SB-10045879-1919

Service Bulletin
Applies To:

12-048
September 21, 2012

2003–11 Civic Hybrid – ALL
2011–12 CR-Z – ALL
2000–06 Insight – ALL
2010–12 Insight – ALL

Junction Board Replacement
(IMA Battery Module Replacement and Transfer of Junction Board)
(Supersedes 12-048, dated September 5, 2012; see REVISION SUMMARY)
NOTE: You must be fully certified in the Electrical
Fundamentals map, and have completed training
modules MAC 10 and 12 in the Electrical Systems
map, in order to do junction board and IMA battery
module replacements.
REVISION SUMMARY
This service bulletin has been revised extensively.
American Honda recommends that you review the
entire bulletin.
BACKGROUND
American Honda is no longer shipping IMA
replacement batteries with junction boards attached.
The junction board will now need to be removed from
the old IMA battery and installed onto the new battery
before the battery is installed into the vehicle.

Safety Equipment
The process of junction board replacement is not
difficult. Special safety high voltage insulated gloves
are required when working on the four electrical
connections. The high voltage insulated gloves are
marked with an inspection date. Their first use can be
no later than 12 months from the inspection date, or
else recertification is required (per OSHA 1910.137).
The gloves must be recertified by an accredited
laboratory every 6 months after their first use. For more
information on how and where to get the high voltage
insulated gloves recertified, go to: www.nail4pet.org.

When the junction board is attached, no high voltage is
accessible by the technician. However, the removal
and replacement of the junction board will expose the
technician to high voltage parts of the IMA battery that
cannot be shut off.

The gloves should always be used with the leather
outer protector gloves to protect the inner gloves from
damage. Prior to each use the gloves should be
inspected for any damage such as tears, holes, or
chemical damage. The rubber and leather gloves
should not be exposed to any cleaning solvents,
gasoline, or other chemicals, and they should be stored
in the high voltage insulated glove bag. If used
properly, the gloves should protect the technician from
electrical shock if accidental contact with a positive and
a negative IMA battery connection occurs.

The IMA battery module (a nickel metal hydride
battery) is made up of a number of individual cells
wired in series. (The number of cells varies with the
vehicle model and year.) All models break the module
into two parts, with each part including several “packs”
of cells. Each part includes individual positive and
negative connections. Terminals on the junction board
(two positive, two negative) combine these connections
to form a complete IMA battery assembly.

Insulated tools are available through the Honda Tool
and Equipment Program, or commercially. The primary
purpose of an insulated tool is to protect the technician
from an accidental short from a positive to negative
IMA battery connection due to contact with the tool. An
accidental short with non-insulated tools would result in
high, uncontrolled current and could possibly melt the
tool and the battery, but could also result in molten
metal flying out and potentially injuring the technician.

When replacing a junction board on an IMA battery, the
technician will be exposed to high voltage at the four
terminal connections. Specifically, a significant
potential for electric shock exists in each half of the
battery between the positive and negative terminal
connections.

Junction Board Components

NOTE: Do not use power tools when working on the
IMA battery or junction board. The bolt threads can be
easily damaged with power tools, and the excessive
torque may also damage the battery itself.

 2012 American Honda Motor Co., Inc. – All Rights Reserved

In addition to junction board replacement, some
junction board components may now be replaced.
Service manual troubleshooting procedures have been
revised online to identify when these components
require replacement. If a junction board component
needs replacement, first remove the junction board
from the IMA battery. Once the junction board has
been removed, no special tools are required to replace
the junction board components.

ATB 48149-48346 (1209)

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CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment,
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
authorized Honda automobile dealer.

TOOL INFORMATION
Required Tools (Auto-shipped):
High Voltage Insulated Gloves Safety Kit:
T/N OTCHON-4755 (Kit includes the following
items, or they may be purchased individually):
High Voltage Insulated Gloves, Small (size 9):
T/N OTCHON-487551
High Voltage Insulated Gloves, Medium (size 10):
T/N OTCHON-487552
High Voltage Insulated Gloves, Large (size 11):
T/N OTCHON-487553
High Voltage Insulated Gloves Bag:
T/N OTCHON-566182
NOTE: The High Voltage Insulated Gloves Safety Kit
was shipped to your dealership automatically during
the week of September 3, 2012.
Recommended Tools (Not required):
Insulated Tools: T/N OTCHON-5999, or equivalent
1,000 volt certified insulated tools (also commercially
available)
Order tools through the Honda Tool and Equipment
Program Online Catalog: Log on to the Interactive
Network (iN), and click on Service/Quick Links/Tool
and Equipment Program, or call 888-424-6857.

SOFTWARE INFORMATION
The replacement IMA battery may have a battery code
label that indicates it is the new IMA battery type. The
existing vehicle’s IMA software is not compatible with
a new IMA battery. After the replacement IMA battery
is installed, the vehicle’s IMA BCM software must be
updated to match the replacement battery type.

