MSA5P1702C – Technician Reference Booklet – 2014 Subaru XV Crosstrek Hybrid

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Technician Reference Booklet MSA5P1702C November 2013 New Technology Training 2014 XV Crosstrek Hybrid Module 702 © Subaru of America, Inc. 2013 702 Rev-1 © Copyright 2013 Subaru of America, Inc. All rights reserved. This book may not be reproduced in whole or in part without the express permission of Subaru of America, Inc. Specifications in this Guide are based on the latest product information available at the time of publication. Some images shown are for illustration purposes only. Subaru of America, Inc. reserves the right at any time to make changes or modifications to systems, procedures, descriptions, and illustrations contained in this book without necessarily updating this document. Information contained herein is considered current as of Novemberr 2013. This Technical Reference Booklet (TRB) is designed to be used in a classroom environment or as a guide for self study. The TRB is not intended to be used as a supplement or substitute for the Subaru Service Manual. Always consult the appropriate Service Manual when performing any diagnostics, maintenance or repair to any Subaru vehicle. © 2013 Subaru of America, Inc. Printed in USA. All rights reserved. Contents may not be reproduced in whole or in part without prior written permission of publisher. Specifications in this Guide are based on the latest product information available at the time of publication. Some images shown are for illustration purposes only. Some equipment shown in photography within this Guide is optional at extra cost. Specific options may be available only in combination with other options. Specific combinations of equipment or features may vary from time to time, and by geographic area. Subaru of America, Inc. reserves the right to change or discontinue at any time, without notice: Prices, colors, materials, equipment, accessories, specifications, models and packages, without incurring any obligation to make the same or similar changes on vehicles previously sold. Colors shown may vary due to reproduction and printing processes. Subaru of America, Inc. is not responsible for typographical errors. Aha™ is a trademark of HARMAN International Industries, Inc.) Alcantara ® is a registered trademark of Alcantara S.p.A., and Alcantara is produced by the Toray Group. BBS ® is a registered trademark of BBS Kraftahrzeugtechnik AG. Bluetooth ® is a registered trademark of Bluetooth SIG, Inc. Brembo ® is a registered trademark of Freni Brembo S.p.A. CS Auto, Circle Surround Automotive and WOW are trademarks of SRS Labs, Inc. Ecsaine ® is a registered trademark of Toray Industries, Inc. Harman Kardon ® is a registered trademark of Harman International Industries, Inc. HD Radio® is a registered trademark of iBiquity Digital Corporation. HomeLink ® is a registered trademark of Prince Corporation, a wholly owned subsidiary of Johnson Controls. iPod ® is a registered trademark of Apple Inc. iTunes ® is a registered trademark of Apple Inc. Metal-Matrix Diaphragm (MMD ®) is a registered trademark of Harman International Industries, Inc. Smart Way ® is a registered trademark of the U.S. Environmental Protection Agency. SRS(•) ® Circle Surround Automotive and WOW are registered trademarks of SRS Labs, Inc. TORSEN LSD ® is a registered trademark of JTEKT TORSEN North America, Inc. SiriusXM ® is a registered trademark of SiriusXM Satellite Radio, Inc. / SiriusXM NavTraffic ® is a registered trademark of SiriusXM Satellite Radio, Inc. Added Security, BRZ, EyeSight, Impreza, Forester, Lineartronic, Legacy, Outback, Subaru, SUBARU BOXER, Tribeca, and WRX, STI, and XV Crosstrek are registered trademarks of Fuji Heavy Industries, Ltd. Subaru STARLINK is a trademark of Fuji Heavy Industries, Ltd. Table of Contents Introduction…………………………………………………………………………………………….7 XV Crosstrek vehicle specifications……………………………………………………..8 Hybrid Service Safety Precautions……………………………………………………. 11 Procedures at an accident scene……………………………………………… 18 Procedure after moving damaged vehicle………………………………….. 19 Pre-delivery Inspection…………………………………………………………………….22 Engine Air Filter……………………………………………………………………………….23 Brake Vacuum Pump ………………………………………………………………………24 Automatic Grill Shutter System………………………………………………………….28 Pedestrian Approach System…………………………………………………………….30 Hybrid Safety Kit……………………………………………………………………………………35 Hybrid Lineartronic™ Continuously Variable Transmission Power Flow (CVT Power Flow)………………………………………………………………..41 CVT Oil Pump………………………………………………………………………..52 Electrical Wiring Configuration………………………………………………………………55 Batteries…………………………………………………………………………………………56 Contactor and High Voltage Battery Voltage………………………………………..66 Driving and Charging Devices……………………………………………………………….69 ISG Terminals and Inputs Signals……………………………………………………… 74 Interconnect Relay…………………………………………………………………………..78 Electrical Operation…………………………………………………………………………80 Before Automatic Start Stop activates………………………………………..80 During Automatic Start Stop Operation………………………………………82 Hybrid Motor…………………………………………………………………………………………83 Hybrid Component and High Voltage Battery………………………………………88 High Voltage Battery Removal………………………………………………………………..91 XV Crosstrek Hybrid CAN Communications…………………………………………. 105 HEV CAN…………………………………………………………………………………….. 106 PU CAN………………………………………………………………………………………. 107 Hybrid Component Locations…………………………………………………. 109 XV Crosstrek Hybrid Diagnostics and Servicing…………………………………… 123 Normal Vehicle Characteristics and Service Cautions………………………… 123 Maintenance Mode……………………………………………………………………….. 134 Hybrid Failsafe Operation………………………………………………………………. 134 Removing/Installing the V-belt Tensioner Assy…………………………………… 139 Removing a Damaged V-belt………………………………………………………….. 141 Installing the V-belt Tensioner Assy & V-belt……………………………………… 143 Jump starting the vehicle………………………………………………………. 145 7 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Introduction 2014 XV Crosstrek Hybrid Engine Cover The 2014 model year Subaru XV Crosstrek model lineup introduces the first Subaru Hybrid model, the XV Crosstrek Hybrid and the XV Crosstrek Hybrid Touring. Subaru XV Crosstrek model lineup: – 2.0i Premium – 2.0i Limited – Hybrid – Hybrid Touring The 2014 XV Crosstrek Hybrid is classified as a mild hybrid vehicle that can provide: – Engine Drive Mode – Electric Vehicle Mode (EV) – Electric Motor Assist – Automatic Start Stop functions The Lineartronic™ Continuously Variable Transmission (CVT Hybrid), which is equipped with a 13.68 horsepower 3 phase Alternating Current (AC) permanent magnet synchronous motor, provides the new Hybrid driving force. Warning: • Only technicians who have received Instructor led technical training for the Hybrid Electrical Vehicle Systems should perform service or maintenance of high voltage circuits. • All the harnesses and connectors for power cables are orange in color. In addition, caution labels indicating [High Voltage] are attached on the High Voltage Battery and the battery cover. Do not touch the wires and parts related to high voltage without proper Personal Protective Equipment. 3 4 8 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) XV Crosstrek vehicle specifications Model 2.0 L 2.0 L HEV Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Valve arrangement DOHC Bore × stroke mm (in) 84.0 × 90.0 (3.31 × 3.54) Displacement cm3 (cu in) 1,995 (121.73) Compression ratio 10.5 10.8 Ignition order 1 — 3 — 2 — 4 Idle speed at parking or neutral position rpm MT: 650±50 CVT: 650±50 MT: 650±100 CVT: 650±100 Maximum output kW (HP)/rpm 110 (147)/6,200 110 (147)/6,000 Maximum torque N·m (kgf-m, ft-lb)/rpm 196 (20.0, 145)/4,200 Engine Specifications Model 2.0 L 2.0 L HEV Ignition timing (at idling) BTDC MT: 16°±10° CVT: 16°±10° MT: 10°±10° CVT: 10°±10° Spark plug Type and manufacturer NGK: SILZKAR7B11 NGK: DILZKAR7B11 Generator 12 V — 110 A — Integrated starter generator (ISG) — 12 V — 180 A Battery Type and capacity (5HR) 12 V — 48 AH (55D23L) 12 V — 48 AH (55D23L) (12 volt auxiliary battery) 12 V — 41 AH (N55-R) (12 volt engine restart battery) CCA 390 A 390 A (12 volt auxiliary battery) 450 A (12 volt engine restart battery) High voltage battery Type and capacity (1HR) — 100.8 V — 5.5 AH Ni-MH (nickel metal hydride) battery Drive motor kind — Three-phase AC synchronous motor Rated voltage — 100 V Maximum output — 10 kW [13.6 PS] Maximum torque — 65 N·m [6.6 kgf-m] Electrical Specifications Model 2.0 L DOHC non-turbo 2.0 L DOHC motor hybrid Transmission type CVT CVT (HEV) Clutch type TCC Gear ratio Forward 3.581 — 0.570 3.420 — 0.544 Rev. 3.667 3.502 Reduction gear (front) Final reduction Type of gear Hypoid Gear ratio 3.700 Transfer reduction ratio 1.000 Reduction gear (rear) Type of gear Hypoid Gear ratio 3.700 CVT Specifications 5 6 7 9 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Model 2.0 L 2.0 L HEV Type Rack and pinion Turns, lock to lock 3.1 2.8 Minimum turning diameter m (ft) Curb to curb 10.6 (34.8) Wall to wall 11.5 (37.7) Steering specifications Model 2.0 L 2.0 L HEV 5MT CVT CVT Fuel tank L (US gal, Imp gal) 60 (15.9, 13.2) 52 (13.7, 11.4) Engine oil Total capacity (at overhaul) L (US qt, Imp qt) 5.7 (6.0, 5.0) When replacing engine oil and oil filter L (US qt, Imp qt) 4.8 (5.1, 4.2) When replacing engine oil only L (US qt, Imp qt) 4.6 (4.9, 4.0) Transmission gear oil L (US qt, Imp qt) 3.5 (3.7, 3.1) — — CVTF L (US qt, Imp qt) — 11.93 — 12.43 (12.6 — 13.1, 10.5 — 10.9) 13.46 — 13.96 (14.2 — 14.8, 11.8 — 12.3) Front differential gear oil L (US qt, Imp qt) — 1.3 — 1.4 (1.4 — 1.5, 1.1 — 1.2) 1.3 — 1.4 (1.4 — 1.5, 1.1 — 1.2) Rear differential gear oil L (US qt, Imp qt) 0.8 (0.8, 0.7) Engine coolant L (US qt, Imp qt) 7.6 (8.0, 6.7) 8.0 (8.5, 7.0) 8.2 (8.7, 7.2) Capacity Specifications Note: No towing with Hybrid Vehicle. Note: Hybrid vehicle must be flat towed. (See Subaru XV Crosstrek Hybrid Owner’s manual) 8 9 10 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Model 5 door 2.0 i-Prm Transmission CVT OP code C0 C0 U5 U6 U5 U6 U5 U6 U5 U6 U5 U6 IE CM 3A 3A 3E 3E 3S 3S VE VE VS VS Curb weight (C.W.) Total kg (lb) 1,440 (3,175) 1,455 (3,208) 1,440 (3,175) 1,440 (3,175) 1,440 (3,175) 1,440 (3,175) 1,455 (3,208) 1,455 (3,208) 1,440 (3,175) 1,440 (3,175) 1,455 (3,208) 1,455 (3,208) Front kg (lb) 860 (1,896) 865 (1,907) 860 (1,896) 860 (1,896) 860 (1,896) 860 (1,896) 865 (1,907) 865 (1,907) 860 (1,896) 860 (1,896) 865 (1,907) 865 (1,907) Rear kg (lb) 580 (1,279) 590 (1,301) 580 (1,279) 590 (1,301) 580 (1,279) 580 (1,279) 590 (1,301) 590 (1,301) 580 (1,279) 580 (1,279) 590 (1,301) 590 (1,301) Gross vehicle weight (G.V.W.) kg (lb) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) Gross axle weight (G.A.W.) Front kg (lb) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) 1,010 (2,227) Rear kg (lb) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 1,000 (2,205) 5 Door 2.0 i-Premium CVT Model 5 door HEV 2.0 i-Prm Transmission CVT (HEV) OP code U5 U5 U5 U5 U5 C5 C5 C5 C5 IA IE IS IE KS IE IS CM 1U Curb weight (C.W.) Total kg (lb) 1,560 (3,440) 1,560 (3,440) 1,580 (3,484) 1,565 (3,451) 1,580 (3,484) 1,560 (3,440) 1,575 (3,473) 1,575 (3,473) 1,580 (3,484) Front kg (lb) 930 (2,051) 930 (2,051) 940 (2,073) 935 (2,062) 940 (2,073) 930 (2,051) 935 (2,062) 935 (2,062) 940 (2,073) Rear kg (lb) 630 (1,389) 630 (1,389) 640 (1,411) 630 (1,389) 640 (1,411) 630 (1,389) 640 (1,411) 640 (1,411) 640 (1,411) Gross vehicle weight (G.V.W.) kg (lb) 2,120 (4,674) 2,120 (4,674) 2,120 (4,674) 2,120 (4,674) 2,120 (4,674) 2,120 (4,674) 2,120 (4,674) 2,120 (4,674) 2,120 (4,674) Gross axle weight (G.A.W.) Front kg (lb) 1,110 (2,447) 1,110 (2,447) 1,110 (2,447) 1,110 (2,447) 1,110 (2,447) 1,110 (2,447) 1,110 (2,447) 1,110 (2,447) 1,110 (2,447) Rear kg (lb) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 5 Door HEV 2.0 i-Premium CVT (HEV) 11 10 11 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Service Safety Precautions CAUTION (HYBRID SYSTEM) 1. PRECAUTIONS FOR MAINTENANCE AND SERVICE The hybrid system includes a high voltage circuit. Mishandling may cause electric shocks and leakage. Therefore, perform proper operations by following procedures in the Subaru Service Manual. • Technicians who have not received Subaru Hybrid training should not perform maintenance or service of high voltage circuits. • All the harnesses and connectors for power cables are orange in color. In addition, caution labels indicating [High Voltage] are attached on the High Voltage battery and its battery cover. Do not touch the wires and parts related to high voltage carelessly. • Use great care, when handling the power supply circuits for high voltage system shown in the figure. High Voltage Battery and Harness • When performing maintenance of the high voltage system, make sure to take measures for preventing electrocution, by wearing insulated gloves, removing the Service Plug, etc. In addition, carry the removed Service Plug in your pocket in order to prevent other servicemen from accidentally installing during work. 2. Service Plug • When performing maintenance of wires and parts for the high voltage system, make sure to remove the Service Plug in order to cut off the high voltage circuits. • Make sure to wear insulated gloves during the work. • Carry the removed Service Plug in your pocket in order to prevent other servicemen from accidentally installing during work. • All the wires and connectors for power cables are orange in color. Removal of Service Plug WARNING: Take the ignition key or access key out of the vehicle to avoid malfunctions of hybrid system. 1) Disconnect the ground cable from battery. NOTE: For the 12 volt engine restart battery, disconnect the ground terminal from battery sensor. 2) Remove the mat – rear cargo area floor. 3) Remove the Service Plug. 20 16 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) WARNING: After removing the Service Plug, be sure to wait for ten minutes before touching the high voltage parts, wires, terminals, and connectors, because of high voltage accumulated in the condenser within high voltage components. Service Plug in place Step 1 and 2 Step 3 (1) Pull up the lever until it touches the stopper. (2) Gently Push the locking tab and pull the lever vertical. Removing Service Plug Exposed Terminals (3) Gently pull the Service Plug straight up and remove from the vehicle. WARNING: Do not touch the exposed terminals of the battery circuit. High voltage may exist. Place electrical tape over the exposed terminals immediately after removal. 21 22 23 24 25 26 17 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Electrical Tape over exposed terminal Service Plug in pocket Place the Service Plug into your pocket. Examine the Service Plug for any abnormality, replace if any defect is found. Service Plug 125 AMP Fuse A 125 AMP fuse is located inside the Service Plug. The fuse is not serviceable. Replace the Service Plug as an assembly. NOTE: A blown fuse indicates a major electrical problem exists. Always follow the service manual when performing any diagnostics and repair. Installation of Service Plug CAUTION: • Before installing the Service Plug, make sure to check again for misplaced parts and tools, tightening conditions of high voltage terminals, and connector connections. • Always replace faulty Service Plug with a new part. • Always use the original Service Plug to install. Never use a Service Plug removed from another vehicle. Install in the reverse order of removal. NOTE: Move the lever to the horizontal position and push it until a click is heard and securely locked. 27 28 29 30 18 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 3. PROCEDURES AT AN ACCIDENT SCENE Preparation items: ◊ Protective equipment (insulated gloves, rubber gloves, protective goggles, and rubber boots for electrical purposes) ◊ Saturated boric-acid solution 20 L (In a container, dissolve 800 g of boric acid powder purchased at a drug store in 20 L of water.) ◊ Red litmus paper (purchase at a drug store) ◊ ABC extinguisher (used for oil fire and electric fire both) ◊ Cloth, old towels (for wiping electrolytic solution) ◊ Insulation tape ◊ CAT III Circuit tester Procedures at an accident scene Do not touch the exposed wires, any wires maybe high voltage. When it is necessary or possible to touch them, make sure to wear insulated gloves and insulate the wires using insulation tape. When vehicle is on fire, extinguish a fire using an ABC extinguisher. Attempting to extinguish a fire with a small amount of water may be more of a danger. Therefore, spray a large amount of water from a fire hydrant, or wait for arrival of firefighters. When the vehicle is submerged in water, do not touch the Service Plug and any other high voltage parts and wires due to a possibility of electrical shock. Perform work after completely pulling out the vehicle. • Check for any leakage in the high voltage battery vicinity. Do not touch any leaked fluid, because it may be a strong alkaline electrolytic solution. When it is necessary to touch it, wear insulated gloves and protective goggles, neutralize with saturated boric-acid solution, confirm that red litmus paper does not change to blue, when sampling the fluid and then wipe off with cloth. • When the vehicle is damaged due to collision, stop the hybrid system in the following steps. 