LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2019 >> Mirai >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling System - Service Information >> Radiator >> Removal [11/2018 - ] >> Procedure

Removal [11/2018 - ]: Procedure

  1. PRECAUTION 
    NOTE:
    • The coolant (Toyota genuine FC stack coolant (Pre-mixed)) is an exclusive coolant.
    • The coolant (Toyota genuine FC stack coolant (Pre-mixed)) cannot be reused, so when filling, be sure to fill with new coolant (Toyota genuine FC stack coolant (Pre-mixed)).
    • To prevent degradation of coolant (Toyota genuine FC stack coolant (Pre-mixed)) performance, do not add or fill any other substances such as tap water or battery electrolyte refill liquid.
    • Do not use cotton work gloves or other gloves that could shed fibers.
    • DO NOT use any container that has previously been used to fill substances such as oil.
    • To prevent foreign matter from contaminating the coolant (Toyota genuine FC stack coolant (Pre-mixed)) passages, wash out the prepared container with tap water, then wipe away any water remaining inside the container before using it.
    • If the coolant (Toyota genuine FC stack coolant (Pre-mixed)) passages are filled incorrectly, follow the countermeasures according to "Countermeasures when coolant (Toyota genuine FC stack coolant (Pre-mixed)) passages are filled incorrectly".

      Refer to PRECAUTION [06/2015 - ] 

    • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

      Refer to PRECAUTION [06/2015 - ]

    • When the vehicle is parked with the power switch off, if the FC control ECU judges that the FC stack temperature will go below 0°C (32°F), it activates the FC air compressor, hydrogen pump and FC cooling water pump for a maximum of 180 seconds and drains water from the FC stack assembly. When performing inspection or repairs with the power switch off (not on (IG) or on (READY)), disconnect the cable from the negative (-) auxiliary battery terminal before performing work.
  2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 2

  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [11/2018 - ]

  4. REMOVE FRONT BUMPER LOWER ABSORBER 

    Refer to PROCEDURE - Step 7

  5. REMOVE NO. 2 MOTOR UNDER COVER 

    Refer to PROCEDURE - Step 1

  6. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 2

  7. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 3

  8. REMOVE FRONT SUSPENSION MEMBER TO CROSSMEMBER BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 17

  9. DRAIN COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed)) 

    See step  7

  10. REMOVE HEADLAMP ASSEMBLY LH 

    Refer to REMOVAL [06/2015 - ]

  11. REMOVE HEADLAMP ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  12. REMOVE FRONT BUMPER ENERGY ABSORBER 

    Refer to PROCEDURE - Step 21

  13. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 22

  14. REMOVE AIR CLEANER INLET 

    Refer to PROCEDURE - Step 24

  15. REMOVE NO. 1 MOTOR UNDER COVER 

    Refer to PROCEDURE - Step 8

  16. REMOVE AIR CLEANER HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 26

  17. REMOVE AIR CLEANER ASSEMBLY WITH ELEMENT 

    Refer to PROCEDURE - Step 25

  18. REMOVE NO. 1 RADIATOR AIR GUIDE RH 
    1. Disengage the 2 claws.
      GTY551717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide to remove the No. 1 radiator air guide RH from the vehicle.
  19. REMOVE NO. 1 RADIATOR AIR GUIDE LH 
    1. Disengage the 2 claws.
      GTY551721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide to remove the No. 1 radiator air guide LH from the vehicle.
  20. DISCONNECT FC RADIATOR INLET HOSE 
    1. Slide the hose clip and disconnect the FC radiator inlet hose from the FC radiator assembly.
      GTY551705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.
      • Perform the work by hand. Do not use tools.
    2. To prevent contamination by foreign matter, cover the connecting portions of the FC radiator inlet hose and FC radiator assembly with plastic bags.
      GTY596446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag
  21. DISCONNECT NO. 1 FC RADIATOR OUTLET HOSE 
    1. Slide the hose clip and disconnect the No. 1 FC radiator outlet hose from the FC radiator pipe.
      GTY551712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator pipe portion.
      • Perform the work by hand. Do not use tools.
    2. To prevent contamination by foreign matter, cover the connecting portions of the No. 1 FC radiator outlet hose and FC radiator pipe with plastic bags.
      GTY597744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag
  22. DISCONNECT FC SUB-RADIATOR INLET HOSE 
    1. Slide the hose clip and disconnect the FC sub-radiator inlet hose from the FC radiator assembly.
      GTY564911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.
      • Perform the work by hand. Do not use tools.
    2. To prevent contamination by foreign matter, cover the connecting portions of the FC sub-radiator inlet hose and FC radiator assembly with plastic bags.
      GTY544956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag
  23. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY 
    1. Disconnect the thermistor assembly connector.
      GTY600431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the vehicle approaching speaker assembly connector.
      GTY551693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the low pitched horn assembly connector.
      GTY551695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the high pitched horn assembly connector.
    5. Disconnect the hood courtesy switch connector (hood lock assembly).
      GTY585257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 5 bolts and upper radiator support sub-assembly from the vehicle.
      GTY603370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disengage the guide and disconnect the hood lock control cable assembly.
      GTY608343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disengage the clamp to disconnect the hood lock control cable assembly.
      GTY586906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FC RADIATOR ASSEMBLY 
    1. Disconnect the cooling fan with controller motor. (For Fan Side)
      GTY603371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Pull up the lever to disengage the lock and disconnect the cooling fan with controller motor connector.
    2. Disconnect the cooling fan with controller motor. (For No. 2 Fan Side)
      GTY564915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Pull up the lever to disengage the lock and disconnect the cooling fan with controller motor connector.
    3. Disengage the 7 clamps to separate the wire harness from the fan shroud.
      GTY564918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 6 bolts, and separate the radiator support sub-assembly and No. 2 radiator support sub-assembly together with the radiator assembly and cooler condenser assembly, as a single unit, from the FC radiator assembly.
      GTY564913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the FC radiator assembly from the vehicle.
      GTY564917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      During removal, make sure not to damage the radiator assembly or FC radiator assembly.

    6. Slide the hose clip and remove the No. 1 FC radiator outlet hose from the FC radiator assembly.
      GTY603368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.
      • Perform the work by hand. Do not use tools.
    7. To prevent contamination by foreign matter, cover the connecting portions of the No. 1 FC radiator outlet hose and FC radiator assembly with plastic bags.
      GTY553192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag
    8. Slide the hose clip and remove the radiator reservoir tank hose from the FC radiator assembly.
      GTY603367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.
      • Perform the work by hand. Do not use tools.
    9. To prevent contamination by foreign matter, cover the connecting portions of the radiator reservoir tank hose and FC radiator assembly with plastic bags.
      GTY563680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag
    10. Remove the 4 bolts.
      GTY564898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Disengage the clamp.
      GTY565057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Disengage the 3 guides to remove the fan with motor from the FC radiator assembly.
      GTY564901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE RADIATOR SUPPORT CUSHION 
    1. Remove the 2 radiator support cushions from the FC radiator assembly.
      GTY564899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE LOWER RADIATOR SUPPORT 
    1. Remove the 2 lower radiator supports from the FC radiator assembly.
      GTY564906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals