Service Bulletin - Engine
Contents
1. 5 Wait at least 5 minutes to let the capacitors in the system discharge 6 Remove the right trunk shelf support five clips and two bolts BOLTS 17 IPU LID RIGHT TRUNK SHELF SUPPORT BoLTS 7 Remove the six mid frame cover bolts Remove the intelligent power unit IPU lid 17 bolts 2of3 10 1 12 13 14 15 16 Measure the voltage at the junction board terminals There should be 30 V or less If you read more than 30 V there is a problem in the circuit do the DTC troubleshooting first JUNCTION BOARD TERMINALS Look at the part number on the motor control module MCM and refer to this chart If there is a replacement part number listed for it you need to order a replacement MCM Model MCM Part Number Replacement Year Part Number M T Models 2000 01 1KO00 PHM 000 thru 1KOO0 PHM 060 1KO00 PHM 050 2000 01 06060 PHM 305 None with ECU Module Kit 2002 03 1KO000 PHM 060 None 2004 1KO00 PHM 070 None CVT Models 2001 1KO00 PHM 900 thru 1KOO0 PHM 905 1KO00 PHM 904 2002 03 1KO00 PHM 905 None 2004 1KO00 PHM 906 None Look at the part number on the battery condition monitor BCM If the part number is not 1K100 PHM A01 you need to order a replacement BCM Use the Honda Diagnostic System HDS with version 1 011 014 or later software to clear any set DTCs Reinstall the IPU lid and the mid frame cover bolts Torq2. HONDA Service Bulletin Applies To 2000 04 Insight ALL 04 028 March 16 2011 IMA System Indicator On With IMA DTC 77 P1447 or DTC 78 P1449 Supersedes 04 028 dated April 30 2010 to revise the information marked by the black bars REVISION SUMMARY Under WARRANTY CLAIM INFORMATION some operation number and flat rate time information was WARRANTY CLAIM INFORMATION The normal warranty applies NOTE IMA components battery module battery changed condition monitor and motor control module are covered under warranty for 8 years or 80 000 miles PROBLEM whichever comes first The IMA system indicator comes on and IMA DTC 77 OP Description FRT P1447 battery module deterioration or DTC 78 P1449 battery module deterioration is set HBTS Replace battery module re B Retrieve and clear codes add 0 3 118116 Replace battery condition monitor 0 5 CORRECTIVE ACTION 118115 Replace motor control module 0 5 Replace the battery module Inspect the motor control module MCM and the battery condition monitor Failed Part P N 1KO000 PHM 000 BCM to determine if they also need to be replaced Defect Code 03214 Symptom Code 03205 PARTS INFORMATION l as Skill Level Repair Technician Battery Module P N 1D010 PHM 999RM To order call 877 785 9175 The battery module INSPECTION PROCEDURE will be shipped with a battery lifting tool to ease its 1 Turn the ignition switch to LOCK 0
3. emove the lifting tool Plug in the connectors and install the Y condenser harness Then install the mounting bolts Torque the bolts to 24 N m 17 Ib ft Install the battery module air duct Torque the bolt to 9 8 N m 7 2 lb ft 04 028 9 10 11 12 13 14 18 19 Connect the high voltage cables to the junction board Torque the bolts to 9 8 N m 7 2 lb ft Install the front and rear IPU braces and the mid frame Torque the bolts to 9 8 N m 7 2 Ib ft Install the foam inserts Install the IPU lid Torque the bolts to 9 8 N m 7 2 lb ft Reinstall the right side trunk shelf support Torque the bolts to 9 8 N m 7 2 lb ft Remove the battery module switch locking cover and flip the switch to ON Reinstall the locking cover Reinstall the battery module switch cover 16 17 Reinstall the cargo floor mat Remove the No 15 40A fuse EPS control unit from the under hood fuse relay box UNDER HOOD FUSE RELAY BOX NO 15 40A FUSE With the transmission in Neutral and the clutch released on M T models start the engine Hold it at 3 500 rpm until the IMA battery level indicator shows at least 50 percent charge Turn off the engine and reinstall the No 15 fuse 3 of 3
4. removal 2 Remove the cargo floor mat see page 20 44 of the 2000 04 Insight Service Manual In ISIS use the keyword FLOOR MAT and select Interior Trim Removal Installation Cargo Area from the list Battery Control Module Battery Condition Monitor P N 1K100 PHM AO1 Control Unit Motor Control Module M T models P N 1K000 PHM 060 3 Order this part only if the existing MCM is not P N 1KO000 PHM 060 1KO00 PHM 070 or 1K000 PHM 305 Control Unit Motor Control Module CVT models P N 1K000 PHM 905 Order this part only if the existing MCM is not P N 1K000 PHM 905 or 1KO00 PHM 906 Remove the battery module switch cover two bolts then remove the locking cover from the switch BOLTS 77 LOCKING COVER fi PA 2011 American Honda Motor Co Inc All Rights Reserved ATB 26873 45800 1103 1of3 Skill Lever CUSTOMER INFORMATION The information in this bulletin is intended for use only by skilled technicians who have the proper tools equipment R and training to correctly and safely maintain your vehicle These procedures should not be attempted by do it yourselfers and you should not assume this bulletin applies to your vehicle or that your vehicle has the condition described To determine whether this information applies contact an REPAIR authorized Honda automobile dealer 4 Flip the battery module switch to OFF Reinstall the locking cover BATTERY LOCKIN R s MODULE SWITCH
5. ue the bolts to 9 8 N m 7 2 Ib ft Reinstall the right trunk shelf support Torque the bolts to 9 8 N m 7 2 Ib ft Remove the battery module switch locking cover and flip the switch to ON Reinstall the locking cover Reinstall the battery module switch cover Reinstall the cargo floor mat 04 028 17 Return the vehicle to your customer Advise your customer that it is OK to drive the vehicle as is until the replacement parts arrive but the vehicle will have reduced power no IMA assist 18 Order a battery module and if needed a BCM an MCM or both REPAIR PROCEDURE 1 Remove the battery module from the vehicle see page 12 113 of the service manual In ISIS use the keyword BAT MOD and select Battery Module Removal installation from the list Remove the lifting tool from the battery module Remove the mounting bolts for the MCM and the BCM eight total Unplug the electrical connectors five for the MCM and three for the BCM then remove the modules BOLTS MCM FIVE CONNECTORS BCM THREE CONNECTORS Install the MCM and the BCM in the new battery module Use the original MCM and BOM if no replacement was needed otherwise use the appropriate replacement parts Torque the mounting bolts to 9 8 N m 7 2 lb ft Install the lifting tool on the battery module 6 With someone to help you carefully lift the battery module into the vehicle and set it down into position R
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