1. Turn the ignition to OFF. NOTE: When the ignition cannot be turned to OFF, remove the fuse in engine compartment. 2. Wear insulated gloves and remove the Service Plug. 4. MOVING DAMAGED VEHICLE • When one of the following conditions applies, use a tow truck to move the vehicle. CAUTION: Refer to [Towing] for towing procedures. • High voltage system parts and wires are damaged. • The ready-to-drive (READY) indicator light does not illuminate with the ignition at ON. 19 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) CAUTION: Using a tow truck, tow the vehicle with the negative terminal of 12 volt auxiliary battery disconnected, and the Service Plug removed. • Move the vehicle by driving it, only when towing by a tow truck is unnecessary and there is no problem to drive the vehicle. CAUTION: When the hybrid system warning light illuminates, or abnormal noise, odor, or strong vibration is detected during driving, perform the following procedures. 1. Bring the vehicle to a stop in a safe place. 2. Apply the parking brake. 3. Turn the ignition to OFF and disconnect the negative terminal from 12 volt auxiliary battery. 4. Wear insulated gloves and remove the Service Plug. Procedure after moving damaged vehicle When there is fluid leakage on the road surface, it may be strong alkaline electrolytic solution. Wear insulated gloves and protective goggles, neutralize with saturated boric-acid solution, confirm that red litmus paper does not change to blue, and then wipe off with cloth. 5. PRECAUTION DURING REPAIR OF DAMAGED VEHICLE Protective equipment ◊ Insulated gloves for electrical purposes ◊ Rubber gloves for electrical purposes ◊ Protective goggles for electrical purposes ◊ Rubber boots for electrical purposes ◊ Saturated boric-acid solution 20 L (In a container, dissolve 800 g of boric acid powder purchased at a drug store in 20 L of water.) ◊ Red litmus paper (purchase at a drug store) ◊ Cloth, old towels (for wiping electrolytic solution) ◊ Insulation tape ◊ CAT III Circuit tester 20 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) CAUTION: Follow the procedures to ensure safety. Make sure to use insulated tools, and wear insulated gloves or rubber gloves, protective goggles, and rubber boots for electrical purposes. Check for any leakage in the high voltage battery vicinity. CAUTION: • Do not touch any leaked fluid, because it may be strong alkaline electrolytic solution. When it is necessary to touch it, wear insulated gloves and protective goggles, neutralize with saturated boric- acid solution, confirm that red litmus paper does not change to blue, and then wipe off with cloth. • If the electrolytic solution should touch the skin directly, immediately wash it away with saturated boric-acid solution or plenty of water. Also, take off the contaminated clothes. • If it enters your eyes, scream for help, do not rub your eyes, immediately wash it away with plenty of water, and consult a doctor. When the vehicle is damaged due to collision, stop the hybrid system in the following steps. CAUTION: Do not touch the exposed wires, when whether they are high voltage wires or not is unknown. When it is necessary or possible to touch them, make sure to wear insulated gloves and insulate the wires using insulation tape. 1. Turn the ignition to OFF. NOTE: When the ignition cannot be turned to OFF, remove the fuse in engine compartment. 2. Wear insulated gloves and remove the Service Plug. 6. PRECAUTION FOR HIGH VOLTAGE BATTERY Through the route specified by the manufacturer, make sure to collect the high voltage batteries that are no longer needed due to replacement or other reasons. CAUTION: • When high voltage batteries are dumped or left without proper measures, electric shock accidents may occur. Be sure to collect the high voltage batteries through the route specified by the manufacturer. • Do not leave the removed high voltage batteries in a place where water may splash, because generated heat may cause fire. • When the collision is severe, high impact is applied to the high voltage battery, possibly causing damage inside the high voltage battery. Therefore, visually check the exterior of high voltage battery, and replace with a new one if deformation or such evidence is found at the following locations. Note: The Hybrid Electrical system will turn off immediately during a severe collision (from any angle with or without airbag deployment) and generate DTC P1C1E AUTODISCONNECT EXPERIENCE. During the time this DTC is in memory of the Drive Motor Control Module (DMCM) vehicle speed will be limited to 12.4 M.P.H. (20 km/h) or slower. 21 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Clearing the DTC with the Select Monitor is the only way to return the vehicle to normal conditions. Always check for physical damage to the Hybrid components before attempting to clear the DTC. PC-00087 Crumple Zones of High Voltage Battery Left C Pillar Trim Vent Note: The cooling system for Hybrid components use a cooling fan and duct work that carries air from the passenger compartment left C pillar trim vent to the Hybrid components package shelf. Do not block the vent. A blocked vent will obstruct air flow through the cooling system and may cause overheating of the Hybrid components. 31 32 22 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) : 12 Voltage HEV00283 : High voltage 100V High Voltage Circuits Pre-delivery Inspection During PDI of the 2014 XV Crosstrek, install the backup power supply fuse and remove the transit fuse. This is the same procedure that is performed on current model year XV Crosstrek vehicles. There are no special procedures for the PDI of a XV Crosstrek Hybrid. Follow the instructions provided in the service manual for complete PDI procedures. PDI Fuses 33 34 23 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Engine Air Filter The introduction of the Restart Battery makes it necessary to relocate the air filter housing and Mass Airflow Meter. Air Filter Housing Location Mass Airflow Meter The housing is now located on the back side of the Intake Manifold. The Mass Airflow Meter is located on the back side of the housing. Air Filter The air filter can be removed after the back side of the housing has been removed. 35 36 37 24 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Brake Vacuum Pump The XV Crosstrek Hybrid provides vehicle operations that operate with the engine off. This makes it necessary to employ an Electric Vacuum Pump to create the negative pressure required for Power Brake operation. Brake Booster Pressure Sensors Brake Vacuum Pump Two Brake Booster Pressure Sensors are utilized to provide more accurate data to the Hybrid Electric Vehicle (HEV) Control Module. Note: Never twist or attempt to remove the Brake Booster Pressure Sensors. If a Sensor fails, replace the Brake Booster. 38 39 25 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) B19 A21 A22 B605 B606 B16 1 F37 B143 BrW A: B: *1 WP OP F134 GR *1 A10 A11 L R A12 A13 L R A14 A15 L R B22 B23 L R WP B564 2 1 A: B: OP HEV-04 K PW WL R98 R2 8 L HEV-09 7 8 WL PW 5 6 BrW OrL B564 B9 B HEV-05 HEV-05 2 B GR Y GR OrL R BW 30A A11 M/B MB-3 (B) ST-2 IG SW (ST) VACUUM PUMP REF. TO GND [GND-10] RELAY HOLDER MB-37 M/B FUSE NO. 5 (B) FB-38 F/B FUSE NO. 12 (IG) TO POWER SUPPLY CIRCUIT REF. TO PUSH BUTTON START SYSTEM [P/S-03] : WITHOUT PUSH BUTTON START : B WWITH PUSH BUTTON START : WG HEV CM VACUUM PUMP RELAY REF. TO POWER SUPPLY CIRCUIT [P-SUP-01][P-SUP(P)-01] REF. TO CAN COMMUNICATION SYSTEM [CAN-02] : WITHOUT PUSH BUTTON START : WITH PUSH BUTTON START Brake Vacuum Pump Wiring Schematic The Brake Vacuum Pump Relay is controlled by the HEV CM. 40 26 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) TCM B604 GT B605 B606 B7 B17 B18 B54 B3 B1 2 1 3 B4 B2 2 1 3 B9 B11 2 B20 4 A9 A18 A: B: B24 A26 A25 A24 A23 1 3 A5 A22 A: WB B565 YB B600 HEV-06 HEV-06 1 J/C B B WR RL P RL P WB V Sb V Sb YB R B601 G G W W BR RB T7 WR 4 BR RB LG W B B B R W LG T3 B12 2 5 3 4 P R N D 1 1 2 3 4 G BL LB W BRAKE PEDAL STROKE SENSOR MB-36 M/B FUSE NO. 16 (B) INHIBITOR SWITCH BRAKE BOOSTER PRESSURE SENSOR 2 BRAKE BOOSTER PRESSURE SENSOR 1 REF. TO GND [GND-01] TO POWER SUPPLY CIRCUIT HEV CM Brake Booster Pressure Sensors Wiring Schematic Input from both Brake Booster Pressure Sensors go to the HEV CM. Work support is provided in the Subaru Select III Monitor to diagnosis the Brake Vacuum Pump System. Note: Operating parameters for the Brake Vacuum Pump system are unique due to the functionality of the Hybrid and Automatic Start Stop operations (Engine Off). An example of operating parameters would be: – Vehicle Speed 0 – Transmission in D range – Atmospheric Pressure 14.6 P.S.I. – Vacuum Pump On at 9.4 P.S.I. (Brake Booster Pressure) – Vacuum Pump Off at 5.8 P.S.I. (Brake Booster Pressure) 41 27 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Brake Vacuum Pump Data The operating parameters are adjusted by altitude and vehicle speed. The results in Work Support of the Select Monitor account for altitude and output failed or pass results from a compulsory test with altitude automatically considered. 42 28 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Automatic Grill Shutter System The 2014 XV Crosstrek Hybrid is equipped with an Automatic Grill Shutter (AGS) System. The AGS is designed to improve fuel efficiency by improving body aerodynamics and decreasing engine warm up time. AGS Closed AGS Open The AGS defaults to the open position in case of electrical communication malfunction. Note: The AGS is not spring loaded to the open position. AGS Actuator AGS Construction The 3 wire actuator receives command signals and transmits position through a single LIN communications wire that is routed to the HEV CM. The actuator drives the top plate of the AGS shutter and a mechanical link drives the lower plate. The Engine Control Module (ECM) determines the position for AGS operation but the ECM is not compatible for LIN operation so the information for control and verification is sent though the Power Unit (PU) CAN. 43 44 45 46 29 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 12 A2 B605 B606 E163 A4 B14 A3 A5 A6 B15 A18 2 3 4 B143 F37 8 1 A4 GOr 1 4 5 14 12 5 11 13 5 1 4 3 2 F108 B361 F157 45 i264 1 2 A: B: BY GOr B: A: B B HEV-07 HEV-07 BY B R ISG L Br R BY L Y WL LW B 15 3 L LW GOr GOr B609 B610 B WG B WL WL LW B WL LW B BY R L Br Y LY Gr Y PL G LY Gr Y PL G B20 M/B 12 E3 B22 B553 i231 F156 F155 B B ACTR AGAS B602 10A B21 E2 G GOr E11 L B598 HEV-01 A A12 12 G BAT-1 (B) FB-18 F/B FUSE NO. 7 (B) BATTERY SENSOR OIL PRESSURE SWITCH APPROACH INFORMATION CONTROL MODULE FUSE HOLDER THROUGH JOINT CONNECTOR REF. TO POWER SUPPLY CIRCUIT [P-SUP-01][P-SUP(P)-01] REF. TO GND [GND-01] REF. TO GND [GND-02] TO POWER SUPPLY CIRCUIT HEV CM TO POWER SUPPLY CIRCUIT AGS Wiring Schematic During service or replacement, the AGS automatically initializes so there is not a special procedure required to calibrate the AGS to the vehicle. Note: The AGS will remain closed if the ambient temperature is lower than 37 degrees Fahrenheit (3 degrees C). The opening and closing of the AGS is determined by ambient temperature, coolant temperature, and vehicle speed. 47 30 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Pedestrian Approach System The XV Crosstrek Hybrid is equipped with a Pedestrian Approach System that emits a sound that varies with vehicle speed. The sound is created to warn Pedestrians of the on-coming Hybrid Electric Vehicle (engine off). The speaker is located behind the front bumper beam on the passenger side of the vehicle. Speaker Control Module The Pedestrian Approach Control Module is located behind the HVAC control panel. Control Contents of Control while in EV Mode Normal sound control • Sound output is according to vehicle speed from 0 to 15 M.P.H. • When the ignition switch is ON and the Select lever is in P range and the Select lever button is pressed and held down, a sound is emitted for 3 seconds as soon as the brake pedal is released. • When the ignition switch is ON and the Select lever is in any range other than P range, a sound is emitted for 3 seconds as soon as the brake pedal is released. Pitch control changes according to vehicle speed The pitch of the notification sound is controlled according to the vehicle speed. Volume UP control When the vehicle is starting, the volume of the notification sound is boosted. Fade-in/fade-out control Sound volume is gradually changed when sound starts and ends. Sound control according to vehicle speed while running Sound ON <—> OFF is controlled according to vehicle speed. 48 49 31 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 1. APPROACH INFORMATION CONTROL MODULE Item Terminal No. (terminal symbol) Measuring condition Measurement value Note Operational power supply 1 (IG) IG ON 10 V or more — STOP light signal 2 (STP) Brake pedal ON OFF 8 V or more less than 1 V — Approach report speaker output (+) 3 (SP+) — — Pulse output Vehicle speed signal 6 (SPD) — — Pulse output GND 7 (GND) Always 0 V — Approach report speaker output (–) 8 (SP–) — — Pulse output K-line 9 (PRST) — — Communication line IND output 10 (IND) OFF 8 V or more — Shift position signal 11 (SFTP) Except for P range 8 V or more — Oil pressure signal 12 (OPSW) Engine running 8 V or more — HEV00005 6 12 11 10 4 9 3 8 2 7 5 1 Approach Information Control Module I/O Chart 50 32 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 12 A2 B605 B606 E163 A4 B14 A3 A5 A6 B15 A18 2 3 4 B143 F37 8 1 A4 GOr 1 4 5 14 12 5 11 13 5 1 4 3 2 F108 B361 F157 45 i264 1 2 A: B: BY GOr B: A: B B HEV-07 HEV-07 BY B R ISG L Br R BY L Y WL LW B 15 3 L LW GOr GOr B609 B610 B WG B WL WL LW B WL LW B BY R L Br Y LY Gr Y PL G LY Gr Y PL G B20 M/B 12 E3 B22 B553 i231 F156 F155 B B ACTR AGAS B602 10A B21 E2 G GOr E11 L B598 HEV-01 A A12 12 G BAT-1 (B) FB-18 F/B FUSE NO. 7 (B) BATTERY SENSOR OIL PRESSURE SWITCH APPROACH INFORMATION CONTROL MODULE FUSE HOLDER THROUGH JOINT CONNECTOR REF. TO POWER SUPPLY CIRCUIT [P-SUP-01][P-SUP(P)-01] REF. TO GND [GND-01] REF. TO GND [GND-02] TO POWER SUPPLY CIRCUIT HEV CM TO POWER SUPPLY CIRCUIT Approach System Wiring Schematic The Pedestrian Approach System Control Module shares the input of the engine oil pressure switch with the Hybrid Electric Vehicle Control Module (HEV CM). The engine oil pressure switch is wired to only these two control units. The oil pressure switch signal communicates engine off (no oil pressure) to the control units. The Approach Control Module uses the information to trigger the on status of sound generation when vehicle speed is sensed or when the brake pedal is released in EV Mode. The HEV CM uses the signal to determine if the engine is off and if the EV Mode should be in standby. The oil pressure signal is placed into the HEV CAN to communicate with the Combination Meter to turn on and off the Oil Pressure Warning Light. Note: The Oil Pressure Warning light will not illuminate while the vehicle is in EV Mode or making the transition to Engine Drive Mode. 51 33 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) HEV00335 miles (1) (1) Approach Report Warning Light The Approach Warning Light will illuminate if the system is not working correctly. 52 34 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Notes : 35 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Safety Kit Technician and vehicle safety considerations should always be the first step with any service or repair to any automobile. To support this fundamental principal, a Technician Hybrid vehicle safety kit is being issued as a new essential tool. NOTE: Always consult the Subaru Service Manual and all Service Bulletins for the most accurate information for Technician and Vehicle safety. CAUTION: Do not attempt to service or repair a Hybrid vehicle until you have received Instructor led training. Hybrid Safety Kit Hybrid Safety Kit Contents The Hybrid Safety Kit J-51311 contains the following items: Rubber Insulation Gloves, Leather Protector Gloves, Rubber floor mat, magnetic Danger sign, ABC fire extinguisher, caution tape, and orange masking tape. The Rubber Insulation tools should always be worn when performing any work on the hybrid component parts or hybrid wiring of the XV Crosstrek. The Leather Gloves should be worn over the Rubber Insulation Gloves to add a layer of protection. This prevents snags or punctures that could take away the Rubber Insulation Gloves ability to isolate the technician from high voltage. 