Removing a 2000-2006 Honda Insight IMA battery. Rev 1.2
It takes a first-timer about three hours to remove the
battery. With practice,
the entire replacement can be done in 45
minutes.The original instructions are here: http://www.hybrid-battery-repair.com/insight/removal/removal.html. Set printer to Landscape. All margins to .5".
Tools: 10mm socket, 12mm socket, extension, T-30 Torx driver, voltmeter, a pair of pliers for one odd bolt.
Open
the hatch.
Remove
the carpet and trunk box.
Open
the little hatch.
Turn
off the switch, put the red cover back on backwards and remove the
little bolt. A pair of pliers is the easiest way to remove it.
Remove
this plate. There are three bolts at the rear and three push-clips
that look like phillips-head screws. Use a sharp knife to pry up the
center of the clip and remove it, Then the ring can be removed.
Remove
all the bolts in the lid. These are 10mm and the three on the each
side are Torx T30.
Remove
the doorsills
by
pulling up on them.
Remove
the seatbelt covers
by
pulling on them. The 4 plastic clips often pop loose or even break.
They can be purchased at most automotive stores.
Peel
back the rug to reveal a row of bolts to be removed.
Remove
the three bolts on the back of the IPU box.
Remove
the lid and remove the styrofoam. The styrofoam must be put back later as it helps
cool the battery and IPU.
Test
for voltage at these two wires. You will probably see 3 Volts. If you
see more than 12 volts, stop and call me! If there are 12V or less,
remove the two bolts. If they are covered in red or orange paint, be
aware that it is wet and will stain everything. Clean it off with a rag
first.
Remove
this ground bolt. It is covered in the same wet paint.
Squeeze
this tab to release the ground wire.
This
plug has a safety interlock. It is clipped to a pin. You have to
reach around it and feel for the flat plastic tab and push the tab
toward the front of the car.
Then
you can slide the plug to the left and off the pin.
Finally,
squeeze the button and pull and the plug comes apart.
The
computer on the left is the BCM and the one on the right is the MCM.
Unplug
these two plugs.
On
the other side,
Remove
this plug.
Remove
these bolts.
Remove
the "Tom Mix" bar.
Remove
this duct retaining bolt and pull the duct away.
Remove
this battery bolt (12mm)
and
this one too.
This
tubular brace
Connects
the battery to the IPU. Remove it.
Remove
the bolts from the rear brace also.
Remove
the front battery bolts.
Remove
the eight bolts that hold the BCM and MCM on.
Unplug
the fan.
Flip
the BCM, MCM and frame up and out of the way.
Unplug
these three connectors.
Have
a helper in the front seat lift that end of the battery as you lift and
pull the battery toward the back of the car.
Once
you have moved it this far, you can lift it out.
Now
either put in the replacement battery, put in the bypass board (junction
board) or tape up the two high voltage cables and close up the car.
Always retest the voltage at the high voltage wires if you have turned
on the key or if it has been a few hours. The capacitors in the IPU can
pick up a charge from the electric motor or from the air.