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

Power Cable Assembly

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) .
  1. Disconnect the ground terminal from battery. Ref. to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .
  2. Remove the service disconnect plug. Ref. to HYBRID ELECTRIC VEHICLE>SERVICE PLUG>REMOVAL .
  3. Move the air intake boot. Ref. to INTAKE (INDUCTION) (H4DO (EXCEPT FOR HEV))>AIR INTAKE BOOT>REMOVAL .
    NOTE: With the PCV hose connected, remove the air intake boot from the air cleaner case (rear) and throttle body.
  4. Disconnect the transmission radio ground terminal. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TH2A)>TRANSMISSION ASSEMBLY>REMOVAL .
  5. Remove the pitching stopper. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TH2A)>TRANSMISSION MOUNTING SYSTEM>REMOVAL>PITCHING STOPPER .
  6. Lift up the vehicle.
  7. Remove the fuel tank protector and the cover of inverter with converter assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL TANK PROTECTOR>REMOVAL .
  8. Remove the protector - inverter.
    1. Remove the bolts and remove the protector - inverter.
      G13939807Courtesy of SUBARU OF AMERICA, INC.
  9. Perform zero-voltage test.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolts, then remove the cover - power cable.
      G13939808Courtesy of SUBARU OF AMERICA, INC.
    2. Release the claws and remove the cover - power connector.
      WARNING: Be sure to use insulated tools.
      G13939809Courtesy 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 

      G13939810Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the floor under protector. Ref. to EXTERIOR/INTERIOR TRIM>FLOOR UNDER PROTECTOR>REMOVAL .
  11. Remove the under cover - front. Ref. to EXTERIOR/INTERIOR TRIM>FRONT UNDER COVER>REMOVAL .
  12. Remove the rear exhaust pipe. Ref. to EXHAUST (H4DO (EXCEPT FOR HEV))>REAR EXHAUST PIPE>REMOVAL .
  13. Remove the propeller shaft. Ref. to DRIVE SHAFT SYSTEM>PROPELLER SHAFT>REMOVAL .
  14. Remove the crossmember support - rear LH. Ref. to FRONT SUSPENSION>CROSSMEMBER SUPPORT>REMOVAL .
  15. Tilt the transmission assembly.
    CAUTION: A helper is required to perform this work.
    1. Set the transmission jack under the transmission.
      NOTE: Make sure that the support plates of transmission jack do not touch the oil pan.
    2. Remove the bolts and remove the transmission rear crossmember.
      G13939811Courtesy of SUBARU OF AMERICA, INC.
    3. While lowering the transmission jack a little at a time, tilt the transmission assembly to an angle where the power cable connector assembly can be disconnected.
      CAUTION: Be careful not to lower the transmission assembly too far because there is the risk of contact with and damage to peripheral parts.
  16. Remove the power cable assembly.
    WARNING: Be sure to wear insulated gloves.
    1. Disconnect the power cable terminal (MG1).
      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.
      1. Remove the bolts, then remove the guard - power cable MG1.
        G13939812Courtesy of SUBARU OF AMERICA, INC.
      2. Release the claws and remove the cover - power connector.
        WARNING: Be sure to use insulated tools.
        G13939813Courtesy of SUBARU OF AMERICA, INC.
      3. Remove the bolts and disconnect the power cable terminal (MG1).
        WARNING: Be sure to use insulated tools.
        G13939814Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the bolts and clips, then remove the guard - power cable cover.
      G13939815Courtesy of SUBARU OF AMERICA, INC.
    3. Disconnect the power cable terminal (MG2).
      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.
      1. Remove the bolt.
      2. Release the clips, then remove the guard - power cable MG2.
        G13939816Courtesy of SUBARU OF AMERICA, INC.
      3. Release the claws and remove the cover - power connector.
        WARNING: Be sure to use insulated tools.
        G13939817Courtesy of SUBARU OF AMERICA, INC.
      4. Remove the bolts and disconnect the power cable terminal (MG2).
        WARNING: Be sure to use insulated tools.
        G13939818Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the power cable clamps.
      G13939819Courtesy of SUBARU OF AMERICA, INC.
    5. 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.
    6. Remove the bolts and nuts and release the clips, then remove the power cable assembly from the vehicle.
      G13939820Courtesy of SUBARU OF AMERICA, INC.
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