54 55 36 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Rubber Insulated Gloves Leather Glove over Rubber Glove The Rubber Insulation Gloves must be inspected every 6 months by a certified high voltage equipment inspection organization. The date printed on the gloves is updated at inspection and serves as reminder to have your gloves inspected again, 6 months from that date. New Rubber Insulation Gloves also have the inspection date. New Rubber Insulation Gloves have a shelf life of 12 months plus 6 months of service time. NOTE: Do not use any new glove with a date older than 18 months, or an in-service glove older than 6 months. Pressure Checking Rubber Glove The gloves must be pressure checked before each use. Roll up the end of the glove and squeeze the captured air. Listen for any leak. Do not use the gloves if a leak is detected. ***Discard any leaking gloves.*** 56 57 58 37 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Correct Glove Positioning Always make sure that the Rubber insulation Glove is at least 2 inches higher up on your arm than the Leather Protector Glove. This ensures electricity that may be present at the Leather Protector does not arc to your unprotected arm. Please monitor STIS, and what’s New, for updates and additional information on the Technician Safety Kit and procedures for inspecting the Rubber Insulation Gloves. Magnetic Danger Sign (Service Hat) The magnetic service hat should always be placed on the roof of any hybrid vehicle that is being serviced. This protects you and others in your service area. For additional safety, advise others working around you that you are servicing a Hybrid vehicle. 59 60 38 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Safety Glasses Yellow Caution Tape Always wear safety glasses when working with suspect fluids in the High Voltage Battery area. The fluids may have a high alkalinity and will cause eye and skin irritation. Consult the Subaru Service Manual for additional information. If a chemical leak has been discovered, flag the rear of the vehicle with caution tape. It is recommended that the Service Plug be removed from the High Voltage Battery if a chemical leak is discovered. WARNING: Never attempt to remove the Service Plug if you have not attended Instructor led Hybrid vehicle training. ABC Fire Extinguisher Component Tray The Technician Safety Kit is equipped with an ABC fire extinguisher; however, the Hybrid Component Tray is made from Magnesium and requires special fire fighting training to extinguish. It is recommended that you call local emergency services in case of fire. 61 62 63 64 39 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Rubber Floor Mat The rubber floor mat should be used to insulate your body from the vehicle. The method of use is based on the service or repair being performed. 65 40 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Notes: 41 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Lineartronic™ Continuously Variable Transmission Power Flow (CVT Power Flow) Conventional input of mechanical power flow through the CVT is from the engine to the Torque Converter and to the Input Shaft of the Forward Clutch Drum or to the Sun Gear of the Planetary Gear set. Input Shaft and Forward Clutch For the purpose of this explanation only the Forward Gear range will be utilized. Equipped with the Hybrid Motor, the CVT Power Flow can change to the input of mechanical power coming from the Hybrid Electric Motor instead of from the engine. A combination of power sources, the engine and the motor, will occur during Electric Motor Assist Mode. Note: The 2014 XV Crosstrek Hybrid provides the following Modes of driving or charging: • Engine Drive Mode • Electric Motor Assist Mode • Electric Vehicle Mode (EV Mode) • D Charge Mode • Regenerative Braking Each of these Driving or Charging Modes can be displayed on the Multi-Function Display. The Power Flow of the CVT will be covered in the following text along with the corresponding Multi-Function Display of that Driving or Charging Mode. 67 42 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Engine Drive Mode MFD During Engine Drive Mode 68 69 43 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) During Engine Drive Mode, the power from the Torque Converter comes into the transmission through the input shaft of the Forward Clutch Drum. The planetary gear set carrier which is splined to the Primary Pulley is the output of the planetary gear set. When the Forward Clutch is engaged, the carrier is locked to the Forward Clutch Drum and a mechanical link is established from the engine to wheels via the transmission. In the transmission, the Primary Pulley turns a chain that drives the Secondary Pulley. The Reduction Drive Gear is splined to the top of the Secondary Pulley, so any time the Secondary Pulley rotates, the Reduction Drive Gear rotates. The Reduction Driven Gear is now equipped with a clutch hub to interact with the Output Clutch. The Output Clutch must be engaged before any power from the engine can be delivered to the wheels. This action occurs before the power gets to the transfer section of the transmission. If the Output Clutch is engaged, the power flows from the Output Clutch driven shaft to the Transfer Drive Gear to the front Differential and Transfer Driven Gear. This provides power to the front and rear wheels. The Electric Motor Rotor is splined to the Primary Pulley, so anytime the Primary Pulley is turning, the Motor Rotor rotates. In the case of the Engine Drive Mode, the Motor is ineffective, providing neither High Voltage Battery charging or driving forces. T32 B603 R608 A: B605 1 2 4 3 5 A1 4 14 17 15 B220 16 B1 B20 A10 B2 A: B54 B: B55 OUTPUT CLUTCH LINEAR SOLENOID MB-26 M/B FUSE NO. 12 (B) TO POWER SUPPLY CIRCUIT TCM OUTPUT CLUTCH RELAY HYBRID POWERTRAIN CM SELF SHUT RELAY Output Clutch Relay Wiring Schematic The Output Clutch is turned off by supplying high current (1 amp) to the Output Clutch Linear Solenoid. The Linear solenoid drains away hydraulic pressure that applies the clutch. Failsafe for the Output Clutch Linear Solenoid is full application. Electrical control is provided by the TCM or the Hybrid Powertrain Control Module. Normal control is through the TCM for all Driving Modes, while the Hybrid Powertrain Control Module provides power and control during a TCM failure. 70 44 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) EV Mode MFD during EV Mode 71 72 45 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) During EV Mode, the engine is off and the Forward Clutch is disengaged. The driving force for vehicle movement is now provided by the Hybrid Motor. The Motor Rotor turns the Primary Pulley which turns the chain, driving the Secondary Pulley. The Output Clutch is engaged, so the Reduction Gear set sends power to the front and rear wheels. Note: The Forward and Reverse Linear Solenoid reduces the pressure in the Forward Clutch by draining away hydraulic pressure. Higher amperage equals lower available pressure. 46 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) D Charge Mode, Output Clutch Off MFD during D Charge Mode 73 74 47 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) During D Charge Mode, the engine is running and the transmission is in Drive gear range. The Forward Clutch is on, driving the Primary Pulley. The Output Clutch is off so power cannot be sent to the front and rear wheels. The Hybrid Motor Rotor is being driven Primary Pulley. This creates a rotating magnetic field inside the Hybrid Motor and generates AC voltage. The Hybrid Motor is wired to the Motor Inverter which rectifies the AC voltage and turns it into approximately 100 volts DC, charging the Hybrid Battery. 48 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Engine Drive and Electric Motor Assist Mode MFD during Engine Drive and Electric Motor Assist Mode 75 76 49 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Electric Motor Assist Mode is created by using the driving force from the engine and the Hybrid Motor at the same time. The Engine Control Module and the Hybrid Electric Vehicle Control Module communicate to establish a target torque (power) output. This prevents one driving force from overpowering the other, slowing down the output of power. The output of torque or power must be exactly synchronized to allow both driving forces to contribute evenly. The Power Flow through the transmission is identical to the Engine Drive Mode with the addition of the mechanical output from the Hybrid Motor. 50 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Regenerative Braking MFD During Regenerative Braking 77 78 51 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) There are two types of Regenerative Braking. Engine Drive Mode Regenerative Braking and EV Mode Regenerative Braking. During Engine Mode Regenerative Braking the Input (Forward) Clutch is still applied but with reduced hydraulic pressure. This functionality allows the kinetic energy of the vehicle to affect the Hybrid Motor (The engine assists with braking). The Output Clutch is applied allowing the energy of the moving front wheels to power the Reduction Driven Gear and the moving rear wheels to power the Output Clutch Driven Shaft, via the Transfer Gear set. The combined power of all moving wheels turns the Reduction Gear Set which turns the Secondary Pulley. The Secondary Pulley turns the chain that powers the Primary Pulley. The rotating Primary Pulley turns the Hybrid Motor, generating AC voltage. During EV Mode Regenerative Braking the Input (Forward) Clutch is turned completely off, allowing all of the kinetic energy to affect the Hybrid Motor. The Power Flow is then the same as during Engine Drive Mode Regenerative Braking. 52 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) CVT Oil Pump The Lineartronic™ Hybrid CVT requires two new methods of supplying the oil pressure required to operate the pulleys and clutches. During EV Mode, the engine is off and the conventional method of driving the oil pump is not available. Oil pressure must be maintained to change pulley ratios and to maintain tension on the drive chain. During normal engine drive, the torque converter impeller housing drives the oil pump drive gear. This is the conventional method of driving the CVT oil pump. The drive gear operates a chain that rotates the driven gear. The driven gear is splined to the oil pump drive shaft. Oil Pump Drive Oil Pump A second mechanical oil pump drive system has been installed into the Hybrid CVT. A second oil pump drive shaft is installed into the back side of the oil pump that is driven from a gear set and chain powered by the rotation of the Primary Pulley. New Oil Pump Drivens Sprocket Each driven gear is equipped with a one-way clutch that allows the slower drive shaft to become ineffective. The new mechanical oil pump drive system functions during deceleration whenever the Primary Pulley speed is greater than engine speed and during Regenerative Braking. 79 80 81 53 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) During EV Mode, the engine is off and the Torque Converter cannot drive the oil pump. At this time high line pressure is still required to change ratios and maintain tension of the drive chain. A new Electric Oil Pump installed on the left rear of the transmission works with the new mechanical oil pump drive to keep the line pressure at the proper level. Note: The Electric Oil Pump (EOP) is on during Automatic Start Stop (during the engine off function). The EOP is also on during the transition from zero vehicle speed to a vehicle speed that enables the new mechanical oil pump drive system to create sufficient secondary pressure. The Electric Oil Pump is 3 phase 100 volts AC operated by the Electric Oil Pump Inverter. Work support is provided with the Subaru Select Monitor. Electrical Oil Pump Internal View of Electric Oil Pump 82 83 54 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) E/G O/P EOP Motor E/G O/P EOP Motor Engine OFF Engine ON E/G O/P EOP Motor EV Mode E/G O/P EOP Motor E/G O/P EOP Motor Electrical Motor Assist Mode Automatic Start Stop Engine OFF E/G O/P EOP Motor Regenerative Braking 84 85 86 87 88 89 55 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Electrical Wiring Configuration The Electrical System of the XV Crosstrek Hybrid operates from the storage capabilities of 3 batteries and the driving or charging functions of 3 devices. The wiring connecting these components are very precisely mounted to the vehicle and should always be returned to their original positions whenever service work is performed. Warning: All wiring contained inside the orange colored wiring jacket should be considered High Voltage. Hybrid High Voltage Wiring Complete Hybrid Motor wiring and Electric Oil Pump wiring are color coded orange and can carry a very high voltage potential of 3 phase AC current. Do not attempt to repair this wiring. Replace the wiring as a single part if any damage to the wiring is diagnosed. High Voltage Harness Routing The Hybrid Wiring Harness is routed from Hybrid component package shelf to the CVT. A single high amperage orange wire, (protected by a black wiring jacket), is routed next to the Hybrid orange wires. This wire carries 12 volts from the DC/DC Converter to the Auxiliary Battery and is the primary charging source for the 12 volt Auxiliary Battery. 91 92 56 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Batteries The Auxiliary Battery is the battery that is usually equipped on gasoline vehicles, charged by the alternator. However, on the XV Crosstrek Hybrid, the Auxiliary Battery is charged by the alternator only after the Hybrid Battery drops below 38 % of full capacity. This can be seen on the MFD display as zero to one bar on the battery meter display. 1. Auxiliary Battery – Provides electrical storage for the conventional starter and all vehicle operations except Automatic Start Stop. A high amperage wire is routed from the positive post of the Auxiliary Battery to the Interconnect Relay. Auxiliary Battery 2. Restart Battery – Provides electrical storage for operation of the Integrated Starter Generator (ISG). The ISG provides the engine restart functions of the Automatic Start Stop system. Restart Battery 93 94 57 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 3. High Voltage Battery – Provides electrical storage for all Electric Vehicle (EV) Mode operations. The High Voltage Battery also provides electrical power to charge the Auxiliary Battery. High Voltage Battery High Voltage Battery Service Plug Removed The 100 volt (Nickel Metal Hydride) High Voltage Hybrid Battery is not serviceable. Always wear rubber insulation gloves with the leather gloves placed over the rubber gloves when removing the battery from the vehicle. This will prevent any accidental tearing to the rubber insulation gloves. If the battery is suspected of having an internal short, place the battery on the rubber safety mat upon removal and contact the Tech line for instructions. Place caution tape across and around the battery. High Voltage Battery Removal High Voltage Battery on Rubber Mat 95 96 97 98 58 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) The High Voltage Hybrid Battery assembly contains many parts that control Hybrid Battery charging and discharging for Hybrid vehicle operation. Warning Never disassemble the High Voltage Battery or remove any of the outer covers. High voltage exists below the covers and at the output terminals. High Voltage Battery Construction The following explanation of the High Voltage Battery construction supports your understanding of Hybrid operation and the information that can be displayed on the Subaru Select Monitor III. There are no serviceable parts in the battery assembly. Top View Battery Cells Individual Cell Rows The High Voltage Battery is constructed of 21 rows of batteries. Each row contains 4 individual, 1.2 volt to 1.5 volt, (84 total individual cells), Nickel Metal Hydride batteries. The batteries are arranged positive to negative (series circuit) so the total voltage of the High Voltage Battery increases with each row. 99 100 101 59 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) High Voltage Battery Passenger Side High Voltage Battery Driver Side The individual rows are attached to each other at the outer sides of the battery case, positive to negative, negative to positive. Wires are attached to specific connections to monitor voltages of groups of rows. 102 103 60 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Battery Pack Voltage A Voltage B Voltage C Voltage D Interlock switch Battery current Voltage Z (reference GND) Voltage E Voltage F Voltage G Battery Energy Control Module (BE CU) 3 Modules 4 Modules 4 Modules 4 Modules 4 Modules 2 Modules Service resistance Service plug High Voltage Battery Construction High Voltage Battery Voltages The Subaru Select Monitor III displays the voltages of 7 points in the battery pack circuit. Each point references the middle of the battery. The middle of the 100 volt battery is approximately 50 volts. High Voltage Battery Voltage 3, as displayed on the Subaru Select Monitor, is the middle of the battery. Since the BECM uses this as a ground reference, the value displayed is 0 volts. This reference point is “Voltage Z” in the picture above. Note: DTCs for the High Voltage Battery and BECM reference voltage points A, B, C, D, E, F, G, and Z. Moving towards the most positive potential voltage, the next point in the battery pack circuit with a different voltage is point C, or High Voltage Battery Voltage 2 (20.88 volts). This value is based on the number of rows in the first group of batteries. Note: See High Voltage Battery Construction artwork to determine the number of rows in each group of batteries. Point B in the battery pack circuit is the value of 2 groups of batteries. The Subaru Select Monitor display, High Voltage Battery Voltage 1, should show the total voltage of the 2 groups (41.75 volts). 