NHTSA ID Number: 10237306
Manufacturer Communication Number: 07-220-23
TSB/Document Date: 2023-06-05
Summary
This service information bulletin announces the diagnostic procedures to be used when DTCs P0AA649 (Hybrid
/EV Battery Voltage System Isolation Internal Electronic Failure) & P1C7E49 (Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure) are detected by the Powertrain Control Unit (PCU).
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TSB/Document ID: 07-220-23
Replacement Service Bulletin Number:
MFR Communication Date: 2023-05-16
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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ATTENTION:
GENERAL MANAGER
q
PARTS MANAGER
q
CLAIMS PERSONNEL
q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE MANAGER
q
© 2023 Subaru of America, Inc. All rights reserved.
SERVICE BULLETIN
APPLICABILITY:
2019-23MY Crosstrek PHEV
SUBJECT:
Diagnostic Procedures / DTCs P0AA649
& P1C7E49
NUMBER: 07-220-23
DATE: 05/16/23
INTRODUCTION:
This service information bulletin announces the diagnostic procedures to be used when DTCs
P0AA649 (Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure) & P1C7E49
(Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure) are
detected by the Powertrain Control Unit (PCU). Follow the procedures outlined in this bulletin if the
described DTCs are encountered.
DIAGNOSTIC PROCEDURE / INFORMATION:
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.
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.
Continued...
Bulletin Number: 07-220-23; Date: 05/16/23
Page 1 of 6
STEP 1: Check Inverter with converter assembly
1. Confirm the service plug is disconnected.
2. Visually inspect the wiring for any physical damage.
3. Disconnect the inverter/converter assembly from Power Cable. (*1)
Procedure
4. Using a megohmmeter (500 V range), measure the resistance between connector (HV99) terminal and chassis ground.
(*1) Replace the inverter/converter, inverter/converter motor cable, and Power
Cable ONLY if water intrusion or rust caused by water intrusion are found on the
inverter/converter assembly side.
■For Motor
(HV99) U2-chassis ground
(HV99) V2-chassis ground
(HV99) W2-chassis ground
Check
List
Are the resistances 1.8 MΩ or more?
■For Generator
(HV99) U1-chassis ground
(HV99) V1-chassis ground
(HV99) W1-chassis ground
Are the resistances 1.8 MΩ or more?
YES
Go to STEP 3.
NO
Go to STEP 2.
Continued...
Bulletin Number: 07-220-23; Date: 05/16/23
Page 2 of 6
STEP 2: Check the motor cable of Inverter with converter
1. Confirm the service plug is disconnected.
2. Visually inspect the wiring for any physical damage.
3. Remove the inverter/converter assembly from the vehicle. Refer to STIS: Body &
Electrical/WIRING SYSTEM >HYBRID ELECTRIC VEHICLE > Inverter and
Converter Assembly> Removal
4. Remove the Inverter/converter assembly motor cable cover. (*2)
5. Remove the motor cable from Inverter with converter. (*2)
6. Using a megohmmeter (500 V range), measure the resistance between connector
(HV99) terminal of motor cable of inverter/converter and motor cable case (metal
part).
Procedure
(*2) Replace the inverter/converter, and inverter/converter motor cable ONLY if water
intrusion is found inside the cover or motor cable.
■For Motor
(HV99) U2-motor cable case (metal part)
(HV99) V2-motor cable case (metal part)
(HV99) W2-motor cable case (metal part)
Check
List
Are the resistances 100 MΩ or more?
■For Generator
(HV99) U1-motor cable case (metal part)
(HV99) V1-motor cable case (metal part)
(HV99) W1-motor cable case (metal part)
Are the resistances 100 MΩ or more?
YES
Replace inverter with converter
NO
Replace inverter with converter motor cable.
Continued...
Bulletin Number: 07-220-23; Date: 05/16/23
Page 3 of 6
STEP 3: Check the Power Cable (for Motor) with transmission connected
1. Confirm the service plug is disconnected.
CAUTION: Never turn to READY ON with Service plug removed to prevent faults.
2. Visually inspect the wiring for any physical damage.
3. Turn to READY OFF (Turn the ignition on).
Procedure
NOTE: Since other DTCs are memorized when turning the ignition on with the service plug removed, clear the memory of DTCs after inspection.
4. Check that ATF oil temperature is less than 50 Celsius (122 Fahrenheit) by using
Subaru Select Monitor: Subaru Select Monitor > [P-HEV hybrid powertrain control]
> Data Monitor.
5. Using a megohmmeter (500 V range), measure the resistance between connector
(HV99) terminal of Power Cable (For Motor) (on inverter/converter assembly side)
and chassis ground and shield line ground.
(HV99) U2-chassis ground and shield line ground
(HV99) V2-chassis ground and shield line ground
(HV99) W2-chassis ground and shield line ground
Are the resistances 44 MΩ or more? (CONFIRM the ATF oil temperature less than
50 Celsius (122 Fahrenheit)).
Reference EXAMPLE for chassis ground:
Check
List
Reference EXAMPLE for shield line ground:
YES
Go to STEP 4.
NO
Go to STEP 5.
Continued...
Bulletin Number: 07-220-23; Date: 05/16/23
Page 4 of 6
STEP 4: Check the Power Cable (for Generator) with transmission connected
Procedure
1.
Confirm the service plug is disconnected.
2.
Visually inspect the wiring for any physical damage.
3.
Using a megohmmeter (500 V range), measure the resistance between connector
(HV99) terminal of Power Cable (for Generator) (on inverter/converter assembly
side) and chassis ground and shield line ground.
(HV99) U1- chassis ground and shield line ground
(HV99) V1- chassis ground and shield line ground
(HV99) W1- chassis ground and shield line ground
Check
List
Are the resistances 100 MΩ or more?
YES
Normal operation at this time.
NO
Go to STEP 5.
STEP 5: Check the Power Cable (for Motor) without Transmission connected
1. Confirm the service plug is disconnected.
2. Visually inspect the wiring for any physical damage.
Procedure
3. Disconnect the Power Cable from Transmission Assy.
4. Using a megohmmeter (500 V range), measure the resistance between connector
(HV99) terminal of Power Cable (for Motor) (on inverter/converter assembly side)
and chassis ground and shield line ground.
Check
List
(HV99) U2- chassis ground and shield line ground
(HV99) V2- chassis ground and shield line ground
(HV99) W2- chassis ground and shield line ground
Are the resistances 100 MΩ or more?
YES
Go to STEP 6.
NO
Replace the Power Cable.
Continued...
Bulletin Number: 07-220-23; Date: 05/16/23
Page 5 of 6
STEP 6: Check the Power Cable (for Generator)
1. Confirm the service plug is disconnected.
Procedure
Check
List
2. Visually inspect the wiring for any physical damage.
3. Using a megohmmeter (500 V range), measure the resistance between connector
(HV99) terminal of Power Cable (for Generator) (on inverter/converter assembly
side) and chassis ground and shield line ground.
(HV99) U1- chassis ground and shield line ground
(HV99) V1- chassis ground and shield line ground
(HV99) W1- chassis ground and shield line ground
Are the resistances 100 MΩ or more?
YES
Replace the Transmission Assembly.
NO
Replace the Power Cable.
SERVICE PROCEDURE INFORMATION:
There have been no changes made to the work procedures. Always refer to the applicable Service
Manual and review the full requirements of the repair being performed. The Service Manual
procedures contain information critical to performing an effective repair the first time, every time.
This includes but is not limited to important SAFETY precautions, proper inspection criteria,
necessary special tools, required processes and related one-time-use parts needed for a complete and
lasting repair.
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: 07-220-23; Date: 05/16/23
Page 6 of 6
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