Subaru XV Crosstrek Hybrid 2014 Technicians Reference Booklet
  1. Manuals
  2. Brands
  3. Subaru Manuals
  4. Automobile
  5. XV CROSSTREK HYBRID 2014
  6. Technicians reference booklet

Subaru XV Crosstrek Hybrid 2014 Technicians Reference Booklet

Hide thumbs Also See for XV Crosstrek Hybrid 2014:
Table of Contents

Advertisement

Quick Links

See also: Quick Reference Manual
Technician
Reference
Booklet
2014 XV Crosstrek
Hybrid
Module 702
MSA5P1702C
November 2013

Advertisement

Table of Contents
loading

Related Manuals for Subaru XV Crosstrek Hybrid 2014

Summary of Contents for Subaru XV Crosstrek Hybrid 2014

  • Page 1 Technician Reference Booklet 2014 XV Crosstrek Hybrid Module 702 MSA5P1702C November 2013...
  • Page 3 November 2013. © 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.

  • Page 4: Table Of Contents

    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 ................
  • Page 5 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 ...............

  • Page 7: Introduction

    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 –...

  • Page 8: Crosstrek Vehicle Specifications

    2014 XV Crosstrek Hybrid   (Module 702) XV Crosstrek vehicle specifications y l l q i l n i l n i l × × 90.0 (3.31 × 3.54) Displacement (cu in) 1,995 (121.73) Compression ratio 10.5 10.8 Ignition order 1 —...
  • Page 9 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) November 2013...
  • Page 10 2014 XV Crosstrek Hybrid   (Module 702) 5 door Model 2.0 i-Prm OP code 1,440 1,455 1,440 1,440 1,440 1,440 1,455 1,455 1,440 1,440 1,455 1,455 Total (lb) (3,175) (3,208) (3,175) (3,175) (3,175) (3,175) (3,208) (3,208) (3,175) (3,175) (3,208) (3,208) Curb weight Front...

  • Page 11: Hybrid Service Safety Precautions

    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.
  • Page 12 2014 XV Crosstrek Hybrid   (Module 702) • When touching the high voltage terminals without insulation covering, make sure, in advance, to wear insulated gloves and confirm that the voltage is 0 V using a CAT III multimeter (voltages can be near 200 volts). •...
  • Page 13 2014 XV Crosstrek Hybrid   (Module 702) • During the work for the high voltage system, make sure to alert other servicemen to take precautions, for instance by displaying [HIGH VOLTAGE WORK. DO NOT TOUCH] on the vehicle. (An example is shown. Make a photocopy for use.) HIGH VOLTAGE CAUTION LABEL CAUTION: HIGH VOLTAGE.
  • Page 14 2014 XV Crosstrek Hybrid   (Module 702) • When measuring the voltage or resistance of individual sensors or all control modules, use a tapered pin with a diameter of less than 0.6 mm (0.024 in). Do not insert the pin 4 mm (0.16 in) or more into the part.
  • Page 15 2014 XV Crosstrek Hybrid   (Module 702) Warning Label • When the part is replaced or the warning label is detached, make sure to attach a new warning label in the original position and direction. • This vehicle starts and stops the engine automatically, when the ready-to-drive (READY) indicator light in the meter illuminates.
  • Page 16 2014 XV Crosstrek Hybrid   (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.
  • Page 17 2014 XV Crosstrek Hybrid   (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.

  • Page 18: Procedures At An Accident Scene

    2014 XV Crosstrek Hybrid   (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.) ◊...

  • Page 19: Procedure After Moving Damaged Vehicle

    2014 XV Crosstrek Hybrid   (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. <Ref. to PC- 10, Service Plug, CAUTION (HYBRID SYSTEM), Precaution.> •...
  • Page 20 2014 XV Crosstrek Hybrid   (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.
  • Page 21 2014 XV Crosstrek Hybrid   (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...

  • Page 22: Pre-Delivery Inspection

    2014 XV Crosstrek Hybrid   (Module 702) : High voltage 100V : 12 Voltage HEV00283 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.

