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Removal [06/2015 - 11/2018]: Procedure

  1. PRECAUTION 
    NOTE:
    • 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 - ]

    • Place signs [HIGH PRESSURE GAS WORK IN PROGRESS - DO NOT TOUCH!], etc. to warn other technicians to be cautious. (An example sign is included, so make a copy and use it.)
      GTY597367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • When performing depressurization, do not open or close any parts of the hydrogen gas piping except for the following:

      - Adjustment bolt of the hydrogen tank assembly manual valve

      - Tank shut valve of the hydrogen tank assembly

      - No. 1 hydrogen supply regulator plug

    • When installing or removing hydrogen system components (hydrogen tank assembly, high pressure hydrogen piping, hydrogen inlet receptacle, hydrogen tube joint, hydrogen tank pressure sensor or hydrogen supply regulator assembly), to prevent strain such as twisting from being applied to the high pressure hydrogen piping, use the hydrogen tank installation and removal guide tool and remove the hydrogen tank unit from the vehicle before performing procedures.
    • Even when replacing only the No. 1 hydrogen tank assembly, or only the No. 2 hydrogen tank assembly, to prevent strain from being applied to the high pressure hydrogen piping, use the tank positioning attachment of the hydrogen tank installation and removal tool, and perform positioning of the No. 1 hydrogen tank assembly and No. 2 hydrogen tank assembly.
    • Even when not removing or installing the high pressure hydrogen piping, be careful not to pull or otherwise apply strain to the high pressure hydrogen piping.
    • Do not reuse high pressure hydrogen piping after it has been removed, because the coupling portions will not maintain their airtightness.
    • When reusable parts such as the hydrogen tank assembly valve portion, hydrogen inlet receptacle, hydrogen tube joint and hydrogen supply regulator assembly have been removed, to protect the seal portions and threaded portions from damage as well as to prevent foreign matter such as dust and metal fragments from entering through openings, cover these areas with protective tape.
    • Do not use packing tape, or any other tape that will leave residue on parts, as protective tape.
    • Protect seal portions and threaded portions as shown in the illustration.
      GTY587875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      *b Seal Portion
      *c Threaded Portion
    • To protect the seal portions and threaded portions from damage or contamination by foreign matter, remove the protective tape immediately before installation.
    • When reassembling components that have been removed, make sure that there is no foreign matter adhering to the openings.
    • After installing hydrogen system components, first perform primary leak inspection with low pressure nitrogen gas, and then fill pressurized hydrogen gas at a hydrogen station to perform secondary leak inspection. When performing secondary leak inspection, the vehicle cannot be driven to the hydrogen station under its own power, so transport it using a car carrier, etc.
    • 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.
    • When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.
  2. DISCHAGE COMPRESSED HYDROGEN GAS (When replacing the hydrogen tank assembly) 

    Refer to DISCHARGE COMPRESSED HYDROGEN GAS [06/2015 - ] 

  3. REMOVE NO. 2 MOTOR UNDER COVER 

    Refer to PROCEDURE - Step 1

  4. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 2

  5. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 3

  6. REMOVE FRONT FLOOR CENTER COVER LH 

    Refer to PROCEDURE - Step 4

  7. REMOVE FRONT FLOOR CENTER COVER RH 

    Refer to PROCEDURE - Step 5

  8. REMOVE NO. 2 FLOOR UNDER COVER 

    Refer to PROCEDURE - Step 6

  9. REMOVE NO. 1 FLOOR UNDER COVER 

    Refer to PROCEDURE - Step 7

  10. REMOVE FC EXHAUST TAIL PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 8

  11. REMOVE NO. 3 FC EXHAUST PIPE 

    Refer to PROCEDURE - Step 9

  12. REMOVE NO. 2 FC EXHAUST PIPE 

    Refer to PROCEDURE - Step 10

  13. PRESSURE RELEASE OPERATION 
    1. Prepare SST (hydrogen venting tool).

      See step  6

    2. Check that the open/close valve of the SST (venting stand) is closed.
      GTY543238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Venting Stand)
      • SST: 09404-62010 
        1. 09404-06010
    3. Using an 8 mm hexagon socket wrench, rotate the adjustment bolt clockwise to close the manual valve of the No. 1 hydrogen tank assembly.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      GTY582968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise
      NOTE:
      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.
      • If the hexagonal portion has been damaged, the No. 1 hydrogen tank assembly must be replaced.
    4. Using an 8 mm hexagon socket wrench, rotate the adjustment bolt clockwise to close the manual valve of the No. 2 hydrogen tank assembly.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      GTY602948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise
      NOTE:
      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.
      • If the hexagonal portion has been damaged, the No. 1 hydrogen tank assembly must be replaced.
    5. Before starting the depressurization procedure, first check that there is no mud or other contaminant around the medium pressure leak check port of the hydrogen supply regulator assembly, and clean it as necessary.

      HINT: 

      Installing the No. 1 hydrogen supply regulator plug while any foreign matter adheres to it can cause a hydrogen gas leak.

