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Warranty Extension: Insight IMA Battery Module (06-057)

Publication date: 2011-03-16
Reference number: 06-057

WARRANTY EXTENSION: INSIGHT IMA BATTERY MODULE

WARRANTY EXTENSION: INSIGHT IMA BATTERY MODULE

CAMPAIGN SERVICE BULLETIN

Reference Number(s): 06-057, Date of Issue:  December 8, 2012
HONDA: 2000-04 Insight
CATEGORY: IMA
APPLIES TO: 2000-04 Insight - See VEHICLES AFFECTED
Superceded Bulletin(s): 06-057, Date of Issue:  March 16, 2011
NOTE: (Supersedes 06-057, dated October 18, 2007)

REVISION SUMMARY

Under CORRECTIVE ACTION, WARRANTY CLAIM INFORMATION, and REPAIR PROCEDURE, information was added to transfer the junction board from the original battery to the replacement battery.

REVISION SUMMARY

Under WARRANTY CLAIM INFORMATION, some operation number and flat rate time information was changed.

BACKGROUND

NOTE: This service bulletin extends the models covered in Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage. The IMA battery module on 2002-04 Insights purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first.

To ensure continued reliability with the IMA system, American Honda is announcing an IMA battery module warranty extension for certain 2000-04 Insights. The IMA battery module is now covered for 10 years or 150,000 miles, whichever occurs first. This warranty extension applies to the 43 states not already covered by Service Bulletin 06-027, WARRANTY EXTENSION: IMA BATTERY. 

VEHICLES AFFECTED

This warranty extension affects 2000-04 Insights registered in the shaded  states on this map*:

G07238783

*2000-04 Insights registered in Arizona, California, Colorado, Florida, Hawaii, Nevada, and Texas are covered by Service Bulletin 06-027, WARRANTY EXTENSION: IMA BATTERY .

CUSTOMER NOTIFICATION

Owners of affected vehicles within the 43 affected states will receive a notification of this warranty extension. An example of the warranty extension notification is at the end of this service bulletin.

To verify warranty extension eligibility, you must  do a VIN status inquiry.

CORRECTIVE ACTION

Replace the IMA battery module if it has failed. In addition, replace the battery condition monitor and the motor control module on 2000-01 models or, on 2002-04 models, replace the battery condition monitor only. Also transfer/install the junction board. See Service Bulletin 12-048, Junction Board Replacement.

PARTS INFORMATION

NOTE: Make sure to order the correct parts for the vehicle you are working on.

2000-01 Insight With M/T

IMA Battery Module*

IMA Repair Kit:

P/N 06060-PHM-307, H/C 8317562

(Contains a BCM [P/N 1K100-PHM-A01,

H/C 7687452], and an MCM

[P/N 1K000-PHM-070, H/C 7595390])

2001 Insight With CVT

IMA Battery Module*

IMA Repair Kit:

P/N 06060-PHM-309, H/C 7595408

(Contains a BCM [P/N 1K100-PHM-A01,

H/C 7687452], and an MCM

[P/N 1K000-PHM-906, H/C 7595408])

All 2002-04 Insights

IMA Battery Module*

Battery Condition Monitor:

P/N 1K100-PHM-A01, H/C 7687452

*Battery modules cannot be ordered through normal channels. To order a battery module and the tool to help lift it, refer to Service Bulletin 10-061, IMA BATTERY EXCHANGE PROGRAM .

WARRANTY CLAIM INFORMATION

NOTE: The IMA battery module warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law.
WARRANTY CLAIM INFORMATION

OP# Description FRT
1181H5 Replace the IMA battery module. 1.0
A Add for replacing battery condition monitor, or motor control module and battery condition monitor. 0.4
B Retrieve and clear codes - add 0.3
C Transfer/Install Junction Board 0.6