  • Page 23: Engine Air Filter

    2014 XV Crosstrek Hybrid   (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.

  • Page 24: Brake Vacuum Pump

    2014 XV Crosstrek Hybrid   (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.
  • Page 25 2014 XV Crosstrek Hybrid   (Module 702) TO POWER SUPPLY CIRCUIT FB-38 ST-2 MB-37 MB-3 IG SW F/B FUSE NO. 12 M/B FUSE NO. 5 (IG) (ST) HEV-04 HEV-09 : WITHOUT PUSH BUTTON START : WITH PUSH BUTTON START RELAY : WITHOUT PUSH BUTTON START : B HOLDER WWITH PUSH BUTTON START : WG...
  • Page 26 [GND-01] 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).
  • Page 27 2014 XV Crosstrek Hybrid   (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.

  • Page 28: Automatic Grill Shutter System

    2014 XV Crosstrek Hybrid   (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.
  • Page 29 2014 XV Crosstrek Hybrid   (Module 702) TO POWER SUPPLY TO POWER SUPPLY ACTR E163 F157 CIRCUIT CIRCUIT AGAS BAT-1 FB-18 F/B FUSE NO. 7 FUSE F156 BATTERY HOLDER SENSOR F155 B602 B609 B598 B610 F108 B361 THROUGH JOINT CONNECTOR B143 B553 HEV-01...

  • Page 30: Pedestrian Approach System

    2014 XV Crosstrek Hybrid   (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).
  • Page 31 2014 XV Crosstrek Hybrid   (Module 702) 1. APPROACH INFORMATION CONTROL MODULE HEV00005 Terminal No. (terminal Item Measuring condition Measurement value Note symbol) Operational power supply 1 (IG) IG ON 10 V or more — Brake pedal ON → 8 V or more → less than STOP light signal 2 (STP) —...
  • Page 32 2014 XV Crosstrek Hybrid   (Module 702) TO POWER SUPPLY TO POWER SUPPLY ACTR E163 F157 CIRCUIT CIRCUIT AGAS BAT-1 FB-18 F/B FUSE NO. 7 FUSE F156 BATTERY HOLDER SENSOR F155 B602 B609 B598 B610 F108 B361 THROUGH JOINT CONNECTOR B143 B553 HEV-01...
  • Page 33 2014 XV Crosstrek Hybrid   (Module 702) miles HEV00335 (1) Approach Report Warning Light The Approach Warning Light will illuminate if the system is not working correctly. November 2013...
  • Page 34 2014 XV Crosstrek Hybrid   (Module 702) NOTES: November 2013...

  • Page 35: Hybrid Safety Kit

    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.
  • Page 36 2014 XV Crosstrek Hybrid   (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.
  • Page 37 2014 XV Crosstrek Hybrid   (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.
  • Page 38 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.
  • Page 39 2014 XV Crosstrek Hybrid   (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. November 2013...
  • Page 40 2014 XV Crosstrek Hybrid   (Module 702) NoTeS: November 2013...

  • Page 41: Hybrid Lineartronic™ Continuously Variable Transmission Power Flow (Cvt Power Flow)

    2014 XV Crosstrek Hybrid   (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.
  • Page 42 2014 XV Crosstrek Hybrid   (Module 702) Engine Drive Mode MFD During Engine Drive Mode November 2013...
  • Page 43 2014 XV Crosstrek Hybrid   (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.
  • Page 44 2014 XV Crosstrek Hybrid   (Module 702) EV Mode MFD during EV Mode November 2013...
  • Page 45 2014 XV Crosstrek Hybrid   (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.
  • Page 46 2014 XV Crosstrek Hybrid   (Module 702) D Charge Mode, Output Clutch Off MFD during D Charge Mode November 2013...
  • Page 47 2014 XV Crosstrek Hybrid   (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.
  • Page 48 2014 XV Crosstrek Hybrid   (Module 702) Engine Drive and Electric Motor Assist Mode MFD during Engine Drive and Electric Motor Assist Mode November 2013...
  • Page 49 2014 XV Crosstrek Hybrid   (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.
  • Page 50 2014 XV Crosstrek Hybrid   (Module 702) Regenerative Braking MFD During Regenerative Braking November 2013...
  • Page 51 2014 XV Crosstrek Hybrid   (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).