    6. Make sure that the manual valves of the No. 1 hydrogen tank assembly and No. 2 hydrogen tank assembly are closed.
    7. Apply paint marks to the hydrogen supply regulator union and the body of the hydrogen supply regulator assembly as shown in the illustration.

      HINT: 

      When loosening the No. 1 hydrogen supply regulator plug, there is a possibility that the hydrogen supply regulator union could turn together with it and be loosened, so applying paint marks will enable judgment of whether the hydrogen supply regulator union has been loosened.

      GTY564827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Hydrogen Supply Regulator Union
      *a Body
      *b Paint Mark
    8. Slowly loosen the No. 1 hydrogen supply regulator plug until the hissing sound of gas escaping can be heard, then stop loosening the No. 1 hydrogen supply regulator plug and wait for the sound to stop. Repeat this procedure multiple times until the sound stops occurring, in order to depressurize the compressed hydrogen gas from the medium pressure leak check port of the hydrogen supply regulator assembly.
      GTY601467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:
      • Do not perform depressurization procedures when the manual valve of the hydrogen tank assembly is open.
      • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.
      GTY571542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Manual Valve Open
      • When performing depressurization, do not perform procedures by hand without wearing protective glasses and gloves.
        GTY564671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • High pressure nitrogen gas could cause a serious accident.
      NOTE:

      When performing depressurization, only loosen the No. 1 hydrogen supply regulator plug. Do not remove it.

    9. Blow compressed air at the underside of the vehicle to disperse any accumulated hydrogen gas.
      GTY601758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the No. 1 hydrogen supply regulator plug from the hydrogen supply regulator union.
      NOTE:

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    11. Remove the O-ring from the hydrogen supply regulator union.
      GTY556346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union with protective tape.
      GTY573353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    13. Check that the hydrogen supply regulator union has not been loosened.
      GTY570540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      *c Paint Mark

      HINT: 

      If the hydrogen supply regulator union has been loosened, there is the possibility of a compressed hydrogen gas leak, so it is necessary to remove the hydrogen supply regulator union and replace the O-ring with a new one.

    14. Procedures for when the hydrogen supply regulator union has been loosened:
      1. Remove the hydrogen supply regulator union.
        GTY598361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      2. To prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union installation portion with protective tape.
        GTY586968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protective Tape
      3. Remove the O-ring from the hydrogen supply regulator union.
        GTY542388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Perform the procedure by hand. Do not use any tools.

      4. Clean and degrease the threaded portion of the hydrogen supply regulator union.
      5. To prevent the O-ring from being damaged during installation, apply protective tape as shown in the illustration.
        GTY597696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Hydrogen Supply Regulator Union
        *a Protective Tape

        HINT: 

        Cover the hydrogen supply regulator union with protective tape so that the threaded portion and the hole cannot be seen.

      6. Coat a new O-ring with TOYOTA Genuine FC Grease.
      7. Install the O-ring to the hydrogen supply regulator union.
        GTY542391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Make sure not to damage the O-ring.
        • Make sure the O-ring is not twisted.
      8. Remove the protective tape from the hydrogen supply regulator union.
        NOTE:

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      9. Coat the O-ring and the threaded portion of the hydrogen supply regulator union with TOYOTA Genuine FC Grease.
        GTY542429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. To prevent the hydrogen supply regulator union installation portion from being contaminated by dust, metal fragments, etc., do not remove the protective tape from it until immediately before performing the work.
        NOTE:

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      11. Install the hydrogen supply regulator union.

        Torque: 41.5 N*m (423 kgf*cm, 31 ft.*lbf) 

        NOTE:

        When installing the O-ring, make sure that it is not pinched.

    15. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, do not remove the protective tape covering the seal portions, threaded portions, and openings of the hydrogen supply regulator union until immediately before performing work.
      NOTE:

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    16. Apply TOYOTA Genuine FC Grease to a new O-ring and to the threaded portion of the hydrogen supply regulator union.
      GTY556344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Install the O-ring to the hydrogen supply regulator union.
      NOTE:

      During installation, make sure not to damage the O-ring.

    18. Connect the SST (hydrogen venting tool).

      <Concept of SST (hydrogen venting tool) Connection> 

      GTY576620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Venting Stand) *b SST (Flexible Hose)
      *c SST (Upper Release Pipe) *d SST (Middle Release Pipe)
      *e SST (Lower Release Pipe) - -
      • SST: 09404-62010 
        1. 09404-06010
        2. 09404-06020
        3. 09404-06030
        4. 09404-06040
        5. 09404-06050
      1. Using SST (open end wrench), install the SST (flexible hose) to the hydrogen supply regulator union.
        GTY608276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Flexible Hose)
        *b SST (Open End Wrench)
        *c SST Fulcrum Length
        *d Torque Wrench Fulcrum Length
        • SST: 09922-10240 
        • SST: 09404-62010 
          1. 09404-06020

        Specified tightening torque 

        Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

        NOTE:
        • Make sure that the SST (flexible hose) does not interfere with any part of the vehicle.
        • If the SST (flexible hose) interferes with any part of the vehicle, protect it with a piece of cloth, etc.

