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Home >> Subaru >> 2020 >> Crosstrek Base, Automatic CVT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (Hybrid Electric Vehicle System) >> Inverter And Converter Assembly >> Removal

Inverter And Converter Assembly: Removal

WARNING: This page is about a different variant/trim than selected.
WARNING: The hybrid system includes a high voltage circuit. Mishandling could cause accidents such as electric shock or leak. Refer to PRECAUTION/WARNING>Warning (HYBRID SYSTEM) .
CAUTION: Airbag system satellite safing sensor is located under the front center of the rear seat cushion. Be careful not to apply strong impact to the sensor when working with the rear seat cushion removed.
  1. Disconnect the ground terminal from battery and wait for at least 60 seconds before starting work. Refer to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .
  2. Remove the service disconnect plug. Refer to HYBRID ELECTRIC VEHICLE>SERVICE PLUG>REMOVAL .
  3. Remove the rear seat cushion assembly and the backrest assembly LH. Refer to SEATS>REAR SEAT>REMOVAL .
  4. Disconnect the main battery cable assembly.
    WARNING: Be sure to wear insulated gloves.
    1. Release the clip and hook, and then remove the cover - interlock.
      G13235540Courtesy of SUBARU OF AMERICA, INC.
    2. Disconnect the ground terminal and remove the cable clip.
    3. Disconnect the connector and disconnect the main battery cable assembly.
      CAUTION:
      • Be sure to insulate the disconnected connector by wrapping it with insulating tape.
      • Apply tape or similar item (that will not leave adhesive residue) to close the opening after the cable was disconnected so that foreign matter, water drops, or other substance does not enter.
      G13235541Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the cover - inverter.
    WARNING: Be sure to wear insulated gloves.
    1. Disconnect the connector and remove the screw.
    2. Remove the cable grommet and harness grommet, then remove the cover - inverter
      G13235667Courtesy of SUBARU OF AMERICA, INC.
  6. Disconnect the connector of inverter with converter assembly.
    WARNING: Be sure to wear insulated gloves.
    1. Raise the lock lever as shown in the figure and disconnect the connector of inverter with converter assembly.
      CAUTION:
      • When disconnecting the connector, be careful not to scratch the connector housing or the inverter with converter assembly.
      • Be sure to insulate the disconnected connector by wrapping it with insulating tape.
      • Apply tape or similar item (that will not leave adhesive residue) to close the opening and connector seal after the terminal was disconnected so that foreign matter, water drops, or other substance does not enter.
      G13235668Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the HV air conditioning wire.
    WARNING: Be sure to wear insulated gloves.
    1. Disconnect the compressor assembly connector.
      CAUTION:
      • Be sure to insulate the disconnected connector by wrapping it with insulating tape.
      • Apply tape or similar item (that will not leave adhesive residue) to close the opening after the cable was disconnected so that foreign matter, water drops, or other substance does not enter.
      1. Release the claws and then remove the cable clip.
      2. Use protective tape to wrap a flat tip screwdriver of an appropriate size for the insertion opening, and disengage lock (a).
      3. Press the tab (b) to disconnect the connector.
      G13234276Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the nut and disconnect the positive terminal of the HV air conditioning wire.
    3. Release the claws and remove the wire clamp.
      G13235670Courtesy of SUBARU OF AMERICA, INC.
  8. Lift up the vehicle.
  9. Remove the fuel tank protector and the cover of inverter with converter assembly. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL TANK PROTECTOR>REMOVAL .
  10. Remove the protector - inverter.
    1. Remove the bolts and remove the protector - inverter.
      G13235671Courtesy of SUBARU OF AMERICA, INC.
  11. Perform zero-voltage test.
    WARNING: Be sure to wear insulated gloves.
    1. Check the power cable terminal.
      1. Remove the bolts, then remove the cover - power cable.
        G13235672Courtesy of SUBARU OF AMERICA, INC.
      2. Release the claws and remove the cover - power connector.
        WARNING: Be sure to use insulated tools.
        G13235673Courtesy of SUBARU OF AMERICA, INC.
      3. Measure the voltage of the high voltage line between power cable assembly terminals.