  • Page 52: Cvt Oil Pump

    2014 XV Crosstrek Hybrid   (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.
  • Page 53 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...
  • Page 54 2014 XV Crosstrek Hybrid   (Module 702) Motor Motor Engine OFF Engine ON Motor EV Mode Motor Motor Electrical Motor Assist Mode Automatic Start Stop Engine OFF Motor Regenerative Braking November 2013...

  • Page 55: Electrical Wiring Configuration

    2014 XV Crosstrek Hybrid   (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.

  • Page 56: Batteries

    2014 XV Crosstrek Hybrid   (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.
  • Page 57 2014 XV Crosstrek Hybrid   (Module 702) Please review the Hybrid Battery area of the Fixed Operation Policies and procedures manual. The manual can be found at Subarunet.com / Fixed Operations / Policies and Procedures. The section covers the following areas related to the new hybrid battery PN 82009FJ000 and associated core PN 82009FJ000C1: https://www.subarunet.com ◊...
  • Page 58 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.
  • Page 59 2014 XV Crosstrek Hybrid   (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.
  • Page 60 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).
  • Page 61 (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.

  • Page 62: Battery Voltage

    2014 XV Crosstrek Hybrid   (Module 702) Hybrid Battery Pack Voltage A 4 Modules Voltage B 4 Modules Voltage C 4 Modules Voltage D Service plug Battery Energy Interlock switch Control Module (BE CU) Service Battery current resistance Voltage Z (reference GND) 2 Modules Voltage E 4 Modules...
  • Page 63 2014 XV Crosstrek Hybrid   (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.
  • Page 64 2014 XV Crosstrek Hybrid   (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.
  • Page 65 2014 XV Crosstrek Hybrid   (Module 702) Pre-charge Pre-charge resistor contactor Positive contactor Junction Module Negative 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.

  • Page 66: Contactor And High Voltage Battery Voltage

    2014 XV Crosstrek Hybrid   (Module 702) Contactor and High Voltage Battery Voltage High Voltage Battery and Contactor Voltages Opposing Reference Point Positive terminal from the High Voltage Battery 1. Always on 2. 100 volts if Service Plug is installed C or D 3.
  • Page 67 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.
  • Page 68 2014 XV Crosstrek Hybrid   (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.

  • Page 69: Driving And Charging Devices

    2014 XV Crosstrek Hybrid   (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.
  • Page 70 2014 XV Crosstrek Hybrid   (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.
  • Page 71 2014 XV Crosstrek Hybrid   (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.
  • Page 72 2014 XV Crosstrek Hybrid   (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.
  • Page 73 2014 XV Crosstrek Hybrid   (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.

  • Page 74: Isg Terminals And Inputs Signals

    2014 XV Crosstrek Hybrid   (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.
  • Page 75 2014 XV Crosstrek Hybrid   (Module 702) TO POWER SUPPLY CIRCUIT B135 B137 BAT-1 BATTERY TEMPERATURE SENSOR E163 B523 B609 B610 BATTERY SENSOR B598 CHG-02 CHG-02 HEV CM B605 B606 REF. TO GND : TERMINAL No. OPTIONAL [GND-02] ARRANGEMENT ISG Wiring Schematic November 2013...
  • Page 76 2014 XV Crosstrek Hybrid   (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.
  • Page 77 2014 XV Crosstrek Hybrid   (Module 702) 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.

  • Page 78: Interconnect Relay

    2014 XV Crosstrek Hybrid   (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.
  • Page 79 2014 XV Crosstrek Hybrid   (Module 702) BATTERY FOR ISG MAIN BATTERY SLOW BLOW SLOW BLOW FUSE FUSE 12V BATTERY RELAY B599 P-SUP-04 P-SUP-04 E163 : B AND W B606 : W AND BUS BAR HEV CM REF. TO GND [GND-03] Interconnect Relay Wiring Schematic The Interconnect (12 Volt Battery Relay) is a normally open relay.

  • Page 80: Electrical Operation

    2014 XV Crosstrek Hybrid   (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.
  • Page 81 2014 XV Crosstrek Hybrid   (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.