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [06/2015 - ]

        • When using SST (fulcrum length of 40 mm (1.57 in.)) + torque wrench (fulcrum length of 255 mm (10.04 in.)):

          21.6 N*m (220 kgf*cm, 16 ft.*lbf)

      2. Connect the SST (flexible hose) to the SST (Venting Stand).
        GTY593609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Flexible Hose)
        *b SST (Venting Stand)
        • SST: 09404-62010 
          1. 09404-06010
          2. 09404-06020
    19. Under basic conditions
      GTY600967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Set the SST (hydrogen venting tool) in an outdoor location.
        NOTE:

        Take care that the compressed hydrogen gas that is discharged during the discharging procedure does not enter any indoor location.

    20. Other than basic conditions (when outdoor setup is not possible)
      GTY545516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. When the SST (hydrogen venting tool) will be set up indoors, locate it along a wall near a window, and with the tip of the SST (upper release pipe) outdoors.
        NOTE:

        Open windows on two sides or more, and ensure that there is adequate ventilation to prevent the compressed hydrogen gas that is discharged from collecting inside.

    21. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies, and after 2 to 3 seconds, close the tank shut valves again.
      WARNING:
      GTY554118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • When opening the tank shut valve and applying pressure to the SST (hydrogen venting tool), stay away from the SST (flexible hose).
      • If the SST (flexible hose) comes off, you could be struck by the loose end of the SST (flexible hose), causing a serious accident.
      NOTE:

      If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2 , 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

    22. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again, and after 2 to 3 seconds, close the tank shut valves.
    23. Perform preliminary leak check (using remaining piping pressure).

      HINT: 

      Perform leak check using the pressure remaining upstream of the tank shut valve.

      1. If there are any water droplets, etc. adhering to the measurement locations, wipe them away before performing the procedure.
        NOTE:

        Performing the measurement while any water droplets, etc. are adhering could damage the hydrogen gas detector.

      2. Using SST and a hydrogen gas detector, inspect for leaks in the locations shown in the illustration.

        <Locations to Check for Leaks> 

        GTY588873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Leak Check Location - -
        • SST: 09401-62010 

        Specified Value

        300 ppm or less

        NOTE:

        If any values are outside the specified range, disconnect those locations that have leaks and assemble the parts again.

    24. Using the Techstream, enter the following menus: Powertrain / FC / Data List / Medium-range Hydrogen Pressure

      Powertrain > FC > Data List 

      Tester Display
      Medium-range Hydrogen Pressure

      HINT: 

      If the Techstream unit setting is absolute pressure (abs), change it to gauge pressure (gauge).

    25. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.
      NOTE:

      If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2 , 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

    26. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again.
    27. Open the open/close valve of the SST (venting stand), and depressurize compressed hydrogen gas.
      • SST: 09404-62010 
      GTY573483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Venting Stand)
    28. Continue to monitor the Data List, and when the value of "Medium-range Hydrogen Pressure (gauge)" becomes 0.8 MPa (8.2 kgf/cm2 , 116 psi), close the open/close valve of the SST (venting stand).
      NOTE:
      • To protect the tank shut valve, make sure to first close the open/close valve of the SST (venting stand).
      • Forgetting to close the open/close valve of the SST (venting stand) and allowing the Data List item "Medium-range Hydrogen Pressure (gauge)" to decrease to below 0.6 MPa (6.1 kgf/cm2 , 87 psi) will cause the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies to forcibly close.
    29. Check that the Data List item "Medium-range Hydrogen Pressure (gauge)" and the pressure on the pressure indicator of the SST (venting stand) are less than 0.8 MPa (8.2 kgf/cm2 , 116 psi).
      NOTE:
      • The pressure immediately after closing the open/close valve of the SST (venting stand) should be less than 0.8 MPa (8.2 kgf/cm2 , 116 psi) for both the Data List item "Medium-range Hydrogen Pressure (gauge)" and on the pressure indicator of the SST (venting stand).
      • If either the Data List item "Medium-range Hydrogen Pressure (gauge)" or the pressure on the pressure indicator of the SST (venting stand) are 0.8 MPa (8.2 kgf/cm2 , 116 psi) or greater, open the open/close valve of the SST (venting stand) and adjust the pressure.

      HINT: 

      If the pressure immediately after closing the open/close valve of the SST (venting stand) is less than 0.8 MPa (8.2 kgf/cm2 , 116 psi) for both the Data List item "Medium-range Hydrogen Pressure (gauge)" and on the pressure indicator of the SST (venting stand), then the pressurized hydrogen gas depressurizing procedure is complete.