104 105 61 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Point A in the battery pack circuit is the most positive potential at 62.67 volts. This is the total of 3 groups of batteries. The Subaru Select Monitor display, High Voltage Battery Voltage 0, indicates the point A value. Hybrid Battery Pack Voltage A Voltage B Voltage C Voltage D Interlock switch Battery current Voltage Z (reference GND) Voltage E Voltage F Voltage G Battery Energy Control Module (BE CU) 3 Modules 4 Modules 4 Modules 4 Modules 4 Modules 2 Modules Service resistance Service plug High Voltage Battery Construction High Voltage Battery Voltages High Voltage Battery Voltage 4, point E in the battery circuit, display is -10.43 volts. The display is negative because the ground reference (Point Z), is more positive. High Voltage Battery Voltage 5, point F in the battery circuit, display is -31.35 volts , the total voltage of 2 groups of batteries. High Voltage Battery Voltage 6, point G in the battery circuit, is the most negative potential in the battery (3 groups of batteries.) Disregard the negative value of point G and add High Voltage Battery Voltage 6 to High Voltage Battery Voltage 1 to determine the total battery voltage. 106 107 62 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Battery Pack Voltage A Voltage B Voltage C Voltage D Interlock switch Battery current Voltage Z (reference GND) Voltage E Voltage F Voltage G Battery Energy Control Module (BE CU) 3 Modules 4 Modules 4 Modules 4 Modules 4 Modules 2 Modules Service resistance Service plug High Voltage Battery Construction The BECM also checks the performance of the High Voltage Battery by monitoring the voltage of 11 Blocks of batteries. Each block is the calculated value of 2 rows of batteries. Since the battery is constructed from an odd number of rows, the value of one row, located between points F and G, is used twice. The BECM uses these calculated values to locate low performance or damaged batteries. Note: High Voltage Battery Block Voltages cannot be added together to determine total battery voltage. Note: During this performance check the BECM calculates the voltages except at High Voltage – Battery Block Voltage 7. Block 7 is the only physical check of 2 rows of batteries (Z to E). 108 63 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) High Voltage Battery Block Voltage High Voltage Battery Voltage Block Voltages are calculated by using the values measured from points A to Z and Z to G. For example: Block Voltages 1 and 2 are calculated by subtracting the voltage measured at point B from the voltage at point A, then dividing the result by the number of 2 row sets of batteries in that group. The calculation is for 2 blocks so the BECM uses the calculated value 2 times. 62.67 – 41.75 = 20.92 20.92/2 = 10.46 Block Voltages 3 and 4 are calculated by subtracting the voltage measured at point C from the voltage at point B, then dividing the result by the number of rows in that group (4) and dividing that result by 2. Block 10 and 11 are calculated by the following: High Voltage Battery Voltage 6 – High Voltage Battery Voltage 5 Drop the negative sign of both numbers, 47.01 – 31.35 = 15.66 Then divide the calculated value of High Voltage Battery Voltage 9 by 2. (This is necessary to get the calculated voltage of just one row of batteries). 10.45/2= 5.22 Then add the one row voltage value to the result of High Voltage Battery Voltage 6 – High Voltage Battery 5. 47.01 – 31.35 = 15.66 15.66 + 5.22 = 20.88 This result is now divided by 2 to represent the calculated value for High voltage Battery Voltage 10 and High voltage Battery Voltage 11. 20.88/2 = 10.44 109 110 64 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Battery Energy Control Module High Voltage Battery Wiring The BECM controls the input and output of electrical power from the High Voltage Battery with a Positive Contactor and a Negative Contactor. The Contactors are large relays designed to operate high voltage and amperage devices. Contactor Contactor Connection Points Internal View of Contact Points Contactor Bridge 111 112 113 114 115 116 65 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Pre-charge resistor Junction Module Positive contactor Negative contactor Pre-charge contactor HEV Ready Light Contactor Configuration The illumination of the Hybrid Ready Light indicates the Battery Energy Control Module (BECM) has closed (turned on) the Contactors. As the High Voltage Battery is turned on, a high amperage flow potential exists. This condition is known as High In Rush Current. High In Rush Current can damage control modules and create high heat loads. Control of High In Rush Current is accomplished with a Pre-Charge Contactor and resistor which allows the High Voltage Battery to turn on, but not at full power. The BECM will close the Negative Contactor and the Pre-Charge Contactor, routing the positive circuit from the High Voltage Battery through a resistor and into the Hybrid electrical circuit. The BECM will close the Positive Contactor after it receives information that all systems are working correctly. After the Positive Contactor closes, the full amperage potential of the High Voltage Battery becomes available to the Hybrid circuit. 117 118 66 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Contactor and High Voltage Battery Voltage High Voltage Battery and Contactor Voltages Opposing Reference Point A. Positive terminal from the High Voltage Battery 1. Always on 2. 100 volts if Service Plug is installed C or D 3. 60 volts if Service Plug is removed E B. Normal positive outlet of the High Voltage Battery 1. 100 volts if Positive Contactor is on C or D 2. 100 volts always if Positive Contactor is in a welded (locked on) condition C or D C. Negative terminal (via wire) of High Voltage Battery 1. Always on 2. 100 volts if Service Plug is installed A or B 3. 40 volts if Service Plug is removed F D. Normal Negative outlet of the High Voltage Battery 1. 100 volts if Negative Contactor is on A or B 2. 100 volts always if Negative Contactor is in a welded (locked on) condition A or B E. Negative connection for Service Plug 1. Always 60 volts A or B F. Positive connection for Service Plug C or D 1. Always 40 volts 119 67 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Shunt Resistor The BECM monitors amperage flow through the High Voltage Battery by measuring the voltage drop through a shunt resistor. As the current flow increases , the amount of voltage drop between the two indicated wires increases. The BECM calculates the amperage by changing the voltage drop into amperage. For example; .050 volts = 100 amps, .025 volts = 50 amps. High Voltage Battery amperage is displayed on the Subaru Select Monitor in the BECM menu selection. High Voltage Battery Temperature Sensors Temperature Sensor Close-up High Voltage Battery temperature is monitored with three sensors. The sensors are seated in between the indicated rows of batteries. 120 121 122 68 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) High Voltage Battery Air Temperature Sensor A temperature sensor for measuring the air surrounding the battery is also employed. The input signal to the BECM from this sensor controls the duty ratio to the Hybrid component cooling fan motor. NOTE: Duty ratio of the fan motor is controlled by the HEV CM. The relay for the cooling fan motor is controlled by the DMCM. Cooling Fan Assembly and Hybrid Component Tray Bottom View of Hybrid Component Tray Left C pillar Trim Vent High Voltage Battery and Cooling System 123 124 125 126 127 69 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Driving and Charging Devices Integrated Starter Generator – A means of starting the gasoline engine while the vehicle is in gear, stationary or moving, must be employed. This task is accomplished using a new Integrated Starter Generator (ISG) and the new Automatic Start Stop System. The ISG is an alternator and a starter motor. ISG and Belt Welded Drive Pulley The ISG provides alternator (charging) functions to the Restart Battery only, except during vehicle operation where the High Voltage Battery State of Charge falls below 38% of maximum. The ISG also restarts the engine during EV Mode engine start, and Automatic Start Stop operation. EV Mode Engine Drive Mode The transition from EV Mode to Engine Drive Mode must be smooth and seamless. This occurs at a vehicle speed from 0 to 25 mph or when established vehicle conditions are met from driving or the driving environment. 129 130 131 132 70 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Engine OFF The Accessory Drive Belt also serves to start the engine from the rotation of the ISG during engine restart. ISG Start The tension of the belt during engine restart must be much higher than normal to prevent belt slippage. A two pulley pendulum tensioner controls the belt tension. During engine restart the belt becomes tighter and automatically reduces the tension after engine start. During engine restart the torque of the rotating ISG, against the stationary belt, pitches the tensioner downward and tightens the belt. NOTE: The two pulleys can move independently. 133 134 71 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Just After Engine Start As the engine starts, the ISG no longer becomes the driving force placed on the belt so the tensioner pitches upward and the tension is reduced. This reduces belt wear and reduces the engine power required to turn the belt. EV Mode Automatic Start Stop During Automatic Start Stop Mode, the engine turns off and saves fuel while all electric, safety, environmental, and operational equipment stays active. MFD during Automatic Start Stop The Multi-function Display will indicate the total time the engine has been turned off during Automatic Start Stop Mode. The time is displayed as Fuel Saving Time. This value will reset to zero if the trip meter stalk is used to clear the trip meters. 135 136 137 72 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) MFD during exit of vehicle Caution: While driving the XV Crosstrek Hybrid in EV Mode and coming to a stop to park the vehicle, always shift to Park, set the Parking Brake, and turn off the ignition. Failure to turn off the ignition will create a warning display on the Multi-function Display and the engine will restart automatically. NOTE: The engine will not automatically restart immediately. There will be a delay. The following message will be displayed after turning off the ignition. MFD during Ignition OFF 138 139 73 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Note: The following conditions are required for activation of Automatic Start Stop and EV Mode. 1. Brake Booster pressure is present. 2. Engine Restart Battery is above 70% fully charged. 3. Engine Restart Battery is above 12.6 volts. 4. Engine Restart Battery temperature and high voltage battery are between 14 and 172 degrees Fahrenheit. 5. Engine Restart Battery is judged to be functioning correctly. 6. Engine Coolant temperature is above 125 degrees Fahrenheit. 7. Gear range is initially in Drive (D Range). Vehicle will not cancel Automatic Start Stop if active and shifted into park or any other gear range. 8. High Voltage Battery is greater than 40% fully charged. 9. ISG temperature is less than 212 degrees Fahrenheit. 10. Vehicle speed is less than 8 miles per hour. 11. The vehicle is not on a steep hill. 12. Accelerator pedal opening is less than 0.5% for Automatic Start Stop and not greater than 20% for EV Mode. 13. Brake pedal is pressed. 14. The front defroster is off. 15. In vehicle temperature is within 5 degrees Fahrenheit of the set temperature. NOTE: The In Vehicle Temperature Sensor is equipped to measure humidity. Temperature and humidity must be within a specified level before EV Mode or Automatic Start Stop can operate. ISG Mounting Bolts ISG rear view The ISG Pulley is welded in place to prevent loosening from high torque operation. 5 bolts secure the ISG to the engine block. 140 141 74 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) ISG Control Unit location ISG Control Unit internal view The ISG Control Unit is mounted on the back side of the ISG and is not serviceable separately. The ISG Control Unit controls the charging and starting functions of the ISG. ISG Terminals and Inputs Signals 1. Positive power supply for ISG Control Unit, Auxiliary Battery 2. Crank inhibit signal (Must turn off before start function begins) This signal is sent from the HEV CM. 3. Crank signal (Energizes rotor slightly advanced of actual start signal) This signal is sent from the HEV CM. 4. LIN communications (HEV CM sends a crank and stop crank signal) 5. Negative power supply for ISG Control Unit, Auxiliary Battery The working power for the ISG Control Unit comes from the Auxiliary Battery. During actual ISG start function, the Restart Battery voltage drops and could create computer errors with the ISG Control Unit. The Crank signal from the HEV CM turns on the rotor and it begins to build a magnetic field. This will take a certain time to reach maximum potential. LIN communications to the ISG Control Unit control the starter motor function of the ISG by activating the H bridge. Modulated three phase AC voltage flowing thorough the stator then interacts with the north and south poles of the rotor. 142 143 75 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) ECM CHG-01 CHG-01 B: B135 D: B137 E163 BY *1 B PL Gr G A CHG-02 B CHG-02 GR 3 Y 4 1 2 ISG 1 2 B523 L GW 1 2 B598 B L GR GR A: B605 B: B606 A6 BY A15 L A14 R A13 L A12 R A5 BY B15 Y B14 Br A4 L B B A3 R A2 R B 1 B B609 B610 L D18 R D19 L D24 B30 R D10 L D21 LY 5 B83 J/C *1 *1 BY 12 Y 5 Br 11 L 13 R LY G PL Y 14 Gr E3 B22 BAT-1 (B) REF. TO GND [GND-02] REF. TO HYBRID SYSTEM [HEV-07] REF. TO POWER SUPPLY CIRCUIT [P-SUP-01][P-SUP(P)-01] HEV CM BATTERY SENSOR BATTERY TEMPERATURE SENSOR TO POWER SUPPLY CIRCUIT : TERMINAL No. OPTIONAL ARRANGEMENT ISG Wiring Schematic 144 76 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) ISG Rotor ISG Brushes The permanent magnets placed between the claw poles of the rotor increase the total magnetic field of the rotor. This adds strength and speed of the ISG for starter and charging functions without adding additional rotor coil windings. Resolver Rotor Resolver The ISG is equipped with resolver to monitor ISG speed and position of the rotor. The ISG Control Unit uses the signals of the resolver to properly time the on and off control of the U,V, and W windings. 145 146 147 148 77 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) + – U V W ISG Transistor and Diode Configuration ISG Stator The U,V, and W windings are the conventional stator windings of the alternator. The number of windings is slightly higher than a typical alternator. The synchronized movement of the alternating magnetic field around the stator attracts and repels the alternating magnetic poles of the rotor. This creates the motor function. ISG Transistors and Diodes (1 set) Diodes and high amperage transistors are connected to the stator windings. The diodes rectify AC voltage during the charging function and the transistors control the motor operation. + – U V W + – U V W Charging Motor Function The ISG is also used to stop the engine faster by creating a heavy mechanical load during the engine off command of Automatic Start Stop operation (alternator goes to high charge). 149 150 151 152 153 78 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Interconnect Relay The Interconnect Relay provides an open or closed circuit from the ISG and Restart Battery to the Auxiliary Battery. This allows the ISG to charge the Auxiliary Battery when the High Voltage Battery state of charge is lower than 38%, or if the DC/DC Converter is not functioning. Note: If the ISG fails, the Interconnect Relay (12 Volt Relay) will close and the battery warning light in the combination meter will illuminate. The DC/DC Converter will turn off the 12 volt output to the Auxiliary Battery, however, the High Voltage Battery will continue to charge. As the State of Charge of the High voltage Battery increases, the amount and timing of the Electric Motor Assist will advance. When the voltage of the Auxiliary and Restart Batteries drop below a specific level, the engine will no longer operate. Interconnect Relay 154 79 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) B606 B22 B23 * 1 *2 B: B B R L B599 B B B B B R L B ISG E163 BY BY 2 4 *2 A P-SUP-04 B P-SUP-04 B B 1 *1 Gr 1 Y 4 PL 3 G 2 LY 5 Or W 250A 80A 200A 3 B B B 450A 60A BATTERY FOR ISG MAIN BATTERY SLOW BLOW FUSE SLOW BLOW FUSE REF. TO HYBRID SYSTEM [HEV-07] 12V BATTERY RELAY REF. TO GND [GND-03] HEV CM : W AND BUS BAR : B AND W BAT-3 BAT-1 BAT-2 P-SUP-03 P-SUP-03 Interconnect Relay Wiring Schematic The Interconnect (12 Volt Battery Relay) is a normally open relay. The HEV CM closes the relay by providing 12 volts positive to terminal 1 of B599. The spring that opens the relay is assisted with an opening coil (electro magnet). The HEV CM turns on the opening coil with 12 volts positive sent to terminal 4 of B599. 