How to Bypass a 2000-2006 Honda Insight Hybrid Battery

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Step Description Picture
Safety First!
Safety Unplug the negative terminal of the 12V battery (the black wire) under the hood. 12v battery. EV Powers Hybrid Battery Service and Repair
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Accessing the battery
O1 Open the rear hatch Open the rear hatch. EV Powers Hybrid Battery Service and Repair
O2 Remove the carpet and trunk box. Remove the carpet and trunk box. EV Powers Hybrid Battery Service and Repair
O3 Open the small cover by removing the two short 10mm bolts. Open the small cover by removing the two short 10mm bolts. EV Powers Hybrid Battery Service and Repair
O4 Turn off the switch, put the red cover back on backwards and remove the little bolt using the 8mm wrench. Turn off the switch, put the red cover back on backwards and remove the little bolt using the 8mm wrench. EV Powers Hybrid Battery Service and Repair
O5 Remove this plate. There are three bolts at the rear and three push-clips that look like phillips-head screws. Use a sharp knife or small screwdriver to pry up the center of the clip and remove it, Then the ring can be removed. Remove this plate. There are three bolts at the rear and three push-clips that look like phillips-head screws. Use a sharp knife or small screwdriver to pry up the center of the clip and remove it, Then the ring can be removed. EV Powers Hybrid Battery Service and Repair
O6 Remove all the bolts in the lid. Most are 10mm except three on the each side are Torx T30. Remove all the bolts in the lid. These are 10mm and the three on the each side are Torx T30. EV Powers Hybrid Battery Service and Repair
O7 Peel back the rug to reveal an additional row of 10mm bolts to be removed. Peel back the rug to reveal an additional row of bolts to be removed. EV Powers Hybrid Battery Service and Repair
O8 Remove the three 10mm bolts on the vertical portion of the lid. Remove the three 10mm bolts on the vertical portion of the lid. EV Powers Hybrid Battery Service and Repair
O9 Remove the lid. This is what you’ll see. Lift off the white foam pieces. You will be working with the computer on the left side on top of the black case (battery pack). Remove the lid. EV Powers Hybrid Battery Service and Repair
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Bypassing the battery. DC/DC converter remains active.
B1 Unplug these two plugs from the computer module. (For additional reference, in the previous picture, O9, it is the computer with the warning tag on it.) The plugs are on the backside of the computer, facing the front of the car. Unplug these two plugs from the computer module. EV Powers Hybrid Battery Service and Repair

That’s it! Now it’s time to put everything back together.

When putting everything back together, begin by threading all the bolts in by hand with only a few turns. Do not tighten them down until all the bolts are in place (step C5). Do not install the switch cover until step C7.

C1 Put the lid on and, using only a few turns, partially install the three 10mm bolts on the vertical portion of the lid. (see picture in step O8)

C2 Using only a few turns, partially install the row of bolts that run under the carpet. (see picture in step O7)

C3 Using only a few turns, partially install all the bolts in the lid.

C4 Put the rear plate into its position. There are three bolts at the rear and three push-clips that look like phillips-head screws. Push the plastic ring in and then push in the center pins, THEN partially put the three bolts in. (see picture in step O5)

C5 NOW you can finish tightening all the lid bolts.(Except the switch cover.)

C6 Install the little 8mm bolt next to the battery switch. DO NOT turn on the switch. Leave it in the “OFF” position.

C7 Put the switch cover back on with its two short 10mm bolts.

C8 Install the trunk box and all the carpet.