    30. Close the tank shut valves of both the No. 1 and No. 2 hydrogen tank assemblies.
    31. Open the open/close valve of the SST (venting stand) and discharge the compressed hydrogen gas remaining inside the SST (flexible hose).
      GTY573483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Venting Stand)
      • SST: 09404-62010 
        1. 09404-06010
      NOTE:
      • Do not disconnect the SST (flexible hose) while there is still pressure remaining inside it.
      • Continue discharging until the pressure gauge of the SST (Venting Stand) becomes "0".
    32. Before performing the disconnection procedure, if there are any contaminants such as water droplets adhering near the medium pressure leak check port of the hydrogen supply regulator assembly, wipe them away before performing the procedure.
    33. Disconnect the SST (flexible hose) from the SST (Venting Stand).
      GTY593609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Flexible Hose)
      *b SST (Venting Stand)
      • SST: 09404-62010 
        1. 09404-06010
        2. 09404-06020
    34. Apply paint marks to the hydrogen supply regulator union and the body of the hydrogen supply regulator assembly as shown in the illustration.

      HINT: 

      When loosening the SST (flexible hose), there is a possibility that the hydrogen supply regulator union could turn together with it and be loosened, so applying paint marks will enable judgment of whether the hydrogen supply regulator union has been loosened.

      GTY559124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Hydrogen Supply Regulator Union
      *a Body
      *b Paint Mark
    35. Using SST (open end wrench), remove the SST (flexible hose) from the hydrogen supply regulator union.
      GTY568888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Flexible Hose)
      *b SST (Open End Wrench)
      • SST: 09922-10240 
      • SST: 09404-62010 
        1. 09404-06020
    36. Remove the O-ring from the hydrogen supply regulator union.
      GTY556346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    37. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union with protective tape.
      GTY573353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    38. Check that the hydrogen supply regulator union has not been loosened.
      GTY570540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      *c Paint Mark

      HINT: 

      If the hydrogen supply regulator union has been loosened, there is the possibility of a compressed hydrogen gas leak, so it is necessary to remove the hydrogen supply regulator union and replace the O-ring with a new one.

    39. Procedures for when the hydrogen supply regulator union has been loosened:
      1. Remove the hydrogen supply regulator union.
        GTY598361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      2. To prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union installation portion with protective tape.
        GTY586968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protective Tape
      3. Remove the O-ring from the hydrogen supply regulator union.
        GTY542388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Perform the procedure by hand. Do not use any tools.

      4. Clean and degrease the threaded portion of the hydrogen supply regulator union.
      5. To prevent the O-ring from being damaged during installation, apply protective tape as shown in the illustration.
        GTY597696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Hydrogen Supply Regulator Union
        *a Protective Tape

        HINT: 

        Cover the hydrogen supply regulator union with protective tape so that the threaded portion and the hole cannot be seen.

      6. Coat a new O-ring with TOYOTA Genuine FC Grease.
      7. Install the O-ring to the hydrogen supply regulator union.
        GTY542391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Make sure not to damage the O-ring.
        • Make sure the O-ring is not twisted.
      8. Remove the protective tape from the hydrogen supply regulator union.
        NOTE:

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      9. Coat the O-ring and the threaded portion of the hydrogen supply regulator union with TOYOTA Genuine FC Grease.
        GTY542429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. To prevent the hydrogen supply regulator union installation portion from being contaminated by dust, metal fragments, etc., do not remove the protective tape from it until immediately before performing the work.
        NOTE:

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      11. Install the hydrogen supply regulator union.

        Torque: 41.5 N*m (423 kgf*cm, 31 ft.*lbf) 

        NOTE:

        When installing the O-ring, make sure that it is not pinched.

    40. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, do not remove the protective tape covering the seal portions, threaded portions, and openings of the hydrogen supply regulator union until immediately before performing work.
      NOTE:

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    41. Apply TOYOTA Genuine FC Grease to a new O-ring and to the threaded portion of the hydrogen supply regulator union.
      GTY556344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    42. Install the O-ring to the hydrogen supply regulator union.
      NOTE:

      During installation, make sure not to damage the O-ring.

    43. Install the No. 1 hydrogen supply regulator plug to the hydrogen supply regulator union.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      GTY554120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISABLE BRAKE CONTROL 

    Refer to PROCEDURE - Step 3

  15. REMOVE REAR WHEEL HOUSE FRONT PLATE LH 

    Refer to PROCEDURE - Step 14

  16. REMOVE REAR BUMPER SIDE SEAL LH 

    Refer to PROCEDURE - Step 2

  17. REMOVE REAR WHEEL HOUSE LINER LH 

    Refer to PROCEDURE - Step 16

  18. REMOVE REAR AXLE BEAM ASSEMBLY 

    Refer to REMOVAL [06/2015 - 11/2018]

