NHTSA ID Number: 10235302
Manufacturer Communication Number: WRD-23
TSB/Document Date: 2023-05-02
Summary
Subaru
of America, Inc. (Subaru) is initiating a new safety recall for certain 2019-2022 model year Crosstrek Hybrid vehicles.
Page 23 of 44
STEP 4: Remove and discard the terminal cap or
protective rubber boot.
STEP 5: Remove the hose clamps from the
connections indicated with yellow arrows in the
right image. Remove the two water pipe mounting
bolts. Install provided rubber caps onto the
aluminum pipes to prevent any coolant drippage
while working. The water pipe can then be lowered
to allow access to the inverter/converter assembly.
NOTE: The following images show the water pipes removed from the inverter/converter assembly in
order to provide more detail for instructional purposes.
STEP 6: Remove the five inverter protector
mounting bolts. The inverter protector can then
be removed.
STEP 7: Place the inverter/converter assembly on
two wooden blocks.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 24 of 44
STEP 8: Remove the two mounting bolts for the
inverter stay. The stay can then be removed.
STEP 9: Remove the mounting bolts and stays
holding the rear inverter bracket. The rear bracket
assembly can then be removed.
IMPORTANT NOTE: The mounting bolts are
one-time use parts and can be discarded. The stays
are NOT to be discarded and MUST be re-used.
IMPORTANT: Insulated tools and gloves MUST be used for STEPS 10, 11, & 14.
STEP 10: Remove the three mounting bolts for the
main battery connector. The connector can then be
removed.
STEP 11: Remove the two mounting bolts for the
HV air conditioning cable. The HV air conditioning
cable can then be removed and discarded.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 25 of 44
STEP 12: Remove the two mounting bolts for the
front inverter/converter bracket assembly. The
bracket assembly and insulator can then be removed.
STEP 13: Remove the two mounting bolts for the
terminal block cover. The terminal block cover can
then be removed.
CAUTION: DO NOT TOUCH the center screw
of the terminal block cover.
STEP 14: Remove the ten mounting bolts for the
motor cable terminal block. The motor cable terminal
block can then be removed.
STEP 15: Cover the opening of each electrical connection with masking tape. This will reduce the
risk of foreign matter intrusion.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 26 of 44
STEP 16: Rotate the inverter/converter assembly so the 12v terminal is facing upward.
STEP 17: Place the inverter/converter assembly on two wooden blocks. Align the bolt head of the
cover with the wooden blocks. DO NOT place the block directly on the cover.
CAUTION: CAREFULLY place the inverter/converter assembly on the wooden blocks as
shown in the images provided below in order to prevent any damage to the connector and cover.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 27 of 44
STEP 18: Remove the eight mounting bolts
front the converter lid. Prepare a small
flathead screwdriver with tape wrapped
around the blade. CAREFULLY remove the
inverter/converter lid as shown in the images
below.
EXAMPLE
IMPORTANT CAUTIONS:
•
DO NOT damage the sealing surface of the inverter/converter assembly.
•
DO NOT lift the screwdriver handle in the upward direction. ONLY push the handle of
the screwdriver in the downward direction when inserted between the lid and case.
•
ONLY insert the blade portion of the screwdriver between the lid and case. Deep
insertion of the screwdriver can cause damage to the case and internal components.
•
Work with bare hands or insulated gloves in order to prevent any static electricity and
foreign mater intrusion into the internal electrical components.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 28 of 44
STEP 19: CAREFULLY retrieve any sealant that may have dropped into the case. DO NOT touch
any of the internal components. Remove the three mounting bolts for the 12v terminal.
Once the mounting bolts are removed, pull the
terminal away from the case to remove.
CAUTION: Confirm the original seal is
removed with the terminal and
is not left inside the case.
STEP 20: CONFIRM the seal is free of debris then install the NEW 12v terminal supplied in the
terminal output kit (p.n. SOA635176) by aligning the location pins on the terminal. Torque the
INNER mounting bolt to 5Nm (3.7ft-lbs). Torque the OUTER mounting bolts to 6Nm (4.4ft-lbs).
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 29 of 44
CAUTION: CONFIRM the bus bar portion of the 12v terminal is not positioned on top of the
bus bar located inside the case.
STEP 21: Detach the scraper from
the prevention cover (From Kit #
SOA635176). Discard the scraper since it is
not to be used for this procedure.
STEP 22: CONFIRM no sealant has
dropped into the case.
STEP 23: Rotate the inverter/converter
assembly with the terminal block
connection facing upward. This position
will help prevent removed sealant from
entering the internal case.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 30 of 44
STEP 24: Install the sealant drop prevention
cover and secure it with masking tape.
