ATTENTION:

CLAIMS PERSONNEL q

IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.

SERVICE MANAGER

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PARTS MANAGER

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SERVICE BULLETIN
APPLICABILITY: XV Crosstrek Hybrid (HEV)

NUMBER: 16-108-17

SUBJECT: New Service Procedure for Repair of
DTC P172A and P0B0B

DATE: 6/28/2017

INTRODUCTION:
In conjunction with current TSB 16-94-15R, this bulletin provides a new service procedure for
repairing the drive motor case assembly. Previously, failure of the non-serviceable o-rings on the
electric oil pump relief valve located inside the case required replacement of the complete motor
case assembly. Although these o-rings are still not serviceable, a new relief valve assembly, p.n.
31869AA001 (with new o-rings already installed) is now available separately.

PART INFORMATION:
The following parts will be required to perform the relief valve replacement:
Part No.
31869AA001
31325AA190
806921110
31377AA600
806912200
806917100
806921120
806929070
31759AA040
31377AA590
31377AA490

Part Name
VALVE CP-RELIEF
BOLT ASSY-SEAL
O RING-21.2X2.4
RING-SEAL
O RING-12.3X2.4
O RING-17.4X3
O RING-21.8X2.4
O RING-29.7X2.4
CLIP
RING-SEAL
RING-SEAL

Qty. Req’d.
1
2
1
2
5
1
1
1
1
2
1

NOTE: This parts
list is supplied for
reference only. Make
sure to always order
the most up-to-date
part numbers.

Continued...
CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD
RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS.
Subaru Service Bulletins are intended for use by professional technicians ONLY. They
are written to inform those technicians of conditions that may occur in some vehicles,
or to provide information that could assist in the proper servicing of the vehicle. Properly
trained technicians have the equipment, tools, safety instructions, and know-how to
do the job correctly and safely. If a condition is described, DO NOT assume that this
Service Bulletin applies to your vehicle, or that your vehicle will have that condition.

Bulletin Number: 16-108-17; Date 06/28/17

SUBARU OF AMERICA, INC. IS
ISO 14001 COMPLIANT
ISO 14001 is the international standard for
excellence in Environmental Management
Systems. Please recycle or dispose of
automotive products in a manner that is friendly
to our environment and in accordance with all
local, state and federal laws and regulations.

Page 1 of 6

Part No.
Part Name
31377AA470 RING-SEAL
806911080 O RING-11.5X2.1
99079AA100 HOSE-ATF
99079AA110 HOSE-ATF
806913250 O RING-13.8X2.4
806735300 OILSEAL-35X50X9
806735290 OILSEAL-35X50X9
33295AA000 GSKT-CVR PWR CONN
31759AA060 CLIP-TRANS HARNESS
44022AA123 GASKET EXHAUST PIPE-REAR
44022AA020 GASKET EXHAUST PIPE-FRONT
28333AG010 CIRCLIP-CVJ
806916050 O-RING
THREE BOND 1215B
DIFFERENTIAL GEAR OIL
CVTF

Qty. Req’d.
1
1
1
1
1
1
1
1
1
1
2
2
1
As needed
As needed
As needed

ADDITIONAL TOOLS REQUIRED:
•

Digital Voltage / Ohm Meter (DVOM) with test leads (1000v, CAT III)

•

¼” drive T-25 or T-30 TORX® bit for battery cover screws

•

Electrical tape to insulate power cable terminal ends (3- 2” long pieces of tape)

•

Personal Protective Equipment (Hybrid Safety Kit J-51311, check Expiration Date on Gloves)

DIAGNOSIS PROCEDURE / INFORMATION:
VERY IMPORTANT SAFETY WARNING: The HEV system includes a high-voltage circuit.
Mishandling of HEV-related components may cause electric shock and serious personal injury.
Technicians who have not received Subaru Hybrid training should NOT perform testing or
repairs related to the HEV system. **See Subaru Technician Reference Booklet, Module 702
(MSA5P1702C) for more HEV information.
NOTE: Before starting the diagnosis procedure, use the SSMIII to confirm the CVT fluid
temperature is below 104 degrees F (40 C).
IMPORTANT: The next steps require that Personal Protective Equipment be worn.
•

Remove the rear cargo area floor mat and the sub-trunk (storage tray).

•

Remove the orange HEV Service Disconnect plug and put it in your pocket.

Bulletin Number: 16-108-17; Date 06/28/17

Continued...
Page 2 of 6

WARNING: After pulling out the service disconnect plug, high voltage is accumulated in the
condenser inside the inverter. If touching any of the high voltage parts, wiring harness,
terminals and connectors is required, wait for 10 minutes before starting the operation.
•

Remove the TORX screws and necessary trim clips securing the aluminum battery cover.