  19. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 3 bolts and separate the No. 2 parking brake cable assembly from the vehicle.
      GTY556355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 bolts and separate the No. 3 parking brake cable assembly from the vehicle.
      GTY556352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. SEPARATE NO. 3 FLOOR WIRE 
    1. Disconnect the No. 1 hydrogen tank assembly connector.
      GTY601462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp and separate the No. 1 hydrogen tank assembly connector from the wire harness clamp bracket.
    3. Disconnect the No. 2 hydrogen tank assembly connector.
      GTY556361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the clamp and separate the No. 3 floor wire from the hydrogen tank tube clamp bracket.
    5. Disconnect the hydrogen detector connector.
      GTY556360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the rear height control sensor sub-assembly connector.
      GTY556365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the 2 hydrogen tank pressure sensor connectors.
      GTY556363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disengage the 8 clamps and separate the No. 3 floor wire from the front center hydrogen tank frame and wire harness clamp bracket.
  22. SEPARATE NO. 2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY 
    1. Remove the 2 bolts and separate the No. 2 hydrogen supply tube sub-assembly from the vehicle.
      GTY556359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT NO. 1 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the No. 1 hydrogen supply tube sub-assembly from the No. 2 hydrogen supply tube sub-assembly.
      GTY556356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    2. Remove the 2 O-rings from the No. 1 hydrogen supply tube sub-assembly.
      GTY556324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. To prevent contamination by foreign matter, cover the openings of the No. 1 hydrogen supply tube sub-assembly and No. 2 hydrogen supply tube sub-assembly with plastic bags.
      GTY563144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag
  24. REMOVE WIRING HARNESS CLAMP BRACKET 
    1. Remove the bolt and separate the No. 2 hydrogen supply tube sub-assembly from the wire harness clamp bracket.
      GTY556330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wire harness clamp bracket from the front hydrogen tank frame sub-assembly LH.
  25. SEPARATE HYDROGEN TANK TUBE CLAMP BRACKET 
    1. Remove the bolt and separate the hydrogen tank tube clamp bracket from the vehicle.
      NOTE:

      When loosening the bolt, to prevent the high pressure hydrogen piping from rotating together and being strained, hold the hydrogen tube clamp bracket in place by hand while performing the procedure.

      GTY556339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT HYDROGEN TANK TUBE ASSEMBLY 
    WARNING:
    GTY552272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a After depressurization procedures, the high pressure piping union nut that is loosened first.
    • After performing depressurization procedures, when first loosening the union nut of the high pressure hydrogen piping, do not loosen the union nut by hand without wearing protective glasses and gloves.
    • Even when depressurization procedures are performed, the pressurized hydrogen gas inside the high pressure hydrogen piping cannot be completely depressurized, so the highly pressurized hydrogen gas remaining in the high pressure hydrogen piping could blow out, resulting in a serious accident.
    1. Using a 17 mm union nut wrench, loosen the union nut and disconnect the hydrogen tank tube assembly from the hydrogen inlet receptacle assembly.
      GTY575127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adapter Portion
      *b Hold
      NOTE:
      • When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.
      • While using an adjustable wrench to hold the adapter portion of the hydrogen inlet receptacle assembly in place, loosen the union nut.
    2. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen inlet receptacle assembly with protective tape.
      GTY540106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      If the hydrogen inlet receptacle assembly will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape. However, do not remove the protective cap of the new component until immediately before installing it.

    3. Remove the bolt and separate the bracket of the hydrogen tank tube assembly from the vehicle.
      NOTE:

      When loosening the bolt, to prevent the high pressure hydrogen piping from rotating together and being strained, hold the bracket portion in place by hand while performing the procedure.

      GTY556338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE HYDROGEN TANK UNIT 
    WARNING:
    • Because the hydrogen tank unit is extremely heavy, make sure to follow the work procedures described in the repair information.
    • If work is not performed according to the procedures described in the repair information, there is a danger that the engine lifter could drop and components could fall down.
    GTY599351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Heavy load exceeding the weight limits or size limits of the engine lifter
    1. Set the SST (hydrogen tank stand) on the engine lifter and secure it with the belt.
      • SST: 09403-62010 
        1. 09403-06010
        2. 09403-06020
        3. 09403-06030
        4. 09403-06040
        5. 09403-06050
        6. 09403-06060
        7. 09403-06070
        8. 09403-06080
        9. 09403-06090
        10. 09403-06100
        11. 09403-06110
      GTY589472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Hydrogen Tank Stand)
      *b Belt
      NOTE:

      Set the SST (hydrogen tank stand) in the middle of the engine lifter and secure the center portion with the belt.

    2. Remove the SST (nuts) and each tank support type SST.
      GTY543794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Support No. 5)
      *b SST (Support No. 6)
      *c SST (Nut)
      • SST: 09403-62010 
        1. 09403-06050
        2. 09403-06060
        3. 09403-06090
    3. Remove the SST (bolts) and each SST (tank belt fixture).
      GTY551571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)
      • SST: 09403-62010 
        1. 09403-06100
        2. 09403-06110
    4. For each tank support type SST, disengage the 2 pins and loosen the 2 SST (bolts).
      • SST: 09403-62010 
        1. 09403-06010
        2. 09403-06020
        3. 09403-06030
        4. 09403-06040
        5. 09403-06080

      HINT: 

      This is done to align the SST (hydrogen tank stand) with the installation condition of the hydrogen tank unit on the vehicle.