  • Page 82: During Automatic Start Stop Operation

    2014 XV Crosstrek Hybrid   (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.

  • Page 83: Hybrid Motor

    2014 XV Crosstrek Hybrid   (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...
  • Page 84 2014 XV Crosstrek Hybrid   (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.
  • Page 85 2014 XV Crosstrek Hybrid   (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.
  • Page 86 2014 XV Crosstrek Hybrid   (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.
  • Page 87 2014 XV Crosstrek Hybrid   (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.

  • Page 88: Hybrid Component And High Voltage Battery

    2014 XV Crosstrek Hybrid   (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.
  • Page 89 2014 XV Crosstrek Hybrid   (Module 702) 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.
  • Page 90 2014 XV Crosstrek Hybrid   (Module 702) NOTES: November 2013...

  • Page 91: High Voltage Battery Removal

    2014 XV Crosstrek Hybrid   (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.
  • Page 92 2014 XV Crosstrek Hybrid   (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 November 2013...
  • Page 93 2014 XV Crosstrek Hybrid   (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.
  • Page 94 2014 XV Crosstrek Hybrid   (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.
  • Page 95 2014 XV Crosstrek Hybrid   (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.
  • Page 96 2014 XV Crosstrek Hybrid   (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.
  • Page 97 2014 XV Crosstrek Hybrid   (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.
  • Page 98 2014 XV Crosstrek Hybrid   (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.
  • Page 99 2014 XV Crosstrek Hybrid   (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.
  • Page 100 2014 XV Crosstrek Hybrid   (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.
  • Page 101 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. November 2013...
  • Page 102 2014 XV Crosstrek Hybrid   (Module 702) Bus Bar DC/DC Connector DC/DC Converter Induction Amperage Sensor, Noise Suppressor and Motor Inverter November 2013...
  • Page 103 2014 XV Crosstrek Hybrid   (Module 702) Motor Inverter and Noise Suppressor Bottom view of Motor Inverter (IPU) Motor Inverter (IPU) Hybrid Component Tray (Magnesium) November 2013...
  • Page 104 2014 XV Crosstrek Hybrid   (Module 702) NOTES: November 2013...

  • Page 105: Crosstrek Hybrid Can Communications

    2014 XV Crosstrek Hybrid   (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. B137 B310 VDC CM HYBRID B605 POWERTRAIN CM HIGH VOLTAGE...

  • Page 106: Hev Can

    2014 XV Crosstrek Hybrid   (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.

  • Page 107: Pu Can

    2014 XV Crosstrek Hybrid   (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.
  • Page 108 2014 XV Crosstrek Hybrid   (Module 702) Accelerator pedal Accelerator pedal sensor Brake stroke sensor ISG CU Brake Pedal Battery sensor High-voltage battery Temperature/current/ BE CU 12 V battery (for restart) voltage sensor Battery current/voltage/ Contactor temperature sensor Drive motor 12 V battery Drive motor inverter interconnection relay...

