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Home >> Toyota >> 2019 >> Mirai >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System - Service Information (2 Of 2) >> Regulator Assembly >> Removal [06/2015 - 11/2018] >> Procedure

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.
    • Do not insert any sharp objects into the exhaust tube of the hydrogen supply regulator assembly release valve.
      GTY560315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Exhaust Tube
      *b Atmosphere Ventilation Hole Cap
    • Do not remove the atmosphere ventilation hole cap of the hydrogen supply regulator assembly.
    • 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 NO. 2 MOTOR UNDER COVER 

    Refer to PROCEDURE - Step 1

  3. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 2

  4. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 3

  5. REMOVE FRONT FLOOR CENTER COVER LH 

    Refer to PROCEDURE - Step 4

  6. REMOVE FRONT FLOOR CENTER COVER RH 

    Refer to PROCEDURE - Step 5

  7. REMOVE NO. 2 FLOOR UNDER COVER 

    Refer to PROCEDURE - Step 6

  8. REMOVE NO. 1 FLOOR UNDER COVER 

    Refer to PROCEDURE - Step 7

  9. REMOVE FC EXHAUST TAIL PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 8

  10. REMOVE NO. 3 EXHAUST PIPE 

    Refer to PROCEDURE - Step 9

  11. REMOVE NO. 2 EXHAUST PIPE 

    Refer to PROCEDURE - Step 10

  12. PRESSURE RELEASE OPERATION 

    Refer to PROCEDURE - Step 13

  13. DISABLE BRAKE CONTROL 

    Refer to PROCEDURE - Step 3

  14. REMOVE REAR WHEEL HOUSE FRONT PLATE LH 
    1. Remove the screw, 2 clips and rear wheel house front plate LH from the vehicle.
      GTY589428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR BUMPER SIDE SEAL LH 

    Refer to PROCEDURE - Step 2

  16. REMOVE REAR WHEEL HOUSE LINER LH 
    1. Using a 4 mm socket hexagon wrench, remove the hexagon screw.
      GTY549514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hexagon Screw
    2. Remove the 12 clips and rear wheel house liner LH from the vehicle.
  17. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 

    Refer to PROCEDURE - Step 1

  18. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  19. REMOVE NO. 2 LUGGAGE COMPARTMENT TRIM HOOK 

    Refer to PROCEDURE - Step 3

  20. REMOVE FRONT LUGGAGE COMPARTMENT TRIM COVER 

    Refer to PROCEDURE - Step 4

  21. REMOVE REAR FLOOR FINISH PLATE 

    Refer to PROCEDURE - Step 5

  22. REMOVE ROPE HOOK 

    Refer to PROCEDURE - Step 6

  23. REMOVE LUGGAGE COMPARTMENT TRIM COVER ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  24. REMOVE FUEL LID WITH MOTOR LOCK ASSEMBLY 

    Refer to PROCEDURE - Step 8

  25. DISCONNECT HYDROGEN INLET RECEPTACLE CAP 
    1. Disconnect the hydrogen inlet receptacle cap from the hydrogen inlet receptacle assembly.
      GTY586586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FUEL TANK CAP COVER 

    Refer to PROCEDURE - Step 3

  27. REMOVE FUEL TANK FILLER PIPE SHIELD 

    Refer to PROCEDURE - Step 4

  28. REMOVE FUEL FILLER OPENING LID SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  29. REMOVE REAR AXLE BEAM ASSEMBLY 

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

  30. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 19

  31. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 20

  32. SEPARATE NO. 3 FLOOR WIRE 

    Refer to PROCEDURE - Step 21

  33. SEPARATE NO. 2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 22

  34. DISCONNECT NO. 1 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 23

  35. REMOVE WIRING HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 24

  36. DISCONNECT HYDROGEN TANK TUBE CLAMP BRACKET 

    Refer to PROCEDURE - Step 30

  37. DISCONNECT HYDROGEN TANK TUBE ASSEMBLY 
    1. Remove the bolt and disconnect 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
  38. DISCONNECT HYDROGEN INLET RECEPTACLE BRACKET SUB-ASSEMBLY 
    1. Disengage the clamp and separate the wire harness clamp from the hydrogen inlet receptacle bracket sub-assembly.
      GTY589440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the hydrogen fuel control transmitter connector.
    3. Remove the 5 bolts and disconnect hydrogen inlet receptacle bracket sub-assembly from the vehicle.
      GTY556341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. 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.
      • SST: 09403-62010 
        1. 09403-06050
        2. 09403-06060
        3. 09403-06090
      GTY543794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Support No. 5)
      *b SST (Support No. 6)
      *c SST (Nut)
    3. Remove the SST (bolts) and each SST (tank belt fixture).
      • SST: 09403-62010 
        1. 09403-06100
        2. 09403-06110
      GTY551571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)
    4. For each tank support type SST, disengage the 2 pins and loosen the 2 SST (bolts).

      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
      • SST: 09403-62010 
        1. 09403-06010
        2. 09403-06020
        3. 09403-06030
        4. 09403-06040
        5. 09403-06080
    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 - -
      • SST: 09403-62010 
      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. While shifting the hydrogen inlet receptacle assembly approximately 25 mm (0.98 in.) to the vehicle inner side, operate the engine lifter and slowly remove the hydrogen tank unit from the vehicle.
      GTY547179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shift
      NOTE:
      • Do not apply excessive force to the high pressure hydrogen piping.
      • 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).
      GTY555912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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.
  40. REMOVE NO. 2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 28

  41. REMOVE NO. 6 HYDROGEN TANK TUBE 
    WARNING:
    • 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.
    GTY584581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a After depressurization procedures, the high pressure piping union nut that is loosened first.
    1. Using a 17 mm union nut wrench, loosen the 2 union nuts and remove the No. 6 hydrogen tank tube from the hydrogen supply regulator assembly and hydrogen tank tube joint.
      NOTE:

      Do not reuse the No. 6 hydrogen tank tube.

      GTY586373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 and hydrogen supply regulator assembly with protective tape.
      GTY539248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      • When replacing the hydrogen supply regulator assembly with a new one, it is not necessary to protect the seal portions and thread portions with protective tape.
      • 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.
  42. SEPARATE HYDROGEN TANK TUBE JOINT SUPPLY BRACKET 
    1. Remove the 2 bolts and separate the hydrogen tank tube joint supply bracket from the front center hydrogen tank frame.
      GTY608224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE HYDROGEN SUPPLY REGULATOR ASSEMBLY 
    1. Remove the 4 bolts.
      GTY550868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lift Upwards
      Remove
    2. While slightly lifting up the hydrogen tank tube joint supply bracket, remove the hydrogen supply regulator assembly from the hydrogen tank frame FR CTR.
      NOTE:

      Do not damage or deform the No. 4 hydrogen tank tube or the No. 5 hydrogen tank tube.

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