Recall - DC - DC Converter Blows Main Fuse: Overview
11-013March 8, 2011
Applies To:
2006 Civic Hybrid - From VIN JHMFA362.6S000019 thru JHMFA362.6S031156
2007 Civic Hybrid - From VIN JHMFA362.7S000003 thru JHMFA362.7S005536
Safety Recall: DC-DC Converter Blows Main Fuse
BACKGROUND
There is a potential for the voltage converter that relays power from the Integrated Motor Assist (IMA) system to the vehicle's electrical components to fail, which will cause the headlights to turn off, the engine to stall, and prevent the vehicle from being restarted, thereby increasing the risk of a crash.
CUSTOMER NOTIFICATION
Owners of affected vehicles will receive a notification of this campaign. An example of the customer notification is at the end of this service bulletin.
Not all vehicles within the listed VIN ranges are affected by this campaign. To verify vehicle eligibility, you must check for at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark below the 15th character of the engine compartment VIN. A punch mark in that location means this campaign has already been completed.
Some vehicles affected by this campaign may be in your used vehicle inventory. As a matter of federal law, these vehicles must be repaired before they are sold.
Should a dealership sell an unrepaired vehicle that subsequently causes an injury or damage because of the recalled item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify American Honda for any resulting claims. To see if a vehicle in inventory is affected by this campaign, do a VIN status inquiry before selling it.
CORRECTIVE ACTION
Replace the DC-DC converter.
PARTS INFORMATION
DC-DC Kit: P/N 06061-RMX-305
(Includes DC-DC converter and terminal cover)
WARRANTY CLAIM INFORMATION
Operation Number: 1181M4
Flat Rate Time: 0.8 hour
Failed Part: P/N 1C800-RMX-003
Defect Code: 5JCOO
Symptom Code: R6900
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
This procedure is in an outline form that you can also use as a checklist for the repair. If you need more details on the procedures listed below, bookmark them in the service manual, or view them online:
^ 12 Volt Battery Terminal Disconnection and Reconnection
^ Rear Seat Removal/Installation
^ Turning Off and On Power High Voltage Circuit
(Keywords Service Precaution)
^ IPU Lid Removal/Installation
NOTE:
The area you will be working in contains high-voltage parts. To work in this area, you must be familiar with the IMA (integrated motor assist) system. Before continuing, make sure you have read the IMA service precautions.
1. Turn the ignition switch to LOCK (0), then disconnect the negative cable from the 12 V battery.
2. Remove the rear seat-back and the rear seat cushion.
3. Turn the battery module switch OFF.
4. Remove the IPU (Intelligent Power Unit) lid.
5. Disconnect the DC-DC converter connector.
6. Remove the wires and the output cable terminal.
7. Check if the output cable terminal has a rubber boot or a plastic terminal cover.
^ If there is a rubber boot, do Service Bulletin 07-009, Safety Recall: DC-DC Converter Output Cable Is Pinched by IPU Lid. Then, go to step 8.
^ If there is a plastic terminal cover, replace it with the one in the kit to make sure the hinge does not break when it is reassembled.
8. Remove the bolts and the DC-DC converter.
9. Install the new DC-DC converter. Torque the DC-DC converter bolts to 9.8 N.m (7.2 lb.ft).
10. Reconnect the wires, including the output terminal cable, then the DC-DC converter connector.
11. Reinstall the IPU lid. Torque the IPU lid bolts to 9.8 N.m (7.2 lb.ft).
12. Turn the battery module switch ON.
13. Reinstall the rear seat-back and the rear seat cushion.
14. Reconnect the 12 V battery.
NOTE:
If the IMA battery level gauge (BAT) displays no segments, start the engine, and hold it between 3,500 rpm and 4,000 rpm without load (in P or N) until the BAT displays at least three segments.
15. Center-punch a completion mark the 15th character of the engine compartment VIN:
Disclaimer