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WARRANTY CLAIM INFORMATION
The normal warranty applies.
OP#

Description

FRT

1181H5 2003–08 Civic Hybrid: Remove the
old IMA battery module, and install
the new battery.
C Transfer the junction board to the new
battery.

1.0

1181H5 2009–11 Civic Hybrid: Remove the
old IMA battery module, and install
the new battery.
C Transfer the junction board to the new
battery.

1.0

1181H5 CR-Z: Remove the old IMA battery
module, and install the new battery.
C Transfer the junction board to the new
battery.

1.7

1181H5 2000–06 Insight: Remove the old IMA
battery module, and install the new
battery.
C Transfer the junction board to the new
battery.

1.0

1181H5 2010–12 Insight: Remove the old IMA
battery module, and install the new
battery.
C Transfer the junction board to the new
battery.

1.3

Failed Part:

1D080-RMX-405RM

Defect Code:

03214

Symptom Code:

03217

0.4

0.3

0.4

0.6

0.4

NOTE: You must be fully certified in the Electrical
Fundamentals map, and have completed training
modules MAC 10 and 12 in the Electrical Systems
map, in order to do junction board and IMA battery
module replacements.

12-048

REPAIR PROCEDURE

6. Install the junction board onto the new battery.

2003–05 Civic Hybrid

7. Install the junction board bolts, and torque them to
7 N.m (5 lb-ft).

NOTE: Make sure the ON/OFF switch on the top of the
junction board is in the OFF position before beginning
this procedure.

8. While wearing high voltage insulated gloves, install
the electrical terminal bolts. Then, install the
terminal covers.

1. Remove the IMA battery module assembly from the
vehicle.

NOTE: Insulated tools are recommended when
installing the bolts.
9. Install the new IMA battery module assembly into
the vehicle.

2. While wearing high voltage insulated gloves,
remove the four electrical terminal covers and
bolts.
NOTE: Insulated tools are recommended when
removing the bolts.

10. Make sure the vehicle’s software matches the
newly installed IMA battery.

SPACERS

ELECTRICAL
TERMINAL BOLTS
AND COVERS

ELECTRICAL
TERMINAL
BOLTS

JUNCTION
BOARD BOLTS (6)

7 N.m (5 lb-ft)

COVERS

3. Remove the six junction board bolts.
4. Remove the junction board from the old battery.
5. While wearing high voltage insulated gloves,
transfer the four spacers located between the four
junction board connections from the old battery to
the new battery.
NOTE: Insulated tools are recommended when
transferring the spacers.

12-048

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2006–08 Civic Hybrid

7. Install the junction board onto the new battery.

NOTE: Make sure the ON/OFF switch on the top of the
junction board is in the OFF position before beginning
this procedure.

8. Install the junction board bolts, and torque them to
9 N.m (7 lb-ft).

1. Remove the IMA battery module assembly from the
vehicle.
2. While wearing high voltage insulated gloves,
remove the four electrical terminal covers and
bolts.
NOTE: Insulated tools are recommended when
removing the bolts.
SPACERS

9. While wearing high voltage insulated gloves, install
the electrical terminal bolts, and torque them to
8 N.m (6 lb-ft). Then, install the terminal covers.
NOTE: Insulated tools are recommended when
installing the bolts.
10. Reconnect the three 2-pin temperature sensor
connectors.
11. Install the new IMA battery module assembly into
the vehicle.
12. Make sure the vehicle’s software matches the
newly installed IMA battery.

TEMPERATURE
SENSOR
CONNECTOR

ELECTRICAL
TERMINAL BOLTS

8 N.m (6 lb-ft)

TEMPERATURE
SENSOR
CONNECTORS
JUNCTION
BOARD BOLTS (4)

9 N.m (7 lb-ft)

COVERS

ELECTRICAL
TERMINAL BOLT

8 N.m (6 lb-ft)

3. Disconnect the three 2-pin temperature sensor
connectors and slide the wires out and to the side
of the junction board.
4. Remove the four junction board bolts.
5. Remove the junction board from the old battery.
6. While wearing high voltage insulated gloves,
transfer the four spacers located between the four
junction board connections from the old battery to
the new battery.
NOTE: Insulated tools are recommended when
transferring the spacers.

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12-048

2009–11 Civic Hybrid

9. Install the junction board onto the new battery.

NOTE: Make sure the ON/OFF switch on the top of the
junction board is in the OFF position before beginning
this procedure.