155 80 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Electrical Operation Before Automatic Start Stop activates When the driver starts the engine (conventional starter), electric power from the Hybrid Battery begins to operate the DC/DC Converter. DC/DC Converter This changes 100 volts DC to approximately 13.8 volts DC and charges the Auxiliary Battery. The Auxiliary Battery provides the working power for the vehicle computers, safety equipment, heating and air conditioning, conventional starter, engine operation, and transmission operation. If the vehicle remains stationary, the Hybrid Battery state of charge will begin to drop. High Voltage Battery Meter When the state of charge of the Hybrid Battery drops below 38%, the DC/DC Converter output will be turned off and the Interconnect Relay will close and the ISG will begin to charge the Auxiliary Battery. Note: The ISG cannot charge the Hybrid Battery. 156 157 81 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Interconnect Relay As the vehicle begins to move the vehicle computers will determine when the best time to charge the Hybrid Battery exists. Charging while Driving Charging while Decelerating (Regenerative Braking) Charging should not inhibit acceleration or contribute to high fuel consumption so charging is performed during light engine load driving and during deceleration. 158 159 160 82 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) During Automatic Start Stop Operation When the driver stops the vehicle and the vehicle computers determine the driver’s intent is to stay stationary with the brake applied in Drive Gear Range, the engine will turn off. MFD during Automatic Start Stop Engine Off All other systems remain active. At this time the DC/DC Converter continues to operate. The Hybrid Battery state of charge will begin to drop. As soon as the state of charge drops below 38%, the engine will start. The state of charge of the Hybrid Battery is still low, the brake is still applied and the transmission is in Drive Gear Range. MFD during D Charge Mode The TCM will now turn off the Output Clutch and the ECM will increase the engine speed to about 1200 RPMs. The engine is now driving the Hybrid Motor which is operating as an AC voltage generator. This begins to charge the Hybrid Battery. The D Charge Mode will remain active until the driver releases the brake pedal or the Hybrid Battery state of charge exceeds 40%. NOTE: D Charge Mode can activate anytime the vehicle is stationary, in Drive Gear Range, and the brake is applied. 161 162 83 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Motor The Hybrid Motor provides mechanical power to the Primary Pulley of the Lineartronic™ Continuously Variable Transmission (CVT). Charging functions are provided when the Primary Pulley is the driving force rather than the driven member. Hybrid Drive Motor Assembly Hybrid Motor The Hybrid Motor assembly is built into the new mid-section of the CVT (Gen 2) and cannot be serviced separately. NOTE: Replacement of the Hybrid Electric Motor, with housing, will be allowed. Hybrid CVT Configuration Coupling Sleeve and Connecting Shaft The Hybrid Electric Motor Rotor is splined to the Primary Pulley with a Coupling Sleeve and a Connecting Shaft. The Connecting Shaft is designed to twist slightly to reduce mechanical shock between the Hybrid Electric Motor Rotor and the Primary Pulley. 164 165 166 167 84 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Resolver Resolver Rotor A Resolver and a Resolver Rotor are positioned over the drive end of the Hybrid Motor to monitor the speed and direction of the Hybrid Motor Rotor. This Resolver functions similar to the Electronic Power Steering Resolver. The Hybrid Motor Control Module (DMCM) controls the working power, and receives the signals from the Hybrid Motor Resolver. M C S S C M M C S M C S M C S S C M M C S M C S 12:00 Position 12:30 Position The Resolver Rotor changes the magnetic field of the Sine and Cosine Windings as it rotates. This action creates changes in voltage and provides the DMCM with signals that allow speed and direction to be determined. 168 169 170 171 85 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Lower Motor Bearing Motor Rotor Support for the Hybrid Motor Rotor is provided by an upper and lower caged ball bearing. The lower bearing is seated in the mid section of the transmission case. A shim selected at the factory controls the clearance between the case and the bearing. The upper bearing is seated in the Hybrid Motor Resolver Housing. Stator U, V, and W The Hybrid Motor Rotor is equipped with very strong permanent magnets. The magnetic field they create is used to provide motor and charging functions. The magnets interact with the stator windings which are wired to the U, V, and W wires. 172 173 174 175 86 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Junction Block Installed Junction Block Bus Bars The three phase stator winding wires connect to an electrical junction block inside the transmission. The electrical junction block provides a connection point for the Hybrid High Voltage wires (orange). The bus bars are protected with a plastic cover. Junction Block O-rings An O-ring located around the junction block mount keeps transmission oil sealed from the Hybrid High Voltage wire connections. High Voltage Access Cover U, V, and W Connections When removing the transmission from the vehicle, the Hybrid High Voltage wires must be disconnected from the transmission. The access cover must be removed to gain access to the bolts securing the wires to the junction block. 176 177 178 179 180 87 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Note: Transmission oil has a very low dielectric constant and is a very poor conductor of electricity. WARNING: The following procedures must be performed before removing the transmission. 1. The Service Plug must be removed. 2. The exposed terminals of the High Voltage Battery Harness must be covered with electrical tape. 3. The negative battery cable ends of Auxiliary and Re-Start Batteries must be removed and covered with electrical tape. WARNING: The Hybrid Electrical Wires at the transmission have a very high voltage potential. Never remove the access cover until all 3 of the warnings above have been completed. Note: Do not over tighten the bolts securing the Hybrid Electrical Wires to the junction block. Note: Always torque the bolts securing the Hybrid Electrical Wires to the junction block to the proper specifications. Failure to do so will create a high resistance connection and create high heat that will damage the junction block. A damaged junction block cannot be replaced separately from the Hybrid Electric Motor Assembly. The Hybrid Electric Wires are wired to the Motor Inverter (IPU) for Hybrid Motor operation and rectification of the AC voltage during charging. NOTE: Intelligent Power Unit (IPU) HV12 3 2 1 2 1 3 HV12 HV11 N P HV10 W V U N P N P N P N P V U W V U N P N P HV2 HV4 HV1 HV9 W V U HV3 W W V U HV7 HV6 HV5 HV8 HEV00327 MB-3 (B) HIGH VOLTAGE BATTERY DRIVE MOTOR INVERTER ELECTRIC NOISE FILTER DRIVE MOTOR INVERTER AMPERAGE SENSOR DRIVE MOTOR ASSY DC/DC CONVERTER ELECTRIC OIL PUMP INVERTER ELECTRIC FLUID PUMP TO POWER SUPPLY CIRCUIT High Voltage Wiring Configuration 181 88 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Component and High Voltage Battery Hybrid System Voltages A. Bus bar connection from High Energy Battery, Positive 100 volts DC with engine running or during engine off with Automatic Start Stop. B. Bus bar connection from High Energy Battery, Negative 100 volts DC with engine running or during engine off with Automatic Start Stop. C. Motor Inverter and Electric Oil Pump Inverter Bus bar connection at Noise Suppressor, Positive 100 volts DC with engine running or during engine off with Automatic Start Stop. D. Motor Inverter and Electric Oil Pump Inverter Bus bar connection at Noise Suppressor, Negative 100 volts DC with engine running or during engine off with Automatic Start Stop. E. Motor Inverter Power Positive Input, 100 volts DC with engine running or during engine off with Automatic Start Stop. F. Motor Inverter Power Negative Input, 100 volts with engine running or during engine off with Automatic Start Stop. G. Electric Oil Pump Inverter Power Positive Input, 100 volts DC with engine running or during engine off with Automatic Start Stop. H. Electric Oil Pump Inverter Power Negative Input, 100 volts DC with engine running or during engine off with Automatic Start Stop. 182 89 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) I. DC/DC Converter Power Positive Input, 100 volts DC with engine running or during engine off with Automatic Start Stop. J. DC/DC Converter Power Negative Input, 100 volts DC with engine running or during engine off with Automatic Start Stop. K. DC/DC Converter Power Output, 13.8 volts DC (Ground is through Magnesium tray). L. Motor Inverter Output U winding, approx. 200 volts AC with engine running, during Hybrid Motor operation and during charging. M. Motor Inverter Output V winding, approx. 200 volts AC with engine running, during Hybrid Motor operation and during charging. N. Motor Inverter Output W winding, approx. 200 volts AC during Hybrid Motor operation and during charging. O. Motor Inverter Output U winding, approx. 200 volts AC with engine running, during Hybrid Motor operation and during charging. P. Motor Inverter Output V winding, approx. 200 volts AC with engine running, during Hybrid Motor operation and during charging. Q. Motor Inverter Output W winding, approx. 200 volts AC with engine running, during Hybrid Motor operation and during charging. R. Electric Oil Pump Inverter Output U winding, approx. 200 volts AC during Hybrid operation and Automatic Start Stop. S. Electric Oil Pump Inverter Output V winding, approx. 200 volts AC during Hybrid operation and Automatic Start Stop. T. Electric Oil Pump Inverter Output W winding, approx. 200 volts AC during Hybrid operation and Automatic Start Stop. NOTE: The circuits between the following points are constructed of individual Bus Bars that are inserted through an Inductive Amperage Sensor: L O M P N Q Inductive Amperage Sensor Amperage Sensor Bus Bar 183 184 90 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Notes : 91 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) High Voltage Battery Removal Service Hat Place the “Danger High Voltage” top hat on the vehicle roof before performing any repair or diagnostics on a Hybrid Vehicle. Auxiliary Battery Auxiliary Battery Terminal Remove the negative battery cable and terminal from the Auxiliary Battery and wrap the terminal with electrical tape. Note: The positive battery cable extends to the DC/DC Converter and the Interconnect Relay. 186 187 188 92 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Restart Battery Negative Cable Remove the negative cable from the Re-start Battery terminal and wrap the cable end with electrical tape. Insulating Ground Cable 189 190 93 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Cargo Area Cargo Area Open Warning Label The High Voltage Hybrid Battery is located under the cargo storage platform. Remove the storage platform and confirm the warning label is in place. Replace any WARNING label that is damaged. Always install the warning label in the same position as the original. WARNING: RUBBER INSULATION GLOVES with LEATHER PROTECTORS must be worn for the remainder of High Voltage Battery removal. Orange Trim Tab Remove the orange trim tab that secures the storage box to the vehicle body Note: Always install an orange trim tab to this location. 191 192 193 194 94 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Removing Service Plug Tape Exposed Terminals While wearing approved and tested insulation gloves, remove the Service Plug. Pull the lever until it contacts the locking tab. Push the locking tab in the direction of the arrow and continue to pull the lever to the vertical position and pull upward. Immediately place electrical tape over the exposed battery terminals. High Voltage Cover Trim High Voltage Cover Trim Tab Keep Service Plug Secure Place the Service Plug in your pocket or in a locked tool box that you control. Remove the trim tabs that secure the left and right side cargo platform supports and remove the supports. 195 196 197 198 199 95 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Torx® Bolts Remove the Torx® bolts (T25) that secure the High Voltage Battery cover. Note: Always position the Torx® socket into the bolt squarely and vertical. Push down on the socket will applying the force required to loosen the bolt. Orange Trim Tab Removing High Voltage Battery Cover Remove the orange trim tab near the Service Plug. Note: Always return an orange trim tab to this location. Lift the cover to clear all of the Hybrid components and remove the cover from the rear of the vehicle. 200 201 202 96 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Air Duct Sliding Connection C Pillar Intake Vent Slide the cooling duct connector in the direction of the arrow. Check the air duct and vent for any obstructions or deformation. Clear the duct or replace any damaged parts that would slow down airflow. High Voltage Battery and Harness High Voltage Battery NOTE: The rear seat has been removed for photography. The rear seat does not need to be removed to remove the High Voltage Battery. Remove the metal wiring harness protectors. Remove bolts from the Inverter Cover. Lift the Inverter Cover, unclip the wiring harness locator tabs, and remove from the rear of the vehicle. 203 204 205 206 97 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Motor and Electric Oil Pump Inverter 3 Phase Wires Labeled Label the wires (U,V,W) of the Hybrid Motor Inverter and the Electric Oil pump Inverter. NOTE: The factory labels one wire on each harness. Removing Electric Oil Pump Wires Tape Wire ends Remove the wires from the Electric Oil Pump Inverter. Tape each wire as it is removed. 207 208 209 210 98 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) DC/DC Output Wire Tape Output Wire Terminal Remove the wire from the output of the DC/DC Converter. Tape the wire end. Removing Motor Wires Tape all wire terminals Remove the wires and tape the wire ends of the Hybrid Motor Inverter. Harness Bracket Harness Bracket Remove the nuts securing the wiring harness to the vehicle. NOTE: The 2 nuts securing the metal bracket, ground the coaxial covering the Hybrid Motor Harness. 211 212 213 214 215 216 99 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Move Harness Clear Air Vent Duct Position the wiring harness away from the leading edge of the High Voltage Battery. Disengage the location tabs of the air vent inlet and remove the Air Inlet. BECM Connector Disconnect the Body Harness from the BECM. 217 218 219 100 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Positive and Negative High Voltage Battery Terminals Noise Suppressor Remove the bolts that connect the High Voltage Battery outlet to the Bus Bars. Remove the bolts securing the Bus Bars to the Noise Suppressor. Bus Bar Remove the Bus Bar. High Voltage Battery Mounting Bolts High Voltage Battery Mounting Bolt Remove the 5 bolts that secure the Hybrid Battery to the vehicle. 220 221 222 223 224 101 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Protect Vehicle Trim Removing High Voltage Battery Place a fender cover over the rear bumper cover and rear gate entry threshold. The next step requires two technicians that are wearing rubber insulation gloves with leather protector gloves. Tilt the driver side of the High Voltage Battery upward and slide the High Voltage Battery slightly towards the driver side of the vehicle. The air duct of the battery must disengage from the air duct of the Hybrid Component Tray. Lift the High Voltage Battery towards the rear of the vehicle and rest it on the fender cover. The technician from the inside of the vehicle should now exit the vehicle and assist with moving the High Voltage Battery to a safe location. Secondary Containment Tray Air Duct Check the Secondary Containment Liner. CAUTION: Any liquid in this area may have a high alkalinity and will cause eye and skin irritations. Review the cautions in the introduction section of this TRB and the Subaru Service Manual for additional information. 