IMA Batt switched off-12V Batt not charging-light is on - what is wrong?

MitchJi · 11-24-2012, 06:25 PM

Hi,

I have a 2000 Insight that I bought about a year ago with a dead IMA pack (code P1449). I turned off the switch under the rear deck which causes the car to use the alternator to charge the 12v battery. This has always been a little flakey. Sometimes the 12v battery charge light would stay on for a while or light up for a while (under 4k rpm).

But recently it started staying on all the time, which with my wife driving the car has caused the car to die (twice) with a dead 12v battery. On a conventional car I think that could be the alternator or the regulator. On the Insight it could be the alternator, the regulator or the computer that decides wether or not to charge the 12v battery with the alternator?

How do I determine the cause of the problem? Can I test the alternator by connecting a meter to the +/- leads at idle or is it more complicated than that? If that's a good test will it be obvious where to connect the leads?

Thanks!

biododge1 · 11-24-2012, 06:36 PM

you dont have a alternator. power is from the IMA motor-12v power comes from the 144v batt then dc to dc converter. More will chime in, but I thought you couldnt just shut off the batt pack without unplugging the bcm also to run the car idenfinately. The best I can tell you at this point is to turn the pack back on to alow the system to run normal (and charge).

**Eli** · 11-25-2012, 11:43 PM

As mentioned, the Insight doesn't have an alternator, it has a DC-DC converter to convert the high voltage DC to 12VDC to maintain the 12V systems.

Your battery has finally reached "Ultra critical", shutting the DC-DC down.

The two options you have are to replace the battery or disconnect the BCM and drive as gas only.

MitchJi · 11-26-2012, 02:58 AM

Hi,

Thanks for the replies! Delayed response because I didn't receive email notification.

Quote:

Originally Posted by Ron

Today a customer drove up to me from Virginia with his battery switch off. The car kept the 12V charged.

Quote:

Originally Posted by unknown

To drive it as a regular car, we just turn the switch off? That seems pretty neat and convenient....

I noticed that above 4000 rpm the battery light came on meaning I assume that the battery was not charging. Light went off after a 30 seconds or so of under 4k rpm driving. The IMA light and engine light both orange in color came on and stayed on however.

Based on the posts above I turned off the switch when I picked up the car in late September or early October 2011. Most of the time the battery light has stayed off, indicating the battery was being charged (and I'm sure it didn't last for 13 month's and 5k miles without being charged). Recently the light started staying on all the time and the battery died.

I'm not claiming it has and alternator but I am stating it was charging the 12v and starting with the 12v starter correctly for over 12 months until something changed. I think its a safe assumption that something has worn out and I'd like to know what needs to be replaced and how to replace it.

Thanks!

**Eli** · 11-26-2012, 03:02 AM

Quote:

Originally Posted by MitchJi

Hi,

Thanks for the replies! Delayed response because I didn't receive email notification.

Based on the posts above I turned off the switch when I picked up the car in late September or early October 2011. Most of the time the battery light has stayed off, indicating the battery was being charged (and I'm sure it didn't last for 13 month's and 5k miles without being charged). Recently the light started staying on all the time and the battery died.

I'm not claiming it has and alternator but I am stating it was charging the 12v and starting with the 12v starter correctly for over 12 months until something changed. I think its a safe assumption that something has worn out and I'd like to know what needs to be replaced and how to replace it.

Thanks!

That information is outdated.

What changed is that one of the voltage taps on the IMA battery has reached the low voltage point where the DC-DC converter is shut down. Your IMA battery is now officially completely dead.

MitchJi · 11-26-2012, 03:23 AM

Hi Eli,

Quote:

Originally Posted by Eli

That information is outdated.

What changed is that one of the voltage taps on the IMA battery has reached the low voltage point where the DC-DC converter is shut down. Your IMA battery is now officially completely dead.

Thanks!

So now it will charge the 12v and start with the 12v starter correctly if I unplug the BCM?

Thanks Again!

**Eli** · 11-26-2012, 03:31 AM

Quote:

Originally Posted by MitchJi

Hi Eli,

Thanks!

So now it will charge the 12v and start with the 12v starter correctly if I unplug the BCM?

Thanks Again!

Indeed, it will.

MitchJi · 11-26-2012, 03:28 PM

Hi Eli,

Quote:

Originally Posted by Eli

Indeed, it will.

Thank you very very much

!!

Two more questions. I saved Ron's pictures and instructions.
1. What should I do if the voltage is higher than 12v at Step 14 (for future reference, it comes after the BCM disconnection step)?:

Quote:

Originally Posted by Ron

Step 14. Test for voltage at these two wires. You will probably see 3 Volts. If you see more than 12 volts, stop and call me!

2. I shrunk the pictures and put them in two word processing documents with the instructions. My intention was to make one with the BCM disconnection instructions and one with the battery removal instructions and make two pdf's. I didn't quite finish (chronic fatigue) but they are mostly complete. I tried to upload them but I got these messages:

Quote:

InsightBatteryRemoval.doc:
Your file of 1.63 MB bytes exceeds the forum's limit of 19.5 KB for this filetype.

Quote:

insightbattfiles.zip:
Your file of 1.82 MB bytes exceeds the forum's limit of 97.7 KB for this filetype.

If you think they would be helpful to anyone please let me know where to put them.

Thanks Again!

MitchJi · 12-05-2012, 02:43 AM

Hi,

Things went relatively smoothly until:

Quote:

Remove the lid and remove the styrofoam on the right side. The styrofoam must be put back later as it helps cool the battery and IPU.

When you get to this point, unplug the three connectors on the left hand silver box (the BCM) - the one with the white sticker with the orange bar. Once you do this, the battery will be bypassed and the car will run like a normal car and charge the front battery.

I couldn't get the connectors to come off. I tried to pry them off with a screwdriver and broke a connector!:

Front connectors:

I'd really appreciate instructions for pulling the connectors and suggestions for dealing with the broken connector. I'm hoping the plug holds together and when I put it back on maybe I can glue on the broken piece for protection.

Thanks Again!

**Rush** · 12-05-2012, 02:53 AM

Oh no... now you've done it...
Under each connector is a little plastic spring lock. You need to push up on the plastic and it will release the connector. Put your finger under the middle of the connector and you should be able to feel the plastic spring by pushing up with your finger. DO NOT PULL the plug out unless you are sure you've gotten the spring unlocked or else you'll mess up another connector.

Another way to get at the connectors is to actually unbolt the MCM and BCM, turn them over to access the connectors and the plastic spring lock on the connector.

Good luch and I hope that the broken one plugs back in correctly...