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.
the carpet and trunk box.
the little hatch.
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.
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.
all the bolts in the lid. These are 10mm and the three on the each
side are Torx T30.
pulling up on them.
the seatbelt covers
pulling on them. The 4 plastic clips often pop loose or even break.
They can be purchased at most automotive stores.
back the rug to reveal a row of bolts to be removed.
the three bolts on the back of the IPU box.
the lid and remove the styrofoam. The styrofoam must be put back later as it helps
cool the battery and IPU.
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
this ground bolt. It is covered in the same wet paint.
this tab to release the ground wire.
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.
you can slide the plug to the left and off the pin.
squeeze the button and pull and the plug comes apart.
computer on the left is the BCM and the one on the right is the MCM.
these two plugs.
the other side,
the "Tom Mix" bar.
this duct retaining bolt and pull the duct away.
this battery bolt (12mm)
this one too.
the battery to the IPU. Remove it.
the bolts from the rear brace also.
the front battery bolts.
the eight bolts that hold the BCM and MCM on.
the BCM, MCM and frame up and out of the way.
these three connectors.
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.
you have moved it this far, you can lift it out.
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.