Failed Part: P/N 1K000-PHM-000

Defect Code: 5KH00

Symptom Code: Q1600

Skill Level: Repair Technician

REPAIR PROCEDURE

NOTE: Do this procedure only if troubleshooting indicates a problem with the IMA battery module.
  1. Turn the ignition switch to the LOCK (0) position.
  2. Remove the cargo floor mat:
  3. Remove the battery module switch cover (two bolts), then remove the locking cover from the switch.
    G07238784
  4. Flip the battery module switch to OFF, then reinstall the locking cover.
    G07238785
  5. Wait at least 5 minutes for the capacitors in the system to discharge.
  6. Remove the rear clips from the middle bulkhead carpet.
    G07238786
  7. Remove the under-cover (two bolts, two clips, and three screw clips).
    G07238787
  8. Remove the IPU (intelligent power unit) lid (six Torx bolts and 17 hex bolts).
    G07238788
  9. Measure voltage at the junction board terminals.
    • If the reading is 30 V or less, the capacitors are discharged enough for you to continue; go to step 10.
    • If the reading is more than 30 V, there is a problem with the IMA system. Troubleshoot the system using the IMA section of the service manual, then continue with this procedure.
      G07238789
  10. Lift out the battery module foam insert.
    G07238790
  11. Remove the mid-frame, then remove the front and rear IPU braces from the junction board.
    G07238791
  12. Disconnect the high-voltage cables from the output terminals on the junction board, and wrap them with insulating tape.
  13. Remove the battery module air duct mounting bolt, then push the duct forward.
    G07238792
  14. Remove the mounting bolts from the battery module. Disconnect the connectors and the Y condenser terminal.
    NOTE: After disconnection, temporarily secure the Y condenser harness on the junction board.
  15. Set the battery module lifting tool on the module, and install the six knurled bolts.
    G07238793
  16. With the help of an assistant, lift the battery module out of the vehicle, and carefully set it down on a flat surface.
  17. Transfer the junction board from the original battery to the replacement battery. See Service Bulletin 12-048, Junction Board Replacement.
  18. Install the new battery module in the reverse order of removal (steps  16,  15,  14,  13,  12, and  11).
  19. Install a new BCM (2002-04 Insights) or a new BCM and MCM (2000-01 Insights):
    • Remove the mounting bolts.
    • Disconnect the connectors: The BCM has three; the MCM has five.
    • Remove the module(s).
    • Install the new module(s) in the reverse order of removal, and torque the mounting bolts to 9.8 N.m (7.2 lb-ft)  .
      G07238794
  20. Reinstall the foam insert.
  21. Reinstall the IPU lid. Torque the bolts to 9.8 N.m (7.2 lb-ft)  .
  22. Reinstall the under-cover (two bolts, two clips, and three screw clips.) Torque the bolts to 9.8 N.m (7.2 lb-ft)  .
  23. Remove the battery module switch locking cover, flip the switch to ON, then reinstall the locking cover.
  24. Reinstall the battery module switch cover.
  25. Reinstall the rear clips on the middle bulkhead carpet.
  26. Reinstall the cargo floor mat.
  27. Check for and clear any DTCs with the HDS.
  28. Remove the No. 15 (40 A) fuse (EPS control unit) from the under-hood fuse/relay box.
    G07238795
  29. With the transmission in neutral (M/T) or Park (CVT), and the clutch released (M/T), start the engine. Hold the engine speed at 3,500 rpm until the IMA battery level indicator shows at least 50 percent charge.
  30. Turn off the engine, and reinstall the No. 15 fuse.

EXAMPLE OF CUSTOMER LETTER

Summer 2006

Warranty Extension: Insight 

Integrated Motor Assist Battery Module 

Dear Insight Owner:

This letter is to notify you of a warranty extension on your vehicle's integrated motor assist (IMA) battery module.

Warranty Extension Details 

The integrated motor assist (IMA) system in your vehicle assists the gasoline engine for better acceleration. To ensure the IMA system remains in top condition, we are announcing a warranty extension for the IMA battery module. The IMA battery module is now covered for 10 years or 150,000 miles, whichever occurs first.

If the IMA indicator on your vehicle's instrument panel stays on while you are driving, take your vehicle to any Honda dealer for an inspection. If the dealer finds the problem to be the IMA battery module, they will replace it. Depending on your vehicle's year and model, the dealer will also replace one or two additional control modules in the IMA system. This work will be done free of charge. Please plan to leave your vehicle at the dealer for a day to allow them flexibility in scheduling.

What to do if you feel this notice is in error. 

Our records show that you are the current owner or lessee of a 2000-04 Insight receiving this warranty extension. If this is not the case, or the name/address information is incorrect, please fill out and return the enclosed, postage-paid Information Change Card.  We will then update our records.

If you paid to have a defective IMA battery module replaced sometime in the past, you may be eligible for reimbursement. Refer to the attached Instructions for Reimbursement  for eligibility requirements and the reimbursement procedure.

If you have questions. 

If you have questions about this notice, or need help contacting a Honda dealer, please call Honda Automobile Customer Service at (800) 999-1009.

Sincerely,

American Honda Motor Co., Inc. 

Honda Automobile Division 

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