10. Install the junction board bolts, and torque them to
8 N.m (6 lb-ft).

1. Remove the IMA battery module assembly from the
vehicle.
2. Disconnect the 3-pin contactor connector.
4-PIN BATTERY
CURRENT SENSOR
CONNECTOR

12-PIN JUNCTION
BOARD CONNECTOR

ELECTRICAL
TERMINAL
BOLTS

3-PIN
CONTACTOR
CONNECTOR

11. While wearing high voltage insulated gloves, install
the electrical terminal bolts, and torque them to
9 N.m (7 lb-ft). Then, install the terminal covers.
NOTE: Insulated tools are recommended when
installing the bolts.
12. Install the 12-pin junction board connector.
13. Reconnect the 4-pin battery current sensor
connector.
14. Reconnect the 3-pin contactor connector.
15. Install the new IMA battery module assembly into
the vehicle.

9 N.m (7 lb-ft)

16. Make sure the vehicle’s software matches the
newly installed IMA battery.

COVER
JUNCTION
BOARD BOLTS (4)

ELECTRICAL
TERMINAL BOLTS

9 N.m (7 lb-ft)

8 N.m (6 lb-ft)
COVER

3. Disconnect the 4-pin battery current sensor
connector.
4. Remove the 12-pin junction board connector from
the junction board.
5. While wearing high voltage insulated gloves,
remove the four electrical terminal covers and
bolts.
NOTE: Insulated tools are recommended when
removing the bolts.
6. Remove the junction board bolts.
7. Remove the junction board from the old battery.
8. While wearing high voltage insulated gloves,
transfer the four spacers located between the four
junction board connections from the old battery to
the new battery.
NOTE: Insulated tools are recommended when
transferring the spacers.

12-048

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2011–12 CR-Z
2010–12 Insight

9. Install the junction board onto the new battery.

NOTE: Make sure the ON/OFF switch on the top of the
junction board is in the OFF position before beginning
this procedure.
1. Remove the IMA battery module assembly from the
vehicle.
2. Release the clips holding the motor control module
(MCM) wire from the metal frame.

MCM CONNECTOR

METAL IPU
FRAME BOLTS (4)
CLIPS

11. While wearing high voltage insulated gloves, install
the electrical terminal bolts, and torque them to
7.7 N.m (5.7 lb-ft). Then, install the terminal
covers.
NOTE: Insulated tools are recommended when
installing the bolts.
12. Reconnect the 4-pin battery current sensor
connector.
13. Reconnect the 3-pin contactor connector.

CONTACTOR
3P CONNECTOR

CLIPS

10. Install the junction board bolts, and torque them to
9.8 N.m (7.2 lb-ft).

METAL IPU
FRAME

14. Reattach the clips holding the motor control module
(MCM) wire to the metal frame.
15. Install the new IMA battery module assembly into
the vehicle.
16. Make sure the vehicle’s software matches the
newly installed IMA battery.

METAL BRACKET

JUNCTION
BOARD
BOLTS (6)
9.8 N.m
(7.2 lb-ft)

COVERS

CURRENT SENSOR
4P CONNECTOR

ELECTRICAL
TERMINAL BOLTS
7.7 N.m (5.7 lb-ft)

3. Disconnect the 3-pin contactor connector.
4. Disconnect the 4-pin battery current sensor
connector.
5. While wearing high voltage insulated gloves,
remove the four electrical terminal covers and
bolts.
NOTE: Insulated tools are recommended when
removing the bolts.
6. Remove the junction board bolts.
7. Remove the junction board from the old battery.
8. Remove the metal IPU frame from the top of the old
battery and the small metal bracket from the side of
the junction board, and transfer them to the new
battery.

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12-048

2000–06 Insight

7. Install the junction board onto the new battery.

NOTE: Make sure the ON/OFF switch on the top of the
junction board is in the OFF position before beginning
this procedure.

8. Install the junction board bolts, and torque them to
7 N.m (5 lb-ft).

1. Remove the IMA battery module assembly from the
vehicle.
2. Remove the cooling fan and air duct from the old
battery and transfer it to the new battery.
CONNECTOR
CLIPS
AIR DUCT
BOLTS (8)

9. While wearing high voltage insulated gloves, install
the four electrical terminal bolts. Then, install the
terminal covers.
NOTE: Insulated tools are recommended when
installing the bolts.
10. Install the new IMA battery module assembly into
the vehicle.
11. Make sure the vehicle’s software matches the
newly installed IMA battery.

7 N.m (5 lb-ft)

COOLING FAN
AND AIR DUCT
JUNCTION BOARD BOLTS (3)

7 N.m (5 lb-ft)

SPACERS
JUNCTION BOARD
BOLTS (3)

7 N.m (5 lb-ft)

ELECTRICAL
TERMINAL BOLTS (4)
AND COVERS

3. While wearing high voltage insulated gloves,
remove the four electrical terminal covers and
bolts.
NOTE: Insulated tools are recommended when
removing the bolts.
4. Remove the junction board bolts.
5. Remove the junction board from the old battery.
6. While wearing high voltage insulated gloves,
transfer the four spacers located between the four
junction board connections from the old battery to
the new battery.
NOTE: Insulated tools are recommended when
transferring the spacers.

12-048

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