  • Page 109: Hybrid Component Locations

    2014 XV Crosstrek Hybrid   (Module 702) Hybrid Component Locations (4) (5) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)(25) (26) HEV00308 12 volt engine restart battery (10) DC/DC converter (19) Electric oil pump Battery sensor (11)
  • Page 110 2014 XV Crosstrek Hybrid   (Module 702) 17 16 15 14 13 12 11 10 16 15 14 13 12 11 10 20 19 18 17 24 23 22 21 26 25 24 23 22 21 20 19 18 TO B: B606 TO A: B605...
  • Page 111 2014 XV Crosstrek Hybrid   (Module 702) Accelerator pedal Accelerator pedal sensor Brake stroke sensor ISG CU Brake Pedal Battery sensor High-voltage battery Temperature/current/ BE CU voltage sensor 12 V battery (for restart) Battery current/voltage/ Contactor temperature sensor Drive motor 12 V battery Drive motor inverter interconnection relay...
  • Page 112 2014 XV Crosstrek Hybrid   (Module 702) Terminal No. (terminal Item Measuring condition Measurement value Note symbol) (B605) No. 21 IG SW input Ignition switch ON 11 — 15 V — (B605) No. 22 Starter drive request sig- Model without push but- 8 —...
  • Page 113 2014 XV Crosstrek Hybrid   (Module 702) Accelerator pedal Accelerator pedal sensor Brake stroke sensor ISG CU Brake Pedal Battery sensor High-voltage battery Temperature/current/ BE CU voltage sensor 12 V battery (for restart) Battery current/voltage/ Contactor temperature sensor Drive motor 12 V battery Drive motor inverter interconnection relay...
  • Page 114 2014 XV Crosstrek Hybrid   (Module 702) Terminal No. (terminal Item Measuring condition Measurement value Note symbol) (B606) No. 20 Brake stroke sensor input When brake pedal is Approx. 4 V — depressed When brake is not Approx. 2.5 V —...
  • Page 115 2014 XV Crosstrek Hybrid   (Module 702) Accelerator pedal Accelerator pedal sensor Brake stroke sensor ISG CU Brake Pedal Battery sensor High-voltage battery Temperature/current/ BE CU voltage sensor 12 V battery (for restart) Battery current/voltage/ Contactor temperature sensor Drive motor 12 V battery Drive motor inverter interconnection relay...
  • Page 116 2014 XV Crosstrek Hybrid   (Module 702) 12 11 10 9 26 25 24 23 22 21 20 19 18 17 16 15 14 22 21 20 19 18 17 16 15 14 13 12 TO A: TO B: R443 R442 Terminal No.
  • Page 117 2014 XV Crosstrek Hybrid   (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.
  • Page 118 2014 XV Crosstrek Hybrid   (Module 702) Terminal No. (terminal Item Measuring condition Measurement value Note symbol) (R442) No. 1 — Cannot be measured — (R442) No. 2 — Cannot be measured — (R442) No. 3 TMP B When ignition switch is 0.23 V —...
  • Page 119 2014 XV Crosstrek Hybrid   (Module 702) Pin number Item Meaning or function No. 1 UN phase driving signal No. 2 UP phase driving signal No. 3 TMP B Motor temperature sensor B input No. 4 TMP A Motor temperature sensor A input No.
  • Page 120 2014 XV Crosstrek Hybrid   (Module 702) R445 HEV00082 Terminal No. (terminal Item Measuring condition Measurement value Note symbol) (R445) No. 1 Main power supply 1 Always 11 — 15 V — — line — line (R445) No. 4 Always —...
  • Page 121 2014 XV Crosstrek Hybrid   (Module 702) Accelerator pedal Accelerator pedal sensor Brake stroke sensor ISG CU Brake Pedal Battery sensor High-voltage battery Temperature/current/ BE CU voltage sensor 12 V battery (for restart) Battery current/voltage/ Contactor temperature sensor Drive motor 12 V battery Drive motor inverter interconnection relay...
  • Page 122 2014 XV Crosstrek Hybrid   (Module 702) NOTES: November 2013...

  • Page 123: Crosstrek Hybrid Diagnostics And Servicing

    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.
  • Page 124 2014 XV Crosstrek Hybrid   (Module 702) NOTES: November 2013...
  • Page 125   (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.
  • Page 126 2014 XV Crosstrek Hybrid   (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).
  • Page 127 2) Leave the vehicle 1 minute unattended. tance (+)» or «High Voltage <Ref. to HEV-17, 3) Using the Subaru Select Monitor, confirm Battery Pack Leakage Resis- High Voltage Bat- the current data of battery energy control sys- tance (–)» 290 kΩ or less? tery.>...
  • Page 128 2014 XV Crosstrek Hybrid   (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.
  • Page 129 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.
  • Page 130 2014 XV Crosstrek Hybrid   (Module 702) CHECK POWER CABLE AND BUS BAR. Go to step 14. Go to step 5. Is the resistance 2 MΩ or 1) Disconnect the power cable (HV10) from more? electric oil pump. 2) Using a megohmmeter (250 V range), mea- sure the resistance between high voltage bat- tery side terminal and chassis ground.
  • Page 131 2014 XV Crosstrek Hybrid   (Module 702) CHECK BUS BAR. Is the resistance 2 MΩ or Even if DTC is Go to step 6. 1) Check the bus bar between the high voltage more? detected, the cir- battery (HV8) and the noise filter (HV7) and the cuit has returned to surrounding area for metallic foreign bodies, a normal condition...
  • Page 132 2014 XV Crosstrek Hybrid   (Module 702) TO POWER SUPPLY CIRCUIT MB-3 DRIVE MOTOR INVERTER HV10 ELECTRIC HIGH VOLTAGE NOISE FILTER BATTERY ELECTRIC HV12 OIL PUMP INVERTER 3 2 1 HV11 DRIVE MOTOR INVERTER AMPERAGE HV12 SENSOR ELECTRIC FLUID PUMP DC/DC CONVERTER DRIVE MOTOR ASSY HEV00327...
  • Page 133 2014 XV Crosstrek Hybrid   (Module 702) Step Check CHECK POWER CABLE AND BUS BAR. Go to step 11. Is the resistance 2 MΩ or Even if DTC is 1) Remove the drive motor inverter current more? detected, the cir- sensor (HV2) from the drive motor inverter.