      GTY556289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Support No. 1)
      *b SST (Support No. 2)
      *c SST (Support No. 3)
      *d SST (Support No. 4)
      *e SST (Bolt)
      *f Pin
    5. Operate the engine lifter, and set the SST (hydrogen tank stand) against the hydrogen tank frame.
      GTY564628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Hydrogen Tank Stand) *b Pin
      *c Groove - -
      NOTE:
      • Align the pins of the each tank support type SST with the pin holes of the hydrogen tank frame.
      • Align the grooves of the each tank support type SST with the tank frame.
    6. Using the SST (bolts), install each SST (tank belt fixture), and support the hydrogen tank frame.
      • SST: 09403-62010 
        1. 09403-06100
        2. 09403-06110
      GTY542882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)
      NOTE:
      • If the hydrogen tank unit is removed from the vehicle without attaching each SST (tank belt fixture), the hydrogen tank frame will spring back because of the spring force and the installation positions of parts will be misaligned.
      • Do not remove any of the tank frame installation bolts until each SST (tank belt fixture) are installed.

      HINT: 

      If it is difficult to install each SST (tank belt fixture), loosen the tank frame installation bolts to a position where the tank frame support attachments can be installed.

    7. Tighten the SST (bolts) of each tank support type SST.
      GTY573115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Support No. 1, Support No. 2, Support No. 3 and Support No. 4)
      *b SST (Bolt)
      • SST: 09403-62010 
        1. 09403-06010
        2. 09403-06020
        3. 09403-06030
        4. 09403-06040
        5. 09403-06080
    8. Remove the 8 bolts.
      GTY556314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Operate the engine lifter and slowly remove the hydrogen tank unit from the vehicle.
      NOTE:

      Make sure the hydrogen tank assembly and high pressure hydrogen piping do not interfere with the vehicle body or surrounding components.

    10. Support the hydrogen tank tube assembly with the SST (support No. 7).
      NOTE:
      • To prevent deformation of the hydrogen tank tube assembly, make sure the hydrogen tank tube assembly does not come off of the SST (support No. 7).
      • To prevent deformation of the hydrogen tank tube assembly, make sure that your body does not catch on it.
      GTY564348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Support No. 7)
  28. REMOVE NO. 2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY 
    1. Remove the bolt and No. 2 hydrogen supply tube sub-assembly from the hydrogen supply regulator assembly.
      GTY601454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    2. Remove the 2 O-rings from the No. 2 hydrogen supply tube sub-assembly.
      GTY556324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. To prevent contamination by foreign matter, cover the openings of the hydrogen supply regulator assembly with protective tape.
      GTY600394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      *b Plastic Bag

      HINT: 

      When the hydrogen supply regular assembly will be replaced with a new one, it is not necessary to protect the openings with protective tape.

    4. To prevent contamination by foreign matter, cover the connecting portions of the hydrogen supply tube sub-assembly with plastic bags.

      HINT: 

      When the No. 2 hydrogen supply tube sub-assembly will be replaced with a new one, it is not necessary to protect the openings with plastic bags.

  29. REMOVE WIRE HARNESS CLAMP 
    1. No. 1 Hydrogen Tank Assembly Side:
      GTY604302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 Hydrogen Tank Assembly Side
      *b No. 2 Hydrogen Tank Assembly Side
      1. Disengage the clamp and remove the wire harness clamp from the wire harness of the No. 1 hydrogen tank assembly and No. 4 hydrogen tube sub-assembly.
    2. No. 2 Hydrogen Tank Assembly Side:
      1. Disengage the clamp and separate the No. 2 hydrogen tank assembly connector from the hydrogen tank tube clamp bracket.
      2. Disengage the clamp and remove the wire harness clamp from the wire harness of the No. 2 hydrogen tank assembly and hydrogen tube sub-assembly.
  30. REMOVE HYDROGEN TANK TUBE CLAMP BRACKET 
    1. Disengage the claw and remove the hydrogen tank tube clamp bracket from the No. 1 fuel tube clamp.
      GTY556321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When there is high pressure hydrogen piping that will not be replaced, be careful not to damage or deform it.
      • If the pipe protector material of the high pressure hydrogen piping is damaged so that the internal pipe itself becomes visible, replace the high pressure hydrogen piping with a new one.
  31. REMOVE NO. 1 FUEL TUBE CLAMP 
    1. Disengage the 3 clamps and remove the No. 1 fuel tube clamp from the hydrogen tank tube assembly, No. 3 hydrogen tank tube and No. 5 hydrogen tank tube.
      GTY556318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When there is high pressure hydrogen piping that will not be replaced, be careful not to damage or deform it.
      • If the pipe protector material of the high pressure hydrogen piping is damaged so that the internal pipe itself becomes visible, replace the high pressure hydrogen piping with a new one.
      • The No. 1 fuel tube clamp cannot be reused.
  32. REMOVE FUEL TUBE GROMMET 
    1. Disengage the 2 clamps and remove the 2 fuel tube grommets from the hydrogen tank tube assembly and No. 3 hydrogen tank tube.
      NOTE:
      • When there is high pressure hydrogen piping that will not be replaced, be careful not to damage or deform it.
      • If the pipe protector material of the high pressure hydrogen piping is damaged so that the internal pipe itself becomes visible, replace the high pressure hydrogen piping with a new one.
      • The fuel tube grommet cannot be reused.
      GTY556317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE HYDROGEN TANK TUBE ASSEMBLY 
    1. Using a 17 mm union nut wrench, loosen the union nut and remove the hydrogen tank tube assembly from the hydrogen tank tube joint.
      GTY556455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.
      • A hydrogen tank tube assembly that has been removed cannot be reused.
    2. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen tank tube joint with protective tape.
      GTY554305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      When replacing the hydrogen tank tube joint with a new one, it is not necessary to protect the seal portions and thread portions with protective tape.

