2000 Honda InsightFACTORY OEM SERVICE PROCEDURE

Safety Precautions

  • The IMA (Integrated Motor Assisted) system uses high voltage (158 V) circuits. Be sure to shut off the electrical circuits and isolate the IMA system and related parts before servicing the IMA system.
  • The high voltage cables and their covers are identified by orange coloring. The caution labels are attached to high voltage and other related parts. Be careful not to touch these cables and parts without adequate protective gear. The front floor under-cover protecting the high voltage cables is marked. See Fig 1.
  • If the 12 V battery has been discharged, or its cable has been disconnected, or the MCM (motor control module) has been reset, the IMA battery level gauge (BAT) will not display the state of charge when the engine is started. Start the engine, and hold it between 3,500 rpm and 4,000 rpm without load (in Park or neutral) until the level gauge (BAT) displays at least three segments.
  • Wear insulated gloves whenever you inspect or service the IMA system. Be sure to check the gloves for pin holes, tears, or other damage.
  • Before disconnecting the high voltage cable terminals, make sure that the voltage between the terminals is below 30 V when measured with a voltmeter.
  • When servicing the parts without the insulating sheath, be sure to use the insulated tools to prevent short circuiting.
  • Wait for 5 or more minutes after turning off the battery module switch, before disconnecting the negative cable from the 12 V battery (it takes about 5 minutes for the PDU capacitor to discharge).
  • As a safety warning, attach a sign saying, "WORKING ON HIGH VOLTAGE PARTS. DO NOT TOUCH!" to the steering wheel.
Fig 1: Identifying Danger/Warning/Caution Labels At High-Voltage Battery
G03680225Courtesy of AMERICAN HONDA MOTOR CO., INC.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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