  • Page 134: Maintenance Mode

    2014 XV Crosstrek Hybrid   (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).
  • Page 135 2014 XV Crosstrek Hybrid   (Module 702) Hybrid Failsafe Detected failure Warning Note Light Level 6 CAN Channel 1 Bus Error U0073 CAN Channel 1 ECU ID not received U0100 Independent control by ECM & CAN Channel 1 TCU ID not received U0101 CAN Channel 1 ECU Erratic data U0401...
  • Page 136 2014 XV Crosstrek Hybrid   (Module 702) Hybrid Failsafe Detected failure Note Warning Light Level 2 CAN Channel 1 VDC ID not received U0122 CAN Channel 1 VDC Erratic data U0416 Inhibit EV mode, Auto LIN Check sum Error (Battery sensor) U1711 Start Stop Vacuum Pump Functional Error...
  • Page 137 2014 XV Crosstrek Hybrid   (Module 702) Fail safe Failure Service Plug High Voltage Fuse P0A95 High Voltage Service Disconnect Open P0B37 Junction Module Hybrid Battery Negative Contactor Circuit Stuck Closed P0AA4 Hybrid Battery Positive Contactor or Pre-charge Contactor Circuit Stuck Closed P1C40 Hybrid Battery Voltage System Isolation Sensor Circuit P0AA7...
  • Page 138 2014 XV Crosstrek Hybrid   (Module 702) Fail safe Battery Voltage Hybrid Battery Voltage Low P0B25 Hybrid Battery Voltage High P0B26 Hybrid Battery Voltage Sense “Z" Circuit P0BB8 Hybrid Battery Voltage Sense "A" Circuit Range/Performance P0B3C Hybrid Battery Voltage Sense "A" Circuit Low P0B3D Hybrid Battery Voltage Sense "A"...

  • Page 139: Removing/Installing The V-Belt Tensioner Assy

    2014 XV Crosstrek Hybrid   (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.
  • Page 140 2014 XV Crosstrek Hybrid   (Module 702) ISG Mounting Plate Bolts Take the V-belt off the idler pulley. 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.

  • Page 141: Removing A Damaged V-Belt

    2014 XV Crosstrek Hybrid   (Module 702) Removing a Damaged V-belt 1. Remove the V-belt tensioner Assy. 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.
  • Page 142 2014 XV Crosstrek Hybrid   (Module 702) Pull out the special tool that was inserted into stopper pin hole A. Remove ST from A Remove the V-belt tensioner Assy. ISG Mounting Plate Bolts November 2013...

  • Page 143: Installing The V-Belt Tensioner Assy & V-Belt

    2014 XV Crosstrek Hybrid   (Module 702) Installing the V-belt Tensioner Assy & V-belt 1. Set the V-belt as shown in the figure below. A) V-belt B) Water pump pulley C) Crank pulley D) ISG pulley E) Idler pulley F) A/C compressor pulley Belt Configuration 2.
  • Page 144 2014 XV Crosstrek Hybrid   (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.

  • Page 145: Jump Starting The Vehicle

    2014 XV Crosstrek Hybrid   (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.
  • Page 146 2014 XV Crosstrek Hybrid   (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. November 2013...
  • Page 147 2014 XV Crosstrek Hybrid   (Module 702) NOTES: November 2013...
  • Page 148 MSA5P1702C...

Table of Contents