  34. REMOVE NO. 3 HYDROGEN TANK TUBE 
    1. Using a 17 mm union nut wrench, loosen the 2 union nuts and remove the No. 3 hydrogen tank tube from the No. 2 hydrogen tank assembly and hydrogen tank tube joint.
      GTY556453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.
      • A No. 3 hydrogen tank tube that has been removed cannot be reused.
    2. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the No. 2 hydrogen tank assembly and hydrogen tank tube joint with protective tape.
      GTY602571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      • If the hydrogen tank tube joint will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
      • If the No. 2 hydrogen tank assembly will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
  35. REMOVE NO. 5 HYDROGEN TANK TUBE 
    1. Using a 17 mm union nut wrench, loosen the 2 union nuts and remove the No. 5 hydrogen tank tube from the No. 2 hydrogen tank assembly and hydrogen tank tube joint.
      GTY556457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.
      • A No. 5 hydrogen tank tube that has been removed cannot be reused.
    2. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the No. 2 hydrogen tank assembly and hydrogen tank tube joint with protective tape.
      GTY568230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      • If the hydrogen tank tube joint will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
      • If the No. 2 hydrogen tank assembly will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
  36. REMOVE NO. 4 HYDROGEN TANK TUBE 
    1. Using a 17 mm union nut wrench, loosen the 2 union nuts and disconnect the No. 4 hydrogen tank tube from the No. 1 hydrogen tank assembly and hydrogen tank tube joint.
      GTY601487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    2. Disengage the clamp and remove the No. 4 hydrogen tank tube from the fuel tube grommet.
      NOTE:
      • A No. 4 hydrogen tank tube that has been removed cannot be reused.
      • A fuel tube grommet for which the clamp has been disengaged cannot be reused.
    3. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the No. 1 hydrogen tank assembly and hydrogen tank tube joint with protective tape.
      GTY538774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      • If the hydrogen tank tube joint will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
      • If the No. 1 hydrogen tank assembly will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
  37. REMOVE NO. 2 HYDROGEN TANK TUBE 
    1. Using a 17 mm union nut wrench, loosen the 2 union nuts and disconnect the No. 2 hydrogen tank tube from the No. 1 hydrogen tank assembly and hydrogen tank tube joint.
      GTY556463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    2. Disengage the clamp and remove the No. 2 hydrogen tank tube from the fuel tube grommet.
      NOTE:
      • A No. 2 hydrogen tank tube that has been removed cannot be reused.
      • A fuel tube grommet for which the clamp has been disengaged cannot be reused.
    3. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the No. 1 hydrogen tank assembly and hydrogen tank tube joint with protective tape.
      GTY547823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      • If the hydrogen tank tube joint will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
      • If the No. 1 hydrogen tank assembly will be replaced with a new one, it is not necessary to cover the seal portions, threaded portions, and openings with protective tape.
  38. REMOVE FUEL TUBE GROMMET 
    1. Disengage the claw and remove the fuel tube grommet from the front hydrogen tank frame sub-assembly LH.
      NOTE:

      A fuel tube grommet that has been removed cannot be reused.

      GTY556462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 2 HYDROGEN TANK ASSEMBLY 
    1. Loosen the 2 bolts and remove the 2 rear hydrogen tank spring bolt cups and 2 compression springs.
      GTY599550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      NOTE:

      While holding the rear hydrogen tank spring bolt cup, loosen the bolt.

    2. Disengage the 2 claws, raise up the rear hydrogen tank frame spring bolt cushion, and remove the bolt.
      GTY555215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Raise Up
      Remove

      HINT: 

      Use the same procedure to remove the other bolt.