225 226 227 228 102 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Bus Bar DC/DC Connector DC/DC Converter Induction Amperage Sensor, Noise Suppressor and Motor Inverter 229 230 231 232 103 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Motor Inverter and Noise Suppressor Bottom view of Motor Inverter (IPU) Motor Inverter (IPU) Hybrid Component Tray (Magnesium) 233 234 235 236 104 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Notes : 105 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) XV Crosstrek Hybrid CAN Communications Note: The following information describes the physical CAN construction of the XV Crosstrek Hybrid. Complete operation of each component part is not included. A10 A11 A15 A15 A14 A2 3 2 HIGH VOLTAGE BATTERY BATTERY ENERGY CU ELECTRIC OIL PUMP INVERTER DRIVE MOTOR CM D21 D10 B9 B10 HYBRID POWERTRAIN CM 15 2 ECM VDC CM TCM 18 17 B55 D18 D19 B137 B310 A: B605 2014 XV Crosstrek Hybrid CAN A conventional drive train, where the engine is the only driving force, uses the engine ECM as the manager of all engine operating commands. The XV Crosstrek Hybrid can be propelled by two forces, the engine or the Hybrid Electric Motor. The human machine interface remains the same sharing the same gas pedal, speedometer, brake system and all vehicle controls. However, with the potential of two driving forces, one Control Module must be in control. This provides seamless transition from engine to electric propulsion. The XV Crosstrek Hybrid Powertrain Control Module monitors all driving conditions, controlling the engine and the Hybrid Electric Motor. This dual control can only be accomplished with the additional communications from two new High Speed Controller Networks (CAN). The XV Crosstrek Hybrid introduces the HEV CAN and the PU CAN. Details of the Hybrid Electric Vehicle CAN and the Power Unit CAN operation will be introduced on the next few pages. Each of the new High Speed Controller Area Networks is constructed similar to the Main CAN. Equipped with 2 terminators, each of their total circuit resistance values is about 60 ohms. 238 106 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Note: The HEV Control Module provides a gateway function that allows all Controller Area Networks to communicate with each other. This function also allows diagnostic communication and work support to be provided over the two CAN wires on the diagnostic connector. HEV CAN The HEV CAN terminators are located in the Hybrid Powertrain Control Module (HEV Control Module) and the Drive Motor Control Module (DMCM). The terminator in the HEV Control Module, connected to the HEV CAN, is dedicated to the HEV CAN. The Electric Oil Pump Inverter and the Battery Energy Control Unit are connected to the HEV CAN in CAN branch circuits. Driving and charging functions are controlled in this CAN circuit. A11 A10 1 4 20 9 A2 A15 2 3 2 3 R446 R455 B98 R2 R454 R436 R445 A: B605 A: R443 HYBRID POWERTRAIN CM HIGH VOLTAGE BATTERY BATTERY ENERGY CU ELECTRIC OIL PUMP INVERTER DRIVE MOTOR CM HEV CAN Information from the HEV Control Module to the Drive Motor Control Module provides torque and rotational speed requirements needed from the Hybrid Electric Motor. The HEV Control Module also sends a signal to the Electric Oil Pump Inverter. Control of the Electric Oil Pump requires no electronic communications back to the Electric Oil Pump Inverter. NOTE: The Secondary Oil Pressure Sensor detects Electric Oil Pump operation. 239 107 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) PU CAN The PU (Power Unit) CAN terminators are located in the Engine ECM and the Hybrid Powertrain Control Module. The TCM is connected as a CAN branch circuit. The terminals of the TCM connecting to the HEV CAN are dedicated to the HEV CAN. B9 B10 D21 A14 D10 A15 B: B55 A: B605 D: B137 ECM TCM HYBRID POWERTRAIN CM PU CAN The Hybrid Powertrain Control Module issues the main engine operating commands and sends them to the Engine ECM through the PU CAN. These commands and instructions include: Torque requirements, Fuel Cut requirements (Automatic Start Stop), and Rotation speed requirements. Normal idling and fuel cut (deceleration) is determined and controlled by the Engine ECM. Inputs for engine speed and engine coolant temperature are sent to the HEV CM through the PU CAN. The PU CAN also controls gear ratios and clutches in the CVT. Communications from the HEV CM to the TCM allow the HEV CM to control gear ratios and the Forward and Output Clutch in EV Mode and Automatic Start Stop Mode. (HEV CM also controls gear ratio in Engine Drive Mode). NOTE: The ECM and TCM will return to conventional control if the PU CAN has failed. 240 108 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Accelerator pedal sensor Brake stroke sensor Brake Pedal High-voltage battery Temperature/current/ voltage sensor Contactor Drive motor Drive motor inverter Current sensor Resolver DC/DC converter High-voltage battery cooling fan Electric oil pump Electric oil pump inverter Brake Booster vacuum sensor Brake vacuum pump DM CU BE CU HP CU Accelerator pedal AGS ISG CU ISG Battery sensor 12 V battery (for restart) Battery current/voltage/ temperature sensor 12 V battery interconnection relay ECM Starter E/G 12 V battery (for auxiliary equipment) Battery temperature sensor Shift position sensor Transmission system solenoid Input clutch solenoid Output clutch solenoid TCU CAN LIN Signal line Serial communication HEV CAN and PU CAN Brake Stroke Sensor NOTE: The Brake Pedal Stroke Sensor provides input that determines the EV Mode On/ Off Status. 241 242 109 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Hybrid Component Locations (1) 12 volt engine restart battery (10) DC/DC converter (19) Electric oil pump (2) Battery sensor (11) High voltage battery cooling fan (20) Power cable (3) 12 V battery-to-battery connecting relay (12) Integrated starter generator (ISG) (21) Drive motor inverter current sensor (4) Hybrid powertrain control module (HPCM) (13) Brake vacuum pump (22) Service plug (5) Engine control module (ECM) (14) Battery temperature sensor (23) High voltage battery (including battery energy control module (BECM)) (6) Drive motor ASSY (15) 12 volt auxiliary battery (24) DMCM power relay (7) Noise filter (16) Brake vacuum pump relay (25) High voltage battery cooling fan/ drive motor inverter power relay (8) Electric oil pump inverter (17) Brake booster (including brake booster pressure sensor) (26) Drive motor control module (DMCM) (9) Drive Motor Inverter (18) Brake pedal ASSY (including brake stroke sensor) HEV00308 (1) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)(25) (26) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Hybrid Component location 243 110 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Terminal No. (terminal symbol) Item Measuring condition Measurement value Note (B605) No. 1 Linear solenoid output — Cannot be measured — (B605) No. 2 Main power supply 1 Always 11 — 15 V — (B605) No. 3 Main power supply 2 Always 11 — 15 V — (B605) No. 4 LIN communication — Cannot be measured LIN communication line (B605) No. 5 GND1 Always 0 V — (B605) No. 6 GND2 Always 0 V — (B605) No. 7 (Not used) — — — (B605) No. 8 (Not used) — — — (B605) No. 9 (Not used) — — — (B605) No. 10 HEV CAN H — Cannot be measured CAN communication line (B605) No. 11 HEV CAN L — Cannot be measured CAN communication line (B605) No. 12 MAIN CAN H — Cannot be measured CAN communication line (B605) No. 13 MAIN CAN L — Cannot be measured CAN communication line (B605) No. 14 PU CAN H — Cannot be measured CAN communication line (B605) No. 15 PU CAN L — Cannot be measured CAN communication line (B605) No. 16 (Not used) — — — (B605) No. 17 (Not used) — — — (B605) No. 18 Oil pressure SW input Engine running 11 — 15 V — When ignition switch is ON 0 V — (B605) No. 19 (Not used) — — — (B605) No. 20 (Not used) — — — B606 B605 17 16 15 14 13 12 11 10 6 5 4 3 2 1 6 5 4 3 2 1 24 23 22 21 20 19 18 17 26 25 24 23 22 21 20 19 18 16 15 14 13 12 11 10 HEV00080 TO B: TO A: 7 89 78 9 Hybrid Powertrain Control Module (HPCM) I/O 244 111 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Accelerator pedal sensor Brake stroke sensor Brake Pedal High-voltage battery Temperature/current/ voltage sensor Contactor Drive motor Drive motor inverter Current sensor Resolver DC/DC converter High-voltage battery cooling fan Electric oil pump Electric oil pump inverter Brake Booster vacuum sensor Brake vacuum pump DM CU BE CU HP CU Accelerator pedal AGS ISG CU ISG Battery sensor 12 V battery (for restart) Battery current/voltage/ temperature sensor 12 V battery interconnection relay ECM Starter E/G 12 V battery (for auxiliary equipment) Battery temperature sensor Shift position sensor Transmission system solenoid Input clutch solenoid Output clutch solenoid TCU CAN LIN Signal line Serial communication HEV CAN and PU CAN Notes : 245 112 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) (B605) No. 21 IG SW input Ignition switch ON 11 — 15 V — (B605) No. 22 Starter drive request signal Model without push button start at cranking 8 — 14 V — Model with push button start at cranking Waveform — (B605) No. 23 P range SW input P range Less than 1 V — Except for P range 8 V or more — (B605) No. 24 R range SW input R range Less than 1 V — Except for R range 8 V or more — (B605) No. 25 N range SW input N range Less than 1 V — Except for N range 8 V or more — (B605) No. 26 D range SW input D range Less than 1 V — Except for D range 8 V or more — (B606) No. 1 GND1 for sensors Always 0 V — (B606) No. 2 GND2 for sensors Always 0 V — (B606) No. 3 Brake booster pressure sensor input 1 Always 0.5 — 4.5 V — (B606) No. 4 Brake booster pressure sensor input 2 Always 0.5 — 4.5 V — (B606) No. 5 (Not used) — — — (B606) No. 6 (Not used) — — (B606) No. 7 Sensor power supply output 1 When ignition switch is ON 4.5 V or more — (B606) No. 8 (Not used) — — — (B606) No. 9 Sensor power supply output 3 When ignition switch is ON 4.5 V or more — (B606) No. 10 (Not used) — — — (B606) No. 11 Brake stroke sensor input 1 When brake pedal is depressed Approx. 1 V — When brake is not depressed Approx. 2.5 V — (B606) No. 12 (Not used) — — — (B606) No. 13 (Not used) — — — (B606) No. 14 ISG CRK output When ignition switch is ON Less than 1 V — (B606) No. 15 ISG INH output When ignition switch is ON Less than 2 V — (B606) No. 16 Brake vacuum pump relay output When brake vacuum pump operates 9 V or more — When brake vacuum pump not activated 0 V — (B606) No. 17 Sensor power supply output 2 When ignition switch is ON 4.5 V or more — (B606) No. 18 Battery voltage 2 monitor input Always 11 — 15 V — (B606) No. 19 Vacuum pump relay monitor input When brake vacuum pump operates 9 V or more — When brake vacuum pump not activated 0 V — Terminal No. (terminal symbol) Item Measuring condition Measurement value Note Hybrid Powertrain HPCM I/O 246 113 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Accelerator pedal sensor Brake stroke sensor Brake Pedal High-voltage battery Temperature/current/ voltage sensor Contactor Drive motor Drive motor inverter Current sensor Resolver DC/DC converter High-voltage battery cooling fan Electric oil pump Electric oil pump inverter Brake Booster vacuum sensor Brake vacuum pump DM CU BE CU HP CU Accelerator pedal AGS ISG CU ISG Battery sensor 12 V battery (for restart) Battery current/voltage/ temperature sensor 12 V battery interconnection relay ECM Starter E/G 12 V battery (for auxiliary equipment) Battery temperature sensor Shift position sensor Transmission system solenoid Input clutch solenoid Output clutch solenoid TCU CAN LIN Signal line Serial communication HEV CAN and PU CAN Notes : 247 114 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) (B606) No. 20 Brake stroke sensor input 2 When brake pedal is depressed Approx. 4 V — When brake is not depressed Approx. 2.5 V — (B606) No. 21 (Not used) — — — (B606) No. 22 Battery relay CLOSE output — — — (B606) No. 23 Battery relay OPEN output — — — (B606) No. 24 GND3 for sensors Always 0 V — Terminal No. (terminal symbol) Item Measuring condition Measurement value Note Hybrid Powertrain HPCM I/O 248 115 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Accelerator pedal sensor Brake stroke sensor Brake Pedal High-voltage battery Temperature/current/ voltage sensor Contactor Drive motor Drive motor inverter Current sensor Resolver DC/DC converter High-voltage battery cooling fan Electric oil pump Electric oil pump inverter Brake Booster vacuum sensor Brake vacuum pump DM CU BE CU HP CU Accelerator pedal AGS ISG CU ISG Battery sensor 12 V battery (for restart) Battery current/voltage/ temperature sensor 12 V battery interconnection relay ECM Starter E/G 12 V battery (for auxiliary equipment) Battery temperature sensor Shift position sensor Transmission system solenoid Input clutch solenoid Output clutch solenoid TCU CAN LIN Signal line Serial communication HEV CAN and PU CAN Notes : 249 116 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Terminal No. (terminal symbol) Item Measuring condition Measurement value Note (R443) No. 1 (Not used) — — — (R443) No. 2 HEVCAN H — Cannot be measured CAN communication line (R443) No. 3 CT W When ignition switch is ON 2.45 — 2.55 V — (R443) No. 4 (Not used) — — — (R443) No. 5 CT V When ignition switch is ON 2.45 — 2.55 V — (R443) No. 6 SVCC2 When ignition switch is ON 4.9 — 5.1 V — (R443) No. 7 CT U When ignition switch is ON 2.45 — 2.55 V — (R443) No. 8 SVCC1 When ignition switch is ON 4.9 — 5.1 V — (R443) No. 9 (Not used) — — — (R443) No. 10 IG When ignition switch is ON 11 — 15 V — (R443) No. 11 SS RY When ignition switch is ON 0 V — (R443) No. 12 GND1 Always 0 V — R443 R442 26 25 24 23 22 21 20 19 18 17 16 15 14 22 21 20 19 18 17 16 15 14 13 12 13 12 11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 TO A: TO B: (R443) No. 13 IG SS1 When ignition switch is ON 11 — 15 V — (R443) No. 14 (Not used) — — — (R443) No. 15 HEVCAN L — Cannot be measured CAN communication line (R443) No. 16 (Not used) — — — (R443) No. 17 SGND2 When ignition switch is ON 0 V — (R443) No. 18 SGND1 When ignition switch is ON 0 V — (R443) No. 19 SCIMOCO — Cannot be measured SCI communication line (R443) No. 20 SCICOMO — Cannot be measured SCI communication line (R443) No. 21 FANPIN When ignition switch is ON 11 — 15 V — (R443) No. 22 FANPOUT When ignition switch is ON 11 — 15 V — (R443) No. 23 (Not used) — — — (R443) No. 24 IPUPWR RY When ignition switch is ON 0 V — (R443) No. 25 GND2 Always 0 V — (R443) No. 26 IG SS2 When ignition switch is ON 11 — 15 V — Drive Motor Control Module (DMCM) I/O 250 117 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Pin number Item Meaning or function No. 1 — — No. 2 HEVCAN H HEV CAN High signal No. 3 CT W Current signal W phase No. 4 — — No. 5 CT V Current signal V phase No. 6 SVCC2 Sensor Voltage supply2 No. 7 CT U Current signal U phase No. 8 SVCC1 Sensor Voltage supply1 No. 9 — — No. 10 IG IG switch input No. 11 SS RY Self Shut Relay (DMCM) driving signal No. 12 GND1 Ground1 No. 13 IG SS1 Main power1 [IG power supply from self shut relay (No.1)] No. 14 — — No. 15 HEVCAN L HEV CAN Low signal No. 16 — — No. 17 SGND2 Signal ground2 of current sensor No. 18 SGND1 Signal ground1 of current sensor No. 19 SCIMOCO Serial communication signal from DMCM to DC/DC No. 20 SCICOMO Serial communication signal from DC/DC to DMCM No. 21 FANPIN FAN Power In No. 22 FANPOUT FAN Power Out No. 23 — — No. 24 IPUPWR RY Power relay for Inverter and battery pack (Driving signal) No. 25 GND2 Ground2 No. 26 IG SS2 IG power supply from self shut relay (No.2) Accelerator pedal sensor Brake stroke sensor Brake Pedal High-voltage battery Temperature/current/ voltage sensor Contactor Drive motor Drive motor inverter Current sensor Resolver DC/DC converter High-voltage battery cooling fan Electric oil pump Electric oil pump inverter Brake Booster vacuum sensor Brake vacuum pump DM CU BE CU HP CU Accelerator pedal AGS ISG CU ISG Battery sensor 12 V battery (for restart) Battery current/voltage/ temperature sensor 12 V battery interconnection relay ECM Starter E/G 12 V battery (for auxiliary equipment) Battery temperature sensor Shift position sensor Transmission system solenoid Input clutch solenoid Output clutch solenoid TCU CAN LIN Signal line Serial communication HEV CAN and PU CAN 251 118 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) (R442) No. 1 UN — Cannot be measured — (R442) No. 2 UP — Cannot be measured — (R442) No. 3 TMP B When ignition switch is ON 0.23 V — 4.6 V — (R442) No. 4 TMP A When ignition switch is ON 0.23 V — 4.6 V — (R442) No. 5 AGND1 Always 0 V — (R442) No. 6 R1 — Cannot be measured — (R442) No. 7 S4 — Cannot be measured — (R442) No. 8 S3 — Cannot be measured — (R442) No. 9 S2 — Cannot be measured — (R442) No. 10 S1 — Cannot be measured — (R442) No. 11 (Not used) — — — (R442) No. 12 WN — Cannot be measured — (R442) No. 13 WP — Cannot be measured — (R442) No. 14 VN — Cannot be measured — (R442) No. 15 VP — Cannot be measured — (R442) No. 16 (Not used) — — — (R442) No. 17 R2 — Cannot be measured — (R442) No. 18 (Not used) — — — (R442) No. 19 (Not used) — — — (R442) No. 20 (Not used) — — — (R442) No. 21 (Not used) — — — (R442) No. 22 SCIIPU — Cannot be measured SCI communication line Terminal No. (terminal symbol) Item Measuring condition Measurement value Note Drive Motor Control Module (DMCM) I/O 252 119 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Pin number Item Meaning or function No. 1 UN UN phase driving signal No. 2 UP UP phase driving signal No. 3 TMP B Motor temperature sensor B input No. 4 TMP A Motor temperature sensor A input No. 5 AGND1 Analog Ground 1 No. 6 R1 Resolver excitation signal 1 No. 7 S4 Detected signal from resolver 4 No. 8 S3 Detected signal from resolver 3 No. 9 S2 Detected signal from resolver 2 No. 10 S1 Detected signal from resolver 1 No. 11 — — No. 12 WN WN phase driving signal No. 13 WP WP phase driving signal No. 14 VN VN phase driving signal No. 15 VP VP phase driving signal No. 16 — — No. 17 R2 Resolver excitation signal 2 No. 18 — — No. 19 — — No. 20 — — No. 21 — — No. 22 SCIIPU Serial communicaton signal with IPU Accelerator pedal sensor Brake stroke sensor Brake Pedal High-voltage battery Temperature/current/ voltage sensor Contactor Drive motor Drive motor inverter Current sensor Resolver DC/DC converter High-voltage battery cooling fan Electric oil pump Electric oil pump inverter Brake Booster vacuum sensor Brake vacuum pump DM CU BE CU HP CU Accelerator pedal AGS ISG CU ISG Battery sensor 12 V battery (for restart) Battery current/voltage/ temperature sensor 12 V battery interconnection relay ECM Starter E/G 12 V battery (for auxiliary equipment) Battery temperature sensor Shift position sensor Transmission system solenoid Input clutch solenoid Output clutch solenoid TCU CAN LIN Signal line Serial communication HEV CAN and PU CAN 253 120 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Terminal No. (terminal symbol) Item Measuring condition Measurement value Note (R445) No. 1 Main power supply 1 Always 11 — 15 V — (R445) No. 2 HEVCAN H — Cannot be measured CAN communication line (R445) No. 3 HEVCAN L — Cannot be measured CAN communication line (R445) No. 4 GND Always 0 V — (R445) No. 5 Main power supply 2 Always 11 — 15 V — (R445) No. 6 IG power supply When ignition switch is ON 11 — 15 V — (R445) No. 7 (Not used) — — — (R445) No. 8 GND Always 0 V — R445 8 7 6 5 4 3 2 1 HEV00082 TO High Voltage Battery 254 121 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Accelerator pedal sensor Brake stroke sensor Brake Pedal High-voltage battery Temperature/current/ voltage sensor Contactor Drive motor Drive motor inverter Current sensor Resolver DC/DC converter High-voltage battery cooling fan Electric oil pump Electric oil pump inverter Brake Booster vacuum sensor Brake vacuum pump DM CU BE CU HP CU Accelerator pedal AGS ISG CU ISG Battery sensor 12 V battery (for restart) Battery current/voltage/ temperature sensor 12 V battery interconnection relay ECM Starter E/G 12 V battery (for auxiliary equipment) Battery temperature sensor Shift position sensor Transmission system solenoid Input clutch solenoid Output clutch solenoid TCU CAN LIN Signal line Serial communication HEV CAN and PU CAN Notes : 255 122 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Notes : 123 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) XV Crosstrek Hybrid Diagnostics and Servicing WARNING: The electrical system of the XV Crosstrek Hybrid has a high voltage circuit. Read all cautions and warning in the appropriate Subaru Service Manual before beginning any diagnostics. Caution: Always test the rubber insulation gloves for air tightness and check the last inspection date of the gloves. Never use a rubber insulation glove with an inspection date older than 6 months (New insulation gloves are inspected at the factory and have a shelf life of 12 months plus 6 months of service). Always wear the leather protectors over the rubber insulation gloves. Position the rubber insulation gloves at least 2 inches higher up on the arm than the leather protectors. Before beginning any service work or diagnostics, place the High voltage service hat on the roof or best visible area of the vehicle and notify personnel working around you that you are servicing a Hybrid vehicle. Normal Vehicle Characteristics and Service Cautions 1. Do not turn on the ignition for at least 10 seconds after connecting all battery cables. This will generate a DTC. 2. When clearing the memory of any control unit, keep the ignition off for at least 30 seconds. Failure to wait for 30 seconds will prevent the DTC from being cleared. 3. The Positive and Negative Contactors do not turn off immediately when the ignition switch is turned off. 4. Never start the vehicle with the Service Plug removed. 5. The vehicle generates and discharges high frequency AC voltage which can create high frequency sound. The High Voltage Battery cover and cargo area platform insulate the noise from the passenger compartment. Operating the vehicle with these devices removed will allow the noise to be heard in the passenger compartment. 6. Always turn the ignition off when parking the vehicle. Failure to do so may result in the vehicle starting automatically in Automatic Start Stop. 7. During engine or vehicle diagnostics that is not associated with the high voltage circuit, place the vehicle in Maintenance Mode manually or with the Subaru Select Monitor. 8. Do not attempt normal operation of the vehicle on an elevated lift. DTCs will generate and the Hybrid system will turn off. If operation on an elevated lift is necessary for diagnostics, do not make rapid changes in acceleration or deceleration rates. Clear all DTCs when the diagnostics are complete. 9. A vibration in the drive train or an intermittent shuttering feeling while driving is a symptom of a shorted Hybrid Electric Motor and/ or associated wiring. The vehicle should be removed from service until repaired. 124 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Notes : 125 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) When performing diagnostics of the XV Crosstrek Hybrid, follow the guidance provided in the Subaru Service Manual. Note: The high voltage circuit is made from many components. The same DTC can be generated from a failure in any of the separate parts or connecting circuits. Example: P0AA6 High Battery Voltage Isolation Fault CW:DTC P0AA6 HYBRID BATTERY VOLTAGE SYSTEM ISOLATION FAULT DIAGNOSIS: • Detects leakage in high voltage system circuit. • If HEV system leakage resistance, leakage resistance in high voltage battery are smaller than the standard, it is judged as faulty. • Immediately at fault recognition TROUBLE SYMPTOM: Normal control CAUTION: Before performing diagnosis, refer to “CAUTION” in “General Description”. WIRING DIAGRAM Hybrid System HV12 3 2 1 2 1 3 HV12 HV11 N P HV10 W V U N P N P N P N P V U W V U N P N P HV2 HV4 HV1 HV9 W V U HV3 W W V U HV7 HV6 HV5 HV8 HEV00327 MB-3 (B) HIGH VOLTAGE BATTERY DRIVE MOTOR INVERTER ELECTRIC NOISE FILTER DRIVE MOTOR INVERTER AMPERAGE SENSOR DRIVE MOTOR ASSY DC/DC CONVERTER ELECTRIC OIL PUMP INVERTER ELECTRIC FLUID PUMP TO POWER SUPPLY CIRCUIT High Voltage Circuit Configuration 257 126 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Before beginning diagnostics review the PID’s of the Battery Energy Control System. Four of the PID’s are very similar in name but are very different in meaning. These two PID’s display the calculated resistance to body ground of the entire Hybrid high voltage wiring except the High Voltage Battery (before the contactors). DTCs generated from faults related to these PID’s can be repaired. HEV System Leakage Resistance (+) HEV System Leakage Resistance (-) BECM Select Monitor Data These two PID’s display the calculated resistance to body ground of the High Voltage Battery. The only repair possible for a failure related to these PID’s is replacement of the High Voltage Battery. High Voltage Battery Pack Leakage Resistance (+) High Voltage Battery Pack Leakage Resistance (-) Caution: Always use the Select Monitor or CAT III approved digital multi-meters when performing diagnostics. Diagnostics in step 1 are confirming if the High Voltage Battery is leaking (shorted) to body ground. 258 127 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) The BECM provides a temporary path to ground before the Contactors to check for Battery leakage. If a leak is detected, the BECM will not turn on the Contactors. This test will be performed within one minute of the ignition coming on. Note: The one minute wait time allows the data to be displayed on the Select Monitor. Step Check Yes No 1 CHECK CURRENT DATA. 1) Turn the ignition switch to OFF ON. 2) Leave the vehicle 1 minute unattended. 3) Using the Subaru Select Monitor, confirm the current data of battery energy control system, the values of «High Voltage Battery Pack Leakage Resistance (+)»«High Voltage Battery Pack Leakage Resistance (–)». Is the value of «High Voltage Battery Pack Leakage Resistance (+)» or «High Voltage Battery Pack Leakage Resistance (–)» 290 k or less? Replace the high voltage battery. Go to step 2. P0AA6 Step 1 Step 2 is confirming the leakage is in the High Voltage wiring and if the problem still exists. 2 CHECK CURRENT DATA. 1) Stop the engine. 2) Start the engine. 3) Leave the vehicle 1 minute unattended. 4) Using the Subaru Select Monitor, confirm the current data of battery energy control system, the values of «HEV System Leakage Resistance (+)» «HEV System Leakage Resistance (–)». Is the value of «HEV System Leakage Resistance (+)» or «HEV System Leakage Resistance (–)» 290 k or less? Go to step 3. Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Step Check Yes No P0AA6 Step 2 After reviewing step 2 and checking the current data, HEV System Leakage Resistance + and -, a short to ground or insulation problem does exist. The next step is to start isolating the problem. Follow the provided diagnostics step by step. Read the entire box before performing any work. 259 260 128 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Step 3 begins the process of checking the High Voltage circuits for possible shorts to ground. It is possible the circuits only short to ground when they are under electrical load. The instructions included in this step are preparing the vehicle for a normal safe High Voltage off condition. Failure to follow these instructions may result in electrical shock. This step in the diagnostics introduces the use of the Mega-Ohm Meter which can output very High Voltage and cause electrical shock. 3 CHECK POWER CABLE AND BUS BAR. 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable of the 12 volt auxiliary battery, and as for the 12 volt engine restart battery, disconnect the ground cable from the battery sensor. 3) Remove the service plug. 4) Wait for 10 minutes. 5) Disconnect the power cable (HV4) from drive motor inverter current sensor. 6) Using a megohmmeter (250 V range), measure the resistance between high voltage battery side terminal and chassis ground. Connector & terminal (HV7) P — Chassis ground: (HV7) N — Chassis ground: Is the resistance 2 M or more? Go to step 13. Go to step 4. Step Check Yes No P0AA6 Step 3 This tool must be use when performing the outlined steps. It is necessary to place the identified circuits in an electrically loaded condition to find the problem. Warning: This device outputs very high voltage. Follow all safety precautions when using for diagnostics. HV12 3 2 1 2 1 3 HV12 HV11 N P HV10 W V U N P N P N P N P V U W V U N P N P HV2 HV4 HV1 HV9 W V U HV3 W W V U HV7 HV6 HV5 HV8 HEV00327 MB-3 (B) HIGH VOLTAGE BATTERY DRIVE MOTOR INVERTER ELECTRIC NOISE FILTER DRIVE MOTOR INVERTER AMPERAGE SENSOR DRIVE MOTOR ASSY DC/DC CONVERTER ELECTRIC OIL PUMP INVERTER ELECTRIC FLUID PUMP TO POWER SUPPLY CIRCUIT Hybrid High Voltage Circuit Configuration 261 262 129 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 50V 100V 250V 500V 1000V INSULATION 250V TEST Release LOCK mode Black Red Mega Ohm Meter The Mega Ohm Meter introduces high voltage into a circuit to check resistance while under electrical load. The meter uses ohms law to determine resistance and therefore insulation condition. The current returned is measured and then the selected voltage is divided by the amperage to determine the resistance. If the current is high (not properly insulated or leaking), the resistance value will drop. A Mega Ohm Meter has several voltage settings that can be selected. Always use the setting that is recommended by the Subaru Service Manual.There are many Mega Ohm meters available for purchase. Review the operating instructions and warnings provided for the meter you purchase. A test button is provided on the meter to activate the flow of electricity into the circuit being tested. Warning: Never touch the circuit being tested or test leads of the Mega Ohm Meter. High voltage is present anytime the test button is activated. Never use the lock button or hold button to keep the test function active. Note: The symbol “M” accompanied by the ohms sign symbol stands for Million. The symbol “m” accompanied by the ohms sign stands for milli-ohms (a thousands of 1 ohm). The remainder of the diagnostic steps continue testing the High Voltage circuit and the High Voltage system components for short to ground. If a part is failed, replace it with a new one and follow the Subaru Service Manual during installation. Do not over tighten or under tighten any bolts. If a foreign object has been found to be the fault, creating the short, remove it and determine where it came from and repair that area. Note: The High Voltage area of the vehicle must be kept dry. Excess moisture can result in creating a High Voltage leak. 263 130 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Step Check Yes No 4 CHECK POWER CABLE AND BUS BAR. 1) Disconnect the power cable (HV10) from electric oil pump. 2) Using a megohmmeter (250 V range), measure the resistance between high voltage battery side terminal and chassis ground. Connector & terminal (HV7) P — Chassis ground: (HV7) N — Chassis ground: Is the resistance 2 M or more? Go to step 14. Go to step 5. P0AA6 Step 4 HV12 3 2 1 2 1 3 HV12 HV11 N P HV10 W V U N P N P N P N P V U W V U N P N P HV2 HV4 HV1 HV9 W V U HV3 W W V U HV7 HV6 HV5 HV8 HEV00327 MB-3 (B) HIGH VOLTAGE BATTERY DRIVE MOTOR INVERTER ELECTRIC NOISE FILTER DRIVE MOTOR INVERTER AMPERAGE SENSOR DRIVE MOTOR ASSY DC/DC CONVERTER ELECTRIC OIL PUMP INVERTER ELECTRIC FLUID PUMP TO POWER SUPPLY CIRCUIT Hybrid High Voltage Circuit Configuration 264 265 131 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Step Check Yes No 5 CHECK BUS BAR. 1) Check the bus bar between the high voltage battery (HV8) and the noise filter (HV7) and the surrounding area for metallic foreign bodies, and if there are any, remove them. 2) Using a megohmmeter (250 V range), measure the resistance between high voltage battery side terminal and chassis ground. Connector & terminal (HV7) P — Chassis ground: (HV7) N — Chassis ground: Is the resistance 2 M or more? Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. Go to step 6. P0AA6 Step 5 Step Check Yes No 6 CHECK POWER CABLE AND BUS BAR. 1) Remove the bus bar between high voltage battery (HV8) and the noise filter (HV7). 2) Using a megohmmeter (250 V range), measure the resistance between High Voltage battery terminals and chassis ground. Connector & terminal (HV8) P — Chassis ground: (HV8) N — Chassis ground: Is the resistance 2 M or more? Go to step 7. Replace the high voltage battery. P0AA6 Step 6 Step Check Yes No 7 CHECK POWER CABLE AND BUS BAR. 1) Check bus bars between the noise filter (HV6), the drive motor inverter (HV5), and electric oil pump inverter (HV9) and the surrounding area for metallic foreign bodies, and if there are any, remove them. 2) Using a megohmmeter (250 V range), measure the resistance between high voltage battery side terminal and chassis ground. Connector & terminal (HV7) P — Chassis ground: (HV7) N — Chassis ground: Is the resistance 2 M or more? Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. Go to step 8. P0AA6 Step 7 266 267 268 132 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) HV12 3 2 1 2 1 3 HV12 HV11 N P HV10 W V U N P N P N P N P V U W V U N P N P HV2 HV4 HV1 HV9 W V U HV3 W W V U HV7 HV6 HV5 HV8 HEV00327 MB-3 (B) HIGH VOLTAGE BATTERY DRIVE MOTOR INVERTER ELECTRIC NOISE FILTER DRIVE MOTOR INVERTER AMPERAGE SENSOR DRIVE MOTOR ASSY DC/DC CONVERTER ELECTRIC OIL PUMP INVERTER ELECTRIC FLUID PUMP TO POWER SUPPLY CIRCUIT Hybrid High Voltage Circuit Configuration Step Check Yes No 8 CHECK POWER CABLE AND BUS BAR. 1) Remove the DC/DC converter (HV3). 2) Using a megohmmeter (250 V range), measure the resistance between high voltage battery side terminal and chassis ground. Connector & terminal (HV7) P — Chassis ground: (HV7) N — Chassis ground: Is the resistance 2 M or more? Replace the DC/ DC converter. Go to step 9. P0AA6 Step 8 Step Check Yes No 9 CHECK POWER CABLE AND BUS BAR. 1) Remove the electric oil pump inverter (HV9). 2) Using a megohmmeter (250 V range), measure the resistance between high voltage battery side terminal and chassis ground. Connector & terminal (HV7) P — Chassis ground: (HV7) N — Chassis ground: Is the resistance 2 M or more? Replace the electric oil pump inverter. Go to step 10. P0AA6 Step 9 269 270 271 133 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Step Check Yes No 10 CHECK POWER CABLE AND BUS BAR. 1) Remove the drive motor inverter current sensor (HV2) from the drive motor inverter. 2) Check the bus bar of the drive motor inverted current sensor (HV2) and the surrounding area for metallic foreign bodies, and remove them if there any, then reinstall the sensor. 3) Using a megohmmeter (250 V range), measure the resistance between high voltage battery side terminal and chassis ground. Connector & terminal (HV7) P — Chassis ground: (HV7) N — Chassis ground: Is the resistance 2 M or more? Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. Go to step 11. P0AA6 Step 10 Freeze Frame Data has been enhanced capture up to 10 samples of time and data. The time between samples and the data captured is depended on the DTC. Trip Count displays the number of ignition cycles since the memory was last cleared. Time Count is the clock time of the ignition cycle when the DTC was generated. Count value can be Common or Not Common. Common means that the control unit clock for that particular control unit is synchronized to the BIU, which holds the master time of the vehicle. Not Common means independent timing. When multiple DTCs are set, check the Time Count to confirm which DTC was set first. The remainder of the DTCs may be the result of a problem and not the actual cause. NOTE: When using this method make sure the Count value is common. P0AA6 Freeze Frame Data 272 273 134 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Maintenance Mode Read all steps before attempting to activate Maintenance Mode. (Auto Start/Stop function OFF and Motor-Only Running function OFF) Maintenance mode can be initiated without the Select Monitor by implementing the following procedure: With the ignition switch ON and the engine OFF, perform the following actions while depressing the brake pedal (Do not press or release the accelerator pedal too quickly). 1. Depress the accelerator pedal 2 times with the transmission in N range. (Fully closed –> Fully open –> Fully closed –> Fully open) Do not press or release the accelerator pedal too fast, the input may not be received. 2. Depress the accelerator pedal 2 times with the transmission in P range. (Fully closed –> Fully open –> Fully closed –>Fully open) 3. Depress the accelerator pedal 2 times with the transmission in N range. (Fully closed –> Fully open –> Fully closed –> Fully open) 4. Shift into P range and start the engine. (The Hybrid Warning Light in the combination meter flashes and Maintenance mode is displayed in the MFD.) 5. Maintenance mode will terminate when the ignition switch is turned OFF. (This also happens when Maintenance mode is initiated with the SSM III). CAUTION • Perform all the above operations within 60 seconds after turning the ignition switch ON. Hybrid Failsafe Operation There are 6 levels of failsafe controls for the XV Crosstrek Hybrid. The control of each level is preset, allowing only partial Hybrid operation or Automatic Start Stop functions. Failsafe level Warning lamp EV / Idling stop mode High voltage relay Driving control 6 On Inhibit Emergency shut down ECM, TCM 5 On Inhibit Emergency shut down HEV control 4 On Inhibit Normal shut down HEV control 3 On Inhibit (No more cranking) HEV control 2 On Inhibit HEV control 1 On HEV control Hybrid Failsafe Levels 274 135 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) CAN Channel 1 Bus Error U0073 ON CAN Channel 1 ECU ID not received U0100 ON CAN Channel 1 TCU ID not received U0101 ON CAN Channel 1 ECU Erratic data U0401 ON CAN Channel 1 TCU Erratic data U0402 ON CAN Channel 2 Bus Error U0075 ON CAN Channel 2 No receive ECU ID U1100 ON CAN Channel 2 TCU ID not received U1101 ON CAN Channel 2 ECU Erratic data U1401 ON CAN Channel 2 TCU Erratic data U1402 ON CAN Channel 3 Bus Error U0076 ON CAN Channel 3 INV ID not received U0110 ON CAN Channel 3 INV Erratic data U0411 ON HPCU microcomputer failure P0A1D ON HPCU RAM failure P0604 ON HPCU ROM failure P0605 ON CAN Channel 3 BAT ID not received U0111 ON CAN Channel 3 BAT Erratic data U0412 ON Level 4 Emergency shut down of high voltage system. Battery should be replaced. Collision detection P1C1E ON 1 LIN Bit Error U1676 ON LIN Check sum Error (ISG) U1720 ON ISG Self-diagnosis Functional Error P1C14 ON ISG Control Circuit failure P0620 ON Auto Start Stop Functional Error P06EF ON Battery Relay Stuck Closed P1C09 ON Starter Battery Charging Error P1C18 ON Battery Relay Open side wiring failure P1C07 ON Battery Relay Close side wiring failure P1C06 ON Note 1: ISG Active test is disabled. Hybrid Warning Light DTC Note Level 3 Normal shut down of high voltage system EV mode, Auto Start Stop is not available. Engine doesn’t restart in EV or Auto Start Stop mode. Igniton key OFF to escape from EV or Auto Start Stop and restart engine manually. Level 5 Emergency shut down of high voltage system Failsafe Detected failure Level 6 Independent control by ECM & TCM HEV CU gives up control. 136 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) CAN Channel 1 VDC ID not received U0122 ON – CAN Channel 1 VDC Erratic data U0416 ON – LIN Check sum Error (Battery sensor) U1711 ON – Vacuum Pump Functional Error P1C10 ON – Vacuum Pump Relay Stuck Open P1C11 ON – Vacuum Pump Relay Stuck Closed P1C12 ON – Vacuum Sensor Erratic Characteristic P0556 ON – Brake Stroke Sensor Erratic Characteristic P057B ON 2 Brake Stroke Sensor 1 Open circuit/Ground short P057C ON 2 Brake Stroke Sensor 1 High voltage short P057D ON 2 Charging system failure P065A ON – Brake Stroke Sensor 2 Open circuit/Ground short P1C0C ON 2 Brake Stroke Sensor 2 High voltage short P1C0D ON 2 Brake Stroke Sensor Learning failure P1C0E ON 2 Battery Sensor Internal Error P1C00 ON 3 Battery Relay Stuck Open P1C08 ON – Rear Wheel Speed Sensor Error P2158 ON 2 Speed Sensor Error P215A ON 2 Brake Switch 2 Lo Failure P0719 ON – Brake Switch 2 Hi Failure P0724 ON – Brake Switch 1 Lo Failure P0572 ON – Brake Switch 1 Hi Failure P0573 ON – CAN Channel 1 BDY ID not received U0140 ON – CAN Channel 1 MET ID not received U0155 ON – CAN Channel 1 EPS ID not received U0131 ON – CAN Channel 1 ACN ID not received U0164 ON – CAN Channel 1 ABG ID not received U0151 ON – CAN Channel 1 EYE ID not received U1235 ON – CAN Channel 1 BDY Erratic data U0422 ON – CAN Channel 1 ACN Erratic data U0424 ON – CAN Channel 1 ABG Erratic data U0452 ON – CAN Channel 1 EYE Erratic data U1433 ON – CAN Channel 1 MET Erratic data U0423 ON – CAN Channel 1 EPS Erratic data U0420 ON – CAN Channel 􃸱 EOP ID not received U0287 ON – CAN Channel 􃸱 EOP Erratic data U0588 ON – Auxiliary Battery Temp. Sensor Ground short P0516 ON – Auxiliary Battery Temp. Sensor Open circuit/High voltage short P0517 ON – Voltage monitor line Open circuit P058D ON 3 Linear Solenoid Open circuit/High voltage short P1C05 ON – Linear Solenoid Ground short P1C04 ON – ISC Charactaristic Lo P0506 ON – ISC Characteristic Hi P0507 ON – Note 2: Regeneration at braking is disabled. Note 3: Active test of 12V Battery relay is disabled. Level 1 Hybrid warning lamp turns ON. Note Level 2 Inhibit EV mode, Auto Start Stop Engine restart at EV mode and Auto Start Stop Failsafe Detected failure DTC Hybrid Warning Light 137 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Failure DTC Reduced output power Shut down Contactors (HPCU fail safe Level 5, Level 6) HPCU Warning Lamp High Voltage Fuse P0A95 a a High Voltage Service Disconnect Open P0B37 a a Hybrid Battery Negative Contactor Circuit Stuck Closed P0AA4 a Hybrid Battery Positive Contactor or Pre-charge Contactor Circuit Stuck Closed P1C40 a a Hybrid Battery Voltage System Isolation Sensor Circuit P0AA7 a Hybrid Battery Contactor Power Supply Circuit P1C42 a a Hybrid Battery Positive Contactor Control Circuit/Open P0AD9 a a Hybrid Battery Positive Contactor Control Circuit Low P0ADB a a Hybrid Battery Negative Contactor Control Circuit/Open P0ADD a a Hybrid Battery Negative Contactor Control Circuit Low P0ADF a Hybrid Battery Pre-charge Contactor Control Circuit P0AE4 a Hybrid Battery Pre-charge Contactor Control Circuit Low P0AE6 a a Hybrid Battery Contactor Power Supply Circuit P1C43 a a Hybrid Battery System Precharge Time Too Long P0C78 a a Hybrid Battery Voltage System Isolation Fault — Minus side, External P0AA6 a Hybrid Battery Voltage System Isolation Fault Minus side, Internal P0AA6 a Hybrid Battery Voltage System Isolation Fault — Plus side, External P0AA6 a Hybrid Battery Voltage System Isolation Fault Plus side, Internal P0AA6 a Hybrid Battery Pack State of Charge Low P0A7D a a a Hybrid Battery Pack State of Charge High P0C30 a a a High Voltage Circuit short P1C41 a a Hybrid Battery Pack Deterioration P0A7F a Hybrid Battery Block Voltage Too Low P1C5E a a Hybrid Battery Charging Current High P0CA6 a a Hybrid Battery Discharging Current High P0CA7 a a Hybrid Battery Pack Current Sensor Circuit Range/Performance P0AC0 a a Hybrid Battery Pack Current Sensor Circuit Low P0AC1 a a Hybrid Battery Pack Current Sensor Circuit High P0AC2 a a Hybrid Battery Pack Current Sensor Circuit Intermittent/Erratic P0AC3 a a Hybrid Battery Pack Current Sensor “A” Circuit P0ABF a a Hybrid Battery Pack Over Temperature P0A7E a a Hybrid Battery Pack Air Temperature Sensor “A” Circuit Range/Performance P0AAD a Hybrid Battery Pack Air Temperature Sensor “A” Circuit Low P0AAE a Hybrid Battery Pack Air Temperature Sensor “A” Circuit High P0AAF a Hybrid Battery Temperature Sensor “A” Circuit Range/Performance P0A9C a a Hybrid Battery Temperature Sensor “A” Circuit Low P0A9D a a Hybrid Battery Temperature Sensor “A” Circuit High P0A9E a a Hybrid Battery Temperature Sensor “B” Circuit Range/Performance P0AC6 a a Hybrid Battery Temperature Sensor “B” Circuit Low P0AC7 a a Hybrid Battery Temperature Sensor “B” Circuit High P0AC8 a a Hybrid Battery Temperature Sensor “C” Circuit Range/Performance P0ACB a a Hybrid Battery Temperature Sensor “C” Circuit Low P0ACC a a Hybrid Battery Temperature Sensor “C” Circuit High P0ACD a a Battery Temperature Battery Current Fail safe Junction Module Service Plug Battery Pack 138 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Reduced output power Shut down Contactors (HPCU fail safe Level 5, Level 6) HPCU Warning Lamp Hybrid Battery Voltage Low P0B25 a a Hybrid Battery Voltage High P0B26 a a Hybrid Battery Voltage Sense “Z” Circuit P0BB8 a a Hybrid Battery Voltage Sense “A” Circuit􀠉Range/Performance P0B3C a a Hybrid Battery Voltage Sense “A” Circuit Low P0B3D a a Hybrid Battery Voltage Sense “A” Circuit High P0B3E a a Hybrid Battery Voltage Sense “B” Circuit􀠉Range/Performance P0B41 a a Hybrid Battery Voltage Sense “B” Circuit Low P0B42 a a Hybrid Battery Voltage Sense “B” Circuit High P0B43 a a Hybrid Battery Voltage Sense “C” Circuit􀠉Range/Performance P0B46 a a Hybrid Battery Voltage Sense “C” Circuit Low P0B47 a a Hybrid Battery Voltage Sense “C” Circuit High P0B48 a a Hybrid Battery Voltage Sense “D” Circuit P0B4A a Hybrid Battery Voltage Sense “D” Circuit􀠉Range/Performance P0B4B a a Hybrid Battery Voltage Sense “D” Circuit Low P0B4C a a Hybrid Battery Voltage Sense “D” Circuit High P0B4D a a Hybrid Battery Voltage Sense “E” Circuit􀠉Range/Performance P0B50 a a Hybrid Battery Voltage Sense “E” Circuit Low P0B51 a a Hybrid Battery Voltage Sense “E” Circuit High P0B52 a a Hybrid Battery Voltage Sense “F” Circuit􀠉Range/Performance P0B55 a a Hybrid Battery Voltage Sense “F” Circuit Low P0B56 a a Hybrid Battery Voltage Sense “F” Circuit High P0B57 a a Hybrid Battery Voltage Sense “G” Circuit􀠉Range/Performance P0B5A a a Hybrid Battery Voltage Sense “G” Circuit Low P0B5B a a Hybrid Battery Voltage Sense “G” Circuit High P0B5C a a Hybrid Battery Block 1 Balancing Performance P1C45 a a Hybrid Battery Block 2 Balancing Performance P1C46 a a Hybrid Battery Block 3 Balancing Performance P1C47 a a Hybrid Battery Block 4 Balancing Performance P1C48 a a Hybrid Battery Block 5 Balancing Performance P1C49 a a Hybrid Battery Block 6 Balancing Performance P1C4A a a HPCU data not arrived U1290 a a DMCU data not arrived U0110 a HPCU counter error U1591 a a MMCU counter error U0411 a HPCU check sum error U1591 a a DMCU check sum error U0411 a CAN1 Bus Off U0076 a a CAN1 Register failure P0604 a a BECU Failure(DataFlashROM) P062F a a BECU Failure (FlashROM) P0605 a a BECU Failure (ADC) P0A1F a a BECU Failure (RAM) P0604 a a BEEU Failure (WDT circuit) P0A1F a a Communication error between MainCPU and SubCPU P1C44 a a SubCPU received HV battery failure state P1C44 a a Battery Energy Control Module P0A1F a a 12V Battery failure ( voltage too high / Low, current/voltage sensor failure) P0000 a Fail safe Battery Voltage Communication, Controller 139 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Removing/Installing the V-belt Tensioner Assy Removing an Undamaged V-belt 1. Lift the engine cover at two points on the front of the cover. Then, while pressing the engine cover at two points on the back of the cover and pushing it toward the rear of the vehicle, lift and remove the engine cover. 2. Remove the V-belt tensioner Assy. 1) Set a tool on the V-belt tensioner Assy and turn it counterclockwise until protruding point Z on the V-belt tensioner Assy moves to a point between stopper pin holes A and B. Then insert the special tool into stopper pin hole B. 499267300: Stopper pin B Z (B) (Z) ST A ST (A) ISG Stopper Pin Positioning Holes 275 140 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) ISG Mounting Plate Bolts 2) Take the V-belt off the idler pulley. 3) Remove the V-belt tensioner Assy and then take off the V-belt. Note: The two pulley pendulum belt tensioner is comprised of 4 major parts. An outer mounted spring, 2 independent pulley assemblies, and a mounting plate. The mounting plate is bolted to the ISG and is stationary. The 2 pulleys with their own mounting plates, are positioned on the main mounting plate. The mounting plates of the pulleys can scissor over each other which allows the pulleys to move towards or away from each other. The spring is always trying to push the two pulleys together. If the accessory belt is in place, only one special tool is required to cage the tension of the spring. If the belt brakes, two special tools are required as both pulleys are pushed away from the indexing point of the main mounting plate. 276 141 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Removing a Damaged V-belt 1. Remove the V-belt tensioner Assy. 1) Turn the V-belt tensioner Assy until stopper pin hole A in the V-belt tensioner Assy and stopper pin hole C in the ISG are in the same position. Then, insert the special tool through stopper pin hole A and stopper pin hole C as far as it will go. ST C C A A A over C Install ST to A 2) Set a tool on the V-belt tensioner Assy. and turn it counterclockwise until protruding point Z on the V-belt tensioner Assy. moves to a point between stopper pin holes A and B. Then insert the special tool into stopper pin hole B. ST Z B B Z A Z to Center of A and B Install ST to B 277 278 142 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 3) Pull out the special tool that was inserted into stopper pin hole A. ST Remove ST from A 4) Remove the V-belt tensioner Assy. ISG Mounting Plate Bolts 279 280 143 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Installing the V-belt Tensioner Assy & V-belt 1. Set the V-belt as shown in the figure below. (A) (C) (B) (D) (E) (F) Belt Configuration 2. Install the V-belt tensioner Assy. Torque Values A) V-belt B) Water pump pulley C) Crank pulley D) ISG pulley E) Idler pulley F) A/C compressor pulley T: 25N•m (2.5 kgf-m, 18.4 ft-lb) 281 282 144 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) 3. Set a tool on the V-belt tensioner Assy and slightly turn it counterclockwise, and then pull out the special tool that was inserted into stopper pin hole B. CAUTION: Before pulling out the special tool, make sure the ribs in the V-belt are properly seated in the rib grooves in each pulley. Belt Alignment 283 145 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Jump starting the vehicle If the Auxiliary Battery state of charge is too low to operate the conventional starter, connect jumper cables to the Auxiliary Battery and another 12 volt battery vehicle or a jump box. Connect to Auxiliary Battery Only Never connect jumper cables to the Restart Battery. The smaller battery posts and clamps will not offer sufficient surface area to hold the jumper cables in place and the jumper cable may fall to body ground. DTC’s may also be created. Small Restart Battery Post Restart Battery Post Cover If this should occur, a short circuit to body ground will occur from Restart Battery to the rear of the vehicle to the DC/DC Converter. The entire Hybrid wiring harness and possibly the DC/DC Converter could be damaged. 284 285 286 146 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Interconnect Relay Do not attempt to place a bypass on the Interconnect Relay. The relay and wiring harness are not designed to conduct the amperage required to operate the starter. 287 147 November 2013 2014 XV Crosstrek Hybrid New Technology Training (Module 702) Notes :

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