•

ONE AT A TIME, remove the 3 bolts securing the orange “W”, “V”, and “U” cables to the
electric oil pump inverter. As each cable is removed, cover each terminal end with one of the
strips of electrical tape to insulate it. Connect the RED (+) test lead from the DVOM to the
“U” cable end and BLACK (-) lead to the “V” cable end as shown. Confirm the “W” cable
end is wrapped with insulating tape.

•

Reinstall the orange HEV Service Disconnect plug.

•

Turn on the DVOM and set it to measure AC Voltage.

•

Start the engine and with the transmission in PARK, hold the engine at 1800 RPM.

•

Read the AC voltage on the DVOM display and record your result.

NOTE: The AT TEMP lamp will stay on because the power cables to the inverter are removed.
•

IF THE DVOM SHOWS 0.5V OR MORE: The relief valve o-rings are damaged.
Replace the relief valve following the new procedure supplied below.

•

IF THE DVOM SHOWS LESS THAN 0.5V: the root cause of the DTC is elsewhere.
Continue diagnosing the DTC using the applicable Service Manual procedure.

VERY IMPORTANT: The next steps also require that Personal Protective Equipment be worn.
REMINDER: ALWAYS disconnect the (orange) Hybrid service plug and put in your pocket
BEFORE reconnecting the electric oil pump inverter power cables.
•

Re-connect the inverter power cables ONE AT A TIME and torque the 10mm bolts to
5.5 ft. lbs.

•

Replace the battery cover and torque the TORX screws to 5.5 ft. lbs.

Bulletin Number: 16-108-17; Date 06/28/17

Continued...
Page 3 of 6

SERVICE PROCEDURE / INFORMATION:
•

Remove the CVT assembly following the procedure in the applicable Service Manual.

•

Remove the drive motor / case assembly from the CVT and place it on the workbench as
shown below. Remove the plug circled in the photo below to gain access to the relief valve.

•

•

Use a pair of needle-nosed pliers to CAREFULLY remove the relief valve from the case.

Inspect the o-rings on the relief valve for any damage.

Damaged O-ring

Bulletin Number: 16-108-17; Date 06/28/17

Cut-Out Portion

Continued...
Page 4 of 6

•

Remove Plug #1 and Plug #2 as shown in the photos below and allow any remaining CVTF
to drain.

Plug #1 (plug
already removed)
Relief Valve Bore
Plug #2

•

REMINDER: Always wear eye protection for this step: Thoroughly clean the bores with
spray parts cleaner then blow dry with compressed air. Always direct the spray away from
other people and vehicles. Re-inspect closely for any remaining contamination.

•

Install new o-rings on both plugs, lubricate with CVTF and re-install. Torque these 2 plugs
to 50 Nm (37 ft. lbs.).

•

Lubricate the o-rings with CVTF then CAREFULLY install the new relief valve assembly
(cut-out portion in first) until it is fully seated in its bore. Use caution to avoid damaging the
new o-rings on the plug threads. The valve can be installed in any rotational position.

•

Install a new o-ring on the relief valve plug, lubricate with CVTF and re-install. Torque this
plug to 44 Nm (32 ft. lbs.).

•

IMPORTANT: Thoroughly clean all residual sealer from the case and component mating
surfaces before reassembling the CVT in reverse order of disassembly.

•

Reinstall the orange HEV Service Disconnect plug, sub-trunk and rear cargo area floor mat.

•

After reassembly and installation, road test to confirm proper CVT operation in all modes.

•

Using the SSM, clear the AT Learning value then perform the AT Learning and Rear
Differential Inspection modes.

•

Always be sure to clear any history codes from the related modules to complete the
procedure.

Bulletin Number: 16-108-17; Date 06/28/17

Continued...
Page 5 of 6

WARRANTY / CLAIM INFORMATION:
For vehicles within the Basic New Car Limited or Powertrain Limited Warranty period or covered by
an active Subaru Added Security Powertrain, Classic or Gold plan, this repair may be submitted using
the following claim information:
Labor Description

Labor Operation #

HEV DRIVE MOTOR ASSEMBLY R&R
ELECTRIC OIL PUMP RELIEF VALVE, REPLACE
HEV SYSTEM TESTING & DIAGNOSIS

B302-001
C302-013
C800-201

Labor
Time
4.8
0.7
0.5

Fail
Code
MTU-16

IMPORTANT REMINDERS:
•

SOA strongly discourages the printing and/or local storage of service information as previously
released information and electronic publications may be updated at any time.

•

Always check for any open recalls or campaigns anytime a vehicle is in for servicing.

•

Always refer to STIS for the latest service information before performing any repairs.

Bulletin Number: 16-108-17; Date 06/28/17

Page 6 of 6