STEP 25: Using a suitable plastic scraper or plastic
razor blade, removed any sealant adhered to the
case sealing surface. ONLY the protruding sealant
is required to be removed. Thin amounts of sealant
without protrusions do not have any affect on the
sealing performance.
STEP 26: Remove residual sealant fragments with
the adhesive side of masking tape.
STEP 27: Clean the surface area with a clean cloth.
CAUTION: DO NOT use a blow gun or
brake/parts cleaner. This can cause damage
to the inverter/converter internals and cause
insufficient sealant curing.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 31 of 44
STEP 28: Once the sealant has been sufficiently removed and the sealing surface is clean and free of
debris, rotate the inverter/converter with sealing surface facing upward.
CAUTION: CONFIRM the inverter/converter is positioned with the mounting bolts on the
wooden blocks. DO NOT cause any damage to the connector or cover.
STEP 29: Remove any masking tape securing the prevention cover to the case.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 32 of 44
STEP 30: Apply a 3mm (0.12in) diameter bead of Three Bond 1207F as detailed in the images
below.
STEP 31: Remove the sealant drop prevention cover.
NOTE: The sealant drop prevention cover is NOT a one-time use tool and is designed for repeated
usage. It is important to keep the cover clean and sealant free for future usage.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 33 of 44
STEP 32: Install the inverter lid. Install
the eight mounting bolts by hand. Torque
the bolts to 7.3Nm (5.4ft-lbs) in the order
specified in the right image.
STEP 33: Perform the torques sequence a
second time.
CAUTIONS:
•
The inverter lid MUST be installed within three minutes after the Three Bond
application.
•
The torques procedures MUST be performed within three minutes after the Three Bond
application.
•
Three Bond 1207F requires 24 hours to become fully cured. The vehicle MUST not be
exposed to heavy moisture such as car wash, rain, and snow until this 24-hour cure time
is complete.
STEP 34: Rotate the inverter/converter assembly on the wooden blocks as shown in the image below.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 34 of 44
STEP 35: Remove the masking tape from the electrical connections. Prepare the following specialty
tools.
STEP 36: Mark the bolt heads of the
Flange Bolts (p.n.010406200) and
(p.n.010406120) for identification and
to prevent possible mixing with any
original equipment hardware.
STEP 37: Install the Repair Tool
(p.n.99804AN030) using the four Flange
Bolts (p.n.010406200) in place of the motor
cable terminal block connection. Tighten
the bolts in an X-Pattern and torque to 5Nm
(5Nm (3.7ft-lbs).
CAUTION: DO NOT use the originally
supplied bolts used for the motor cable
terminal block. CAREFULLY tighten the
bolts evenly. Uneven tightening may cause
incorrect leak detection results.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 35 of 44
STEP 38: Install Connector Holder 1
(p.n.81911FL010) and Connector Holder 2
(p.n.81911FL050) in place of the main battery
cable connection and the HV air conditioning
cable connection. Secure the Holders using the
four Flange Bolts (p.n.010406120). Torque the
Flange Bolts to 5Nm (5Nm (3.7ft-lbs).
STEP 39: Install Connector Holder 3
(p.n.81911FL030) and Connector Holder 4
(p.n.81911FL030) in place of the upper HV
air conditioning connection.
CAUTION: CONFIRM the connection is
secure by pressing down on the lock lever
to ensure it is fully locked. An unsecure
connection may cause incorrect leak detection
results.
STEP 40: Insert the provided silicon hose nozzle
of the portable leak detector.
NOTE: The inner diameter of the hose is 7mm
(0.28 inches).
STEP 41: Connect the opposite end of the
silicon hose to the nozzle located on Repair Tool
(p.n.99804AN030).
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 36 of 44
STEP 42: Connect a 12v external power
supply to the portable leak detector.
STEP 43: Confirm the Power LED in ON.
STEP 44: Press the “Air Only Test”
button to begin the leakage test.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 37 of 44
STEP 45: During the leakage test, confirm the float stays at the bottom.
CAUTION: If leakage is detected, check connection conditions, the testing equipment for
damage and/or deformation of the inverter/converter lid then re-test. If no visible fault is found
and leakage is still found, removed the inverter/converter lid, clean and reseal the lid then
retest.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 38 of 44
STEP 46: Apply masking tape to the mounting surfaces of the front and rear brackets. Cover the 12v
terminal with masking tape. Apply the rustproof wax (3M Cavity Wax Plus) to the contact area of the
inverter lid and case. Spray the area by moving the nozzle at a rate of about 50mm (2 inches) per 1
second. Perform two full rotations of application.
