Stark mentions to JARVIS that they’re on “a secure…lock down” when Maya arrives. He probably shut down any security systems so that it didn’t kill her. You notice he suited up though.

In the first film, JARVIS uploaded himself directly into the Iron Man suit. I’m assuming he did the same with the others too. When the suit ran out of power, JARVIS shut down too. When the suit recharged, JARVIS came back online.
Yes, he did hack into the suit, but he used it to access one of A.I.M.’s satellites, not to control his suit.
Besides the fact that A.I.M. – Advanced Idea Mechanics - is a super genius think-tank funded by Aldrich Killian? Plus, A.I.M. was hired to re-design the Iron Patriot armor.
Killian was trying to force Rhodey out of the suit while damaging it as little as possible, so he just heated it up, forcing the suit to open up automatically. A mere hack ‘n slash would’ve completely destroyed the suit.
Tony makes a comment about that. Plus, that’s why the suit was only at 13% power.
He obviously changed his appearance for the role of the Mandarin. “They promised me more! Not to mention blah, blah, blah, plastic surgery, and a fancy speed boat!”
Watch Agents of S.H.I.E.L.D., The Winter Soldier, etc. to find out.

That’s because once he blew up his suits, he realizes that he’s essentially a changed man, which is why he “decided to take a risk” with the surgery. He just hadn’t thought of doing it before.


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