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Discussion Starter #1
Has anyone experienced this?

According to my dealership service... my new 2006 Insight has failed, and this seems to be the diagnosis.

"Electric Module for the Gas motor is showing low voltage to the unit. That is why the IMA is inoperative. That part will come in from Japan, arriving this Friday. The module is a control unit for a computer, sealed unit. It had motor control low circuit that killed the IMA from being able to work properly"

I'm just wondering if anyone went through this? Any clue (aside from just plain old failure) that could cause something like this to happen that could be avoidable in the future?

BTW, Russ at Honda of Escondido was very professional and has given great service so far.
 

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Discussion Starter #3
I will try to get the code number from Russ. Thanks!
 

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Sounds almost like the ECM/ECU is failing? "electric module for gas motor"...My god, how can these people even call themselves "mechanics"?

If the ECM/ECU is truly showing a "low voltage" (is that a low sensor voltage? low 12V? low output from the LAF? what?) then wiring should be checked before the ECM/ECU is replaced.
 

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Discussion Starter #5
Update:

something majorly went wrong, the dealership is not quite sure what it is, but need special equipment sent to disassemble the transmission. Apparently, this is the 2nd 2006 Insight with the same exact problem- IMA down under 3k miles. The other insight with the same issue is in NY, according to American Honda. They need to get into the sensors in the transmission before they can further disagnose the issue, according to American Honda. Hence- the special equipment, since the tranny in insights have a strng magnet that requires special tool from Japan.

I'm looking at 2-3 weeks for the repair, possibly longer. :( Thankfully, I will be getting a free rental out of this. I hope this is not a lemon... I miss the insight!

I don't have much details yet, but there are 6 codes, all IMA related.

I'll put more info down as I see it.
 

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The magnet is actually the electric motor stator which is mounted between the engine and flywheel. The service manual does not specify removal to access the transmission. The transmission just unbolts from the engine and slides off after the CV joints and related stuff is removed.

Now, there are current sensors at every motor phase that may be a problem. These are the "motor commutation sensors". They do not require motor removal to access (though space down there is a little tight).

The only problem that requires stator removal is a problem in the motor itself and I think you would be the first one with actual physical motor issues...

It would help to have the exact codes and symptoms the dealer is chasing.

As for the parts wait, welcome to Honda! :)
 

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Discussion Starter #7
Okay - my car is back, finally! And I'm going to post what went down with the vehicle. I was pissed off that the tow truck guy left grease handprints over the upholstery and scratched the bumper. :x I'm dealing with the owner to get my bumper repainted and pay me for the $$$ I paid to clean my upholstery.

Sigh.

Okay, here's the detail of what went wrong:

Initial fail code: P1644/P1600 IMA MOTFA Signal Failure/IMA System Malfunction

Replaced MCM Control Module, cleared code and tested. Recoded with code P1565. Motor Commutation Signal problem. Found weak signal from motor commutation sensors located in engine. Removed transmission to replace 3 sensors, cleared codes, operation as normal. Due to signal failure, vehicle was unable to recharge IMA batteries which caused the IMA failure.

My car does drive fine, but I hear a high pitched whirring (almost like a belt running) noise when the engine shuts off as I'm coming to a stop. also, the engine shuts off @ 10mph, rather than after a complete stop. Is this normal? Thanks!
 

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Ah ha! Motor commutation sensor failure! I'm still unsure as to why the transmission was removed. By removing the airbox, those sensors can be removed quite easily...Meh, I'll look over the procedure in the service manual when I get a chance since I could be wrong...

As for the high pitched noise, that's normal. You're hearing the motor controller push some charge back into the batteries. As the speed of the motor changes, the frequency of the AC it generates changes as well. Some of these frequencies are more audible then others.

However if you are hearing this from the car's speakers, then make sure that all the ground straps in the engine bay were reconnected and in good shape.
 

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Discussion Starter #9
Thanks, aaron cake! I will listen to see where I'm hearing the noise from.
 
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