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Home >> Subaru >> 2021 >> Crosstrek Sport >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Hybrid Electric Vehicle System) >> Relay and Fuse >> Removal >> HV Battery Junction Block Assembly

HV Battery Junction Block 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) .
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.
NOTE: Because the HV battery internal relay is integrated with the HV battery junction block assembly, it cannot be removed. If defective, replace the HV battery junction block assembly.
  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. 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.
      G13939636Courtesy 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.
      G13939637Courtesy of SUBARU OF AMERICA, INC.
  7. 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 

      G13939638Courtesy of SUBARU OF AMERICA, INC.
  8. 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.
      G13939639Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Store the removed Interlock clip together with the service disconnect plug.
  9. Remove the bar - floor front COMPL.
    1. Remove the bolts, and remove the bar - floor front COMPL.
      G13939640Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the cover - battery front.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolts, and then remove the cover - battery front.
      G13939641Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the cover - charger.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolts, and then remove the cover - charger.
      G13939642Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the frame battery - upper COMPL.
    WARNING: Be sure to wear insulated gloves.
    1. Remove the bolts and remove the frame battery - upper COMPL.
      G13939643Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the hybrid battery terminal block.
    WARNING:
    • Be sure to wear insulated gloves and use insulated tools.
    • Be sure to use an insulating sheet at locations other than the work location.
    1. Disconnect the connector.
    2. Remove the nut and remove the hybrid battery terminal block.
      G13939644Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the nuts, and remove the bracket - block.
      G13939645Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the HV battery junction block assembly.
    WARNING:
    • Be sure to wear insulated gloves and use insulated tools.
    • Be sure to use an insulating sheet at locations other than the work location.
    1. Disconnect the connector and connector clamp, and remove the cord clips and wire clips.
    2. Detach the flange (a).
    3. Remove the bolts and nuts.
      G13939646Courtesy of SUBARU OF AMERICA, INC.
    4. Disconnect the connector while moving the HV battery junction block assembly, and remove the HV battery junction block assembly.
      CAUTION: Be careful not to damage the cord.
      G13939647Courtesy of SUBARU OF AMERICA, INC.
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