25. Remove the fan duct (F) from the fan and remove the fan.

    Click image to see an enlarged view

    Fig. Removing the cooling fan assembly-Insight

  26.  
  27. Lift the relay pack (A) from its holder and disconnect the harness from the resistors (B).
  28.  
  29. Disconnect the Y condenser ground (C).
  30.  
  31. Disconnect the connector (D) from the PCU and then disconnect the battery cables (E).
  32.  
  33. Disconnect the high voltage DC-DC converter 2P connector (F).
  34.  
  35. Pull away the intake duct (G).
  36.  
  37. Remove the PCU terminal cover (H) and remove the clip (J) and bolts that hold the three phase cables (J) in place.
  38.  
  39. Remove the 4 PCU mounting bolts (K).
  40.  
  41. Remove the PCU and place it on a flat surface.

    Click image to see an enlarged view

    Fig. Removing the power control unit-Insight

  42.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  

Disabling the IMA System Power
  1. Turn the ignition switch off.
  2.  
  3. Remove the luggage compartment floor mat.
  4.  
  5. Remove the battery module cover (A) and the locking cover (B).
  6.  
  7. Turn the battery module switch OFF and install the locking cover.
  8.  
  9. Wait at least 5 minutes to allow the Intelligent Power Unit (IPU) capacitor to discharge.
  10.  
  11. Remove the right side trunk shelf support.
  12.  
  13. Remove the luggage compartment cover clips and the cover.
  14.  
  15. Measure the voltage at the junction board terminals (A). There should be less than 30 volts. If more than 30 volts are present, there is a problem with the system. DO NOT proceed with any procedure without doing a Diagnostic Trouble Code (DTC) troubleshooting to determine the cause.

    Click image to see an enlarged view

    Fig. IMA battery module switch and locking cover location-Insight



    Click image to see an enlarged view

    Fig. Measuring IMA battery voltage-Insight

  16.  

IMA Motor
Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the IMA system power.
  4.  
  5. Remove the transaxle and clutch, if equipped.
  6.  
  7. Remove 8 bolts and the stator cover.
  8.  
  9. Remove 3 of the opposing rotor attaching bolts.
  10.  
  11. Install guide pins in the removed bolt holes and then remove the remaining 3 bolts.
  12.  
  13. Install rotor puller tool 07YAC-PHM1010A over the guide pins and tighten the puller bolts.
  14.  
  15. Turn the tool clockwise and remove the rotor.
  16.  
  17. Remove the 2 stator mounting bolts.
  18.  
  19. Remove the stator.
  20.  
  21. Remove the cover (A) and the motor power cables (B).

    Click image to see an enlarged view

    Fig. IMA power cable locations-Insight

  22.  
  23. Remove the motor commutation sensors (A), (B) and (C).

    Click image to see an enlarged view

    Fig. Removing IMA motor commutation sensors-Insight

  24.  
  25. Installation is the reverse of the removal procedure, noting the following items:
    1. Install the communication sensors in the correct locations.
    2.  
    3. Install the motor power cables in the correct locations.
    4.  
    5. Set the rotor on the special tool and install the rotor with the end of the tool extended as shown
    6.  
    7. Turn the handle of the tool slowly when inserting the rotor into the stator. The rotor is drawn into the stator by magnetic force.

      Click image to see an enlarged view

      Fig. Installing rotor into the stator-Insight

    8.  

  26.  

Integrated Motor Assembly Service Precautions

Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing the integrated motor assembly:



The IMA system uses 144 volt circuits. Always shut off electrical circuits and isolate the IMA system and related parts before servicing the system.
 
The high voltage cables and their covers are identified by an Orange coloring. Caution labels are attached to high voltage and related parts. Be careful not to touch these cables and parts without adequate protective gear.
 
If the 12 volt battery has been discharged or disconnected or the Motor Control Module (MCM) has been reset, the IMA battery level indicator will not show the state of charge when the engine is started. Start the engine and hold the idle at 3500 rpm with no load until the battery level indicator reads full charge.
 
Wear insulated gloves with no tears, pin holes or other damage when inspecting or servicing the IMA.
 
Turn the battery module switch OFF and secure the switch in the OFF position with the locking cover before servicing the IMA system.
 
Wait for 5 minutes or more after turning the battery module switch off, then disconnect the negative battery cable, It takes about 5 minutes for the PDU capacitor to discharge.
 
Before disconnecting the high voltage cables, make sure the voltage between the terminals is less than 30 volts when checked with a voltmeter.
 
When servicing parts without the Orange insulating color, always use insulated tools to prevent shorts.
 
The rotor assembly contains very strong magnets and should be handled with care. People with pacemakers or other magnetically sensitive medical devices should not handle the rotor assembly.
 
Keep the rotor away from magnetically sensitive devices.
 
After disconnecting the high voltage terminals or other parts, isolate them with insulated parts.
 
Attach a sign saying WORKING ON HIGH VOLTAGE PARTS. DO NOT TOUCH, to the steering wheel as a safety measure.

Click image to see an enlarged view

Fig. IMA system component locations-Insight

 

 
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