        Preparation tool: 

        Circuit tester

        Standard: 0 V 

        G13235674Courtesy of SUBARU OF AMERICA, INC.
    2. Check the HV air conditioning wire terminal.
      1. Release the claws, and then open the cap - terminal.
        G13235675Courtesy of SUBARU OF AMERICA, INC.
    3. Measure the voltage at the HV air conditioning wire 12V terminal.

      Preparation tool: 

      Circuit tester

      Standard: 0 V 

      G13235676Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the floor under protector LH. Refer to EXTERIOR/INTERIOR TRIM>FLOOR UNDER PROTECTOR>REMOVAL .
  13. Remove the under cover - front. Refer to EXTERIOR/INTERIOR TRIM>FRONT UNDER COVER>REMOVAL .
  14. Drain the engine coolant (inverter assembly side). Refer to COOLING (H4DO (HEV))>ENGINE COOLANT>REPLACEMENT>DRAINING OF ENGINE COOLANT .
  15. Remove the crossmember support - rear LH and front exhaust pipe. Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>FRONT EXHAUST PIPE>REMOVAL .
  16. Remove the rear exhaust pipe. Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>REAR EXHAUST PIPE>REMOVAL .
  17. Disconnect the power cable assembly.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolts and disconnect the power cable terminal.
      WARNING: Be sure to use insulated tools.
      CAUTION:
      • Be careful not to use excessive force when disconnecting the power cable terminal to avoid any damage.
      • Be sure to insulate the disconnected power cable terminals by wrapping it with insulating tape.
      • Apply tape or similar item (that will not leave adhesive residue) to close the opening and connector seal after the terminal was disconnected so that foreign matter, water drops, or other substance does not enter.
    2. Remove the bolts, nuts and clips, then remove the power cable assembly.
      G13607469Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Perform only the work necessary to remove the inverter with converter assembly.
    3. Prepare the wiring harness and other parts that will be disposed of, then move the power cable assembly to a position where it will not interfere with work and fasten it in place.
  18. Install the protector - inverter.
    1. Temporarily install the protector - inverter.
    2. Tighten the bolts in the order of (a) - (c).

      Tightening torque: 

      18 N.m (1.8 kgf-m, 13.3 ft-lb)

      Fig 1: Protector - Inverter Bolts Tightening Sequence
      G13235678Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the pipe COMPL - center.
    1. Loosen the clamp, and disconnect the inverter inlet hose and Inverter outlet hose.
      CAUTION:
      • After disconnecting the inverter inlet hose and inverter outlet hose, in order to prevent engine coolant from splashing onto surrounding parts and to prevent entry of foreign substances into the engine coolant passage, seal the pipes and hoses with hose plugs or other means, or else wrap them with plastic bags or similar items.
      • Do not apply excessive force to the inverter inlet hose and inverter outlet hose.
      G13235679Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Put alignment marks onto the hoses, clamps, etc. while working.
  20. Remove the inverter with converter assembly.
    WARNING: Be sure to wear insulated gloves.
    CAUTION:
    • Check that the cable terminal and connector opening are sealed with tape or similar item (that will not leave adhesive residue).
    • When removing and storing the inverter with converter assembly, take steps so that foreign matter, water drops, or other substance does not enter.
    NOTE: Remove the inverter with converter assembly together with the HV air conditioning win and main battery cable assembly.
    1. Remove the bolts and disconnect the ground cable.
      G13235680Courtesy of SUBARU OF AMERICA, INC.
    2. Release the claws and disconnect the hose - air breather. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE E) .
      G13235681Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the bolts, nuts, and clips, then remove the HV air conditioning wire.
      G13235682Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the bolts, then remove the electronic parking brake harness LH and support - sub frame LH.
      G13235683Courtesy of SUBARU OF AMERICA, INC.
    5. Place the lower part of the protector - inverter of the inverter with converter assembly onto the transmission jack.
      G13235684Courtesy of SUBARU OF AMERICA, INC.
    6. Remove the bolts and remove the inverter with converter assembly.
      CAUTION:
      • A helper is required to perform this work.
      • Be careful not to damage the HV air conditioning wire and main battery cable assembly.
      • When removing the inverter with converter assembly, be careful to avoid damaging surrounding parts while working. Do not grasp the inverter rear water pipe COMPL.
      • In order to prevent damage caused by static electricity, do not touch the connector terminals of the inverter with converter assembly side.
      G13235685Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Even after draining the engine coolant (inverter assembly side), due to the structure there will still be engine coolant remaining in the inverter with converter assembly. Therefore use hose plugs or other means to seal the openings, or wrap them with plastic bags or similar items, so that engine coolant does not spill when removing the inverter with converter assembly.
  21. Remove the hose - air breather.
    1. Release the hose and remove the hose - air breather from the clamp.
      G13235686Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the cover - inverter rivets and clips.
    G13235687Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Remove the rivets with a rivet cutter, nipper, or similar tool, and open the cover inverter.
  23. Remove the HV air conditioning wire.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolt and disconnect the HV air conditioning wire (air conditioner cable) connector.
      CAUTION:
      • When disconnecting the HV air conditioning wire (air conditioner cable) connector be careful not to use excessive force or damage the connector.
      • Be sure to insulate the disconnected connector by wrapping it with insulating tap
      • Apply tape or similar item (that will not leave adhesive residue) to close the opening and connector seal after the terminal was disconnected so that foreign matter, water drops, or other substance does not enter.
    2. Remove the nut and disconnect the 12V terminal of the HV air conditioning wire (DCDC cable)
    3. Remove the bolts and release the clips, then remove the HV air conditioning wire.
      CAUTION: Be careful not to damage the HV air conditioning wire.
      G13235688Courtesy of SUBARU OF AMERICA, INC.
      G13607481Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the main battery cable assembly.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolts and disconnect the main battery cable connector.
      CAUTION:
      • When disconnecting the main battery cable connector, be careful not to use excessive force or damage the connector.
      • Be sure to insulate the disconnected connector by wrapping it with insulating tape
      • Apply tape or similar item (that will not leave adhesive residue) to close the opening and connector seal after the terminal was disconnected so that foreign matter, water drops, or other substance does not enter.
    2. Remove the bolts and remove the main battery cable assembly.
      CAUTION: Be careful not to damage the main battery cable assembly.
      G13607482Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the inverter rear water pipe COMPL.
    1. Loosen the clamp, and disconnect the inverter inlet hose and Inverter outlet hose.
      CAUTION:
      • After disconnecting the inverter inlet hose and inverter outlet hose, in order to prevent engine coolant from splashing onto surrounding parts and to prevent entry of foreign substances into the engine coolant passage, seal the pipes and hoses with hose plugs or other means, or else wrap them with plastic bags or similar items.
      • Do not apply excessive force to the inverter inlet hose and inverter outlet hose.
      NOTE: Put alignment marks onto the hoses, clamps, etc. while working.
    2. Remove the bolts and remove the inverter rear water pipe COMPL.
      G13235691Courtesy of SUBARU OF AMERICA, INC.
  26. Remove the protector - inverter and cover - inverter.
    1. Remove the bolts and remove the protector - inverter and cover - inverter.
      G13235692Courtesy of SUBARU OF AMERICA, INC.
    2. Place the inverter with converter assembly onto wooden blocks.
      CAUTION: Because there is the risk of damage to the inverter with converter assembly, support it at the position shown in the figure.
      G13235693Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the brackets from the inverter with converter assembly.
    1. Remove the bolts and remove the stay COMPL - inverter.
      G13235694Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the bolts and remove the front bracket assembly - inverter and insulator - front.
      G13235695Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the bolts and remove the rear bracket assembly - inverter and bracket assembly - rear.
      G13235696Courtesy of SUBARU OF AMERICA, INC.
  28. Remove the bolts, and then remove the inverter terminal cover.
    WARNING: Be sure to wear insulated gloves.
    CAUTION: Do not tighten or loosen the inverter terminal cover screws,
    G13235697Courtesy of SUBARU OF AMERICA, INC.
  29. Remove the bolts and detach the motor cable.
    WARNING: Be sure to wear insulated gloves and use insulated tools.
    CAUTION:
    • Be sure to insulate the disconnected motor cable by wrapping it with insulating tape.
    • Protect the disconnected motor cable by wrapping it with a plastic bag or similar item.
    • Apply tape or similar item (that will not leave adhesive residue) to close the opening after the connector was disconnected so that foreign matter, water drops, or other substance does not enter.
    • Apply tape or similar item (that will not leave adhesive residue) to close the opening and motor cable seal after the motor cable was disconnected so that foreign matter, water drops, or other substance does not enter.
    G13607490Courtesy of SUBARU OF AMERICA, INC.
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