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Home >> Subaru >> 2021 >> Crosstrek Sport >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Hybrid Electric Vehicle System) >> Electric Vehicle Charger >> Removal >> EV Charger

EV Charger

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. Always check "WARNING (HYBRID SYSTEM)" and perform the proper operation. Ref. 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. Ref. to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .
  2. Remove the service disconnect plug. Ref. to HYBRID ELECTRIC VEHICLE>SERVICE PLUG>REMOVAL .
  3. Remove the rear seat cushion assembly and the backrest assembly LH. Ref. to SEATS>REAR SEAT>REMOVAL .
  4. Remove the trim panel - rear apron. Ref. to EXTERIOR/INTERIOR TRIM>REAR QUARTER TRIM>REMOVAL .
  5. Remove the Reverse Automatic Braking Control Module. Ref. to REVERSE AUTOMATIC BRAKING>REVERSE AUTOMATIC BRAKING CONTROL MODULE>REMOVAL .
  6. Remove the duct assembly - cooling out. Ref. to HYBRID ELECTRIC VEHICLE>HIGH VOLTAGE BATTERY COOLING SYSTEM>REMOVAL>REAR DUCT .
  7. Remove the charger duct. Ref. to HYBRID ELECTRIC VEHICLE>ELECTRIC VEHICLE CHARGER>REMOVAL>CHARGER DUCT .
  8. 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.
      G13939706Courtesy 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.
      G13939707Courtesy of SUBARU OF AMERICA, INC.
  9. Perform zero-voltage test.
    WARNING: Be sure to wear insulated gloves.
    1. Measure the voltage of the high voltage line between HV battery connector terminals.

      Preparation tool:  Circuit tester

      Standard: 0 V 

      G13939708Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the cover - sensor.
    WARNING: Be sure to wear insulated gloves.
    1. Using the service disconnect plug, release the interlock clip.
      1. Align the projecting portion on the service disconnect plug with the interlock clip groove.
        CAUTION: To avoid damaging the projecting portion and the clip, fit the service disconnect plug completely.
      2. While holding the Interlock clip, rotate and detach the service disconnect plug in the direction of arrow shown in the figure.
    2. Remove the bolts, and then remove the cover - sensor.
      G13939709Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Store the removed Interlock clip together with the service disconnect plug.
  11. Remove the bar - floor front COMPL.
    1. Remove the bolts, and remove the bar - floor front COMPL.
      G13939710Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the cover - battery front.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolts, and then remove the cover - battery front.
      G13939711Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the electric vehicle charger assembly.
    WARNING:
    • Be sure to wear insulated gloves.
    • Be sure to use an insulating sheet at locations other than the work location.
    1. Disconnect the wire harness connector, and remove the connector clip.
      G13939712Courtesy of SUBARU OF AMERICA, INC.
    2. Disconnect the HV battery charger wire No. 1 connector.
      CAUTION: Be sure to insulate the disconnected connector by wrapping it with insulating tape.
      1. Use protective tape to wrap a flat tip screwdriver of an appropriate size for the insertion opening, and disengage lock (a).
      2. Press the tab (b) to disconnect the connector.
        G13939713Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the connector clips and wire clips, and disconnect the HV battery charger wire No. 1.
      G13939714Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the bolts and disconnect the ground terminal.
      G13939715Courtesy of SUBARU OF AMERICA, INC.
    5. Remove the bolts, and then remove the cover - charger.
      G13939716Courtesy of SUBARU OF AMERICA, INC.
    6. Remove the bolts and remove the frame battery - upper COMPL.
      G13939717Courtesy of SUBARU OF AMERICA, INC.
    7. Remove the connector and wire clips, and disconnect the HV battery charger wire No. 2.
      WARNING: Be sure to use insulated tools.
      G13939718Courtesy of SUBARU OF AMERICA, INC.
    8. Remove the bolts, and remove the electric vehicle charger assembly.
      WARNING: Be sure to use insulated tools.
      CAUTION: Be careful not to apply excessive force to the cable or harness, or allow them to contact other parts.
      G13939719Courtesy of SUBARU OF AMERICA, INC.
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