CAUTIONS:
•
The rustproof wax does not completely cure. Avoid touching the wax during work
procedures.
•
Thoroughly shake the can prior to use. Attach the nozzle to allow optimum distribution.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 39 of 44
STEP 47: Confirm there is a sufficient
application of the rustproof wax. Remove all
leakage testing tools and masking tape.
CAUTION: Clean any wax that has made
contact with resin portion of the 12v terminal
and/or the mounting surfaces of the front &
rear brackets.
IMPORTANT: Insulated tools MUST be
used for STEP 48, 51, and 52.
STEP 48: Install the motor cable terminal block.
Torque the four outer bolts in an X-pattern to
7.5Nm (5.5ft-lbs). Torque the inner six bolts to
7.5Nm (5.5ft-lbs).
STEP 49: Install the terminal block cover.
Torque the mounting bolts to 7.5Nm (5.5ft-lbs).
STEP 50: Install the front inverter/converter
bracket and insulator. Torque the two mounting
bolts to 18Nm (13.3ft-lbs).
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 40 of 44
STEP 51: Connect the NEW HV air conditioning
cable. Tighten the two mounting bolts to 7.5Nm
(5.5ft-lbs).
STEP 52: Connect the main battery cable.
Torque the three mounting bolts to 7.5Nm
(5.5ft-lbs).
STEP 53: Install the NEW inverter rear bracket
using NEW mounting bolts. Torque the mounting
bolts to 18Nm (13.3ft-lbs).
CAUTION: DO NOT drop or hit the new
mounting bracket. This can cause the painted
surface to be damaged compromising its
corosion protective strength.
STEP 54: Install the inverter stay using the two
original mounting bolts. Torque the mounting
bolts to 18Nm (13.3ft-lbs).
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 41 of 44
STEP 55: Reinstall the inverter protector with the
original mounting bolts in the following order.
8. Bolt (a)
9. Bolt (b)
10. Bolts (c)
Torque the mounting bolts in the same order to
18Nm (13.3ft-lbs).
STEP 56: Removed the rubber caps from the
water pipe. Reinstall the coolant hoses and
clamps. Reattach the water pipe to the inverter/
converter assembly using the original mounting
bolts. Torque the bolts to 7.5Nm (5.5ft-lbs).
STEP 57: Route the HV air conditioning cable
through the NEW rubber protective boot.
STEP 58: Secure the HV air condition cable to
the inverter/converter using the original bolts and
the new retaining clip. Torque the bolts to 7.5Nm
(5.5ft-lbs).
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 42 of 44
STEP 59: Connect the HV air conditioning cable
to the 12v terminal. Torque the NEW nut to
7.5Nm (5.5ft-lbs).
STEP 60: Attach the new rubber cap to the 12v
terminal.
CAUTION: Confirm the 12v terminal is
completely covered by the rubber cap. The
terminal MUST not be exposed.
STEP 61: Install the inverter/converter with the
three original retaining clips, three original rivet
spacers, and three NEW rivets.
STEP 62: Reinstall all parts in the reverse order
of disassembly.
CAUTION: Three Bond 1207F requires 24
hours to become fully cured. The vehicle
MUST not be exposed to heavy moisture such
as car wash, rain, and snow until this 24-hour
cure time complete.
Continued...
Bulletin Number: WRD-23; Date: 04/24/23
Page 43 of 44
SERVICE PROGRAM IDENTIFICATION LABEL:
Type or print the necessary information on a Campaign Identification Label. The completed label
should be attached to the vehicle’s upper radiator support. Additional labels are available through
normal parts ordering channels. The part number is MSA6P1302, which comes as one sheet of 20
labels.
Claim Reimbursement and Entry Procedures:
Credit to perform this recall will be based on properly completed repair order information. Retailers
may submit claims through Subarunet.com.
Labor Description
Labor Operation #
Labor Time
INVERTER CABLE TERMINAL INSPECTION AND
BRACKET R&R, RUBBER CAP
A104-399
3.3
INVERTER CABLE TERMINAL AND BRACKET R&R,
RUBBER CAP
A104-699
Fail Code
WRD-23
4.3
NOTE: Up to $5.00 can be claimed in sublet for materials used during this procedure.
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: WRD-23; Date: 04/24/23
Page 44 of 44
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TSB/Document ID: WRD-23
Replacement Service Bulletin Number:
MFR Communication Date: 2023-04-24
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Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
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