    3. Remove the 2 bolts and 2 rear hydrogen tank band sub-assemblies from the 2 rear hydrogen tank frame sub-assemblies.
      GTY556460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using an engine sling device and belts, remove the No. 2 hydrogen tank assembly from the rear hydrogen tank frame sub-assembly.
      GTY556438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:
      • When hoisting up the hydrogen tank assembly, do not hoist it when not properly balanced.
      • The hydrogen tank assembly could fall, resulting in a serious accident.
      GTY576740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place the No. 2 hydrogen tank assembly on wheel chocks or similar.
      GTY569733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wheel Chocks
  40. REMOVE NO. 1 HYDROGEN TANK ASSEMBLY 
    1. Loosen the 2 bolts and remove the 2 front hydrogen tank spring bolt cups and 2 compression springs.
      GTY549106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      NOTE:

      While holding the front hydrogen tank spring bolt cup, loosen the bolt.

    2. Disengage the 2 claws, raise up the rear hydrogen tank frame spring bolt cushion, and remove the bolt.
      GTY555216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Raise Up
      Remove

      HINT: 

      Use the same procedure to remove the other bolt.

    3. Remove the 2 bolts and 2 front hydrogen tank band sub-assemblies from the front hydrogen tank frame sub-assembly LH and front hydrogen tank frame sub-assembly RH.
      GTY556431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using an engine sling device and belts, remove the No. 1 hydrogen tank assembly from the front hydrogen tank frame sub-assembly LH and front hydrogen tank frame sub-assembly RH.
      GTY556437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:
      • When hoisting up the hydrogen tank assembly, do not hoist it when not properly balanced.
      • The hydrogen tank assembly could fall, resulting in a serious accident.
      GTY576740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place the No. 1 hydrogen tank assembly on wheel chocks or similar.
      GTY573933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wheel Chocks
  41. REMOVE FRONT CENTER HYDROGEN TANK FRAME 
    1. Remove the 4 bolts and front center hydrogen tank frame from the front hydrogen tank frame sub-assembly LH and front hydrogen tank frame sub-assembly RH.
      GTY601483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE REAR HYDROGEN TANK FRAME SUB-ASSEMBLY 
    1. Remove the SST (bolts) and each SST (tank belt fixture).
      GTY583921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)
      *c SST (Support No. 3)
      *d SST (Support No. 4)
      • SST: 09403-62010 
        1. 09403-06100
        2. 09403-06110
    2. Remove the 2 rear hydrogen tank frame sub-assemblies from each tank support type SST.
      • SST: 09403-62010 
        1. 09403-06030
        2. 09403-06040
  43. REMOVE FRONT HYDROGEN TANK FRAME SUB-ASSEMBLY LH 
    1. Remove the SST (bolts) and each SST (tank belt fixture).
      GTY593545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)
      *c SST (Support No. 1)
      *d SST (Support No. 2)
      • SST: 09403-62010 
        1. 09403-06100
        2. 09403-06110
    2. Remove the front hydrogen tank frame sub-assembly LH from each tank support type SST.
      • SST: 09403-62010 
        1. 09403-06010
        2. 09403-06020
  44. REMOVE FRONT HYDROGEN TANK FRAME SUB-ASSEMBLY RH 
    1. Remove the SST (bolts) and each SST (tank belt fixture).
      GTY540596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)
      *c SST (Support No. 1)
      *d SST (Support No. 2)
      • SST: 09403-62010 
        1. 09403-06100
        2. 09403-06110
    2. Remove the front hydrogen tank frame sub-assembly LH from each tank support type SST.
      • SST: 09403-62010 
        1. 09403-06010
        2. 09403-06020
  45. REMOVE REAR HYDROGEN TANK FRAME SEAT 
    GTY556410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    This procedure is only performed when the rear hydrogen tank frame seat is being replaced.

    1. Disengage the 2 claws and remove the rear hydrogen tank frame seat from the rear hydrogen tank frame sub-assembly.

      HINT: 

      Use the same procedure to remove the other rear hydrogen tank frame seats.

  46. REMOVE FRONT HYDROGEN TANK FRAME SEAT 
    GTY557881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    This procedure is only performed when the front hydrogen tank frame seat is being replaced.

    1. Disengage the 2 claws and remove the front hydrogen tank frame seat from the front hydrogen tank frame sub-assembly LH and front hydrogen tank frame sub-assembly RH.

      HINT: 

      Use the same procedure to remove the other front hydrogen tank frame seats.

  47. REMOVE REAR HYDROGEN TANK FRAME SPRING BOLT CUSHION 
    GTY556413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    This procedure is only performed when the rear hydrogen tank frame spring bolt cushion is being replaced.

    1. Disengage the 2 claws and remove the rear hydrogen tank frame spring bolt cushion from the rear hydrogen tank frame sub-assembly.

      HINT: 

      Use the same procedure to remove the other rear hydrogen tank frame spring bolt cushions.

  48. REMOVE FRONT HYDROGEN TANK FRAME SPRING BOLT CUSHION 
    GTY557880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    This procedure is only performed when the front hydrogen tank frame spring bolt cushion is being replaced.

    1. Disengage the 2 claws and remove the front hydrogen tank frame spring bolt cushion from the front hydrogen tank frame sub-assembly LH and front hydrogen tank frame sub-assembly RH.

      HINT: 

      Use the same procedure to remove the other front hydrogen tank frame spring bolt cushions.

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