LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2019 >> Mirai >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Converters and Controllers >> Fuel Cell (FC) Control System - Service Information >> FC Converter Power Outlet Cable >> Removal [06/2015 - 11/2018] >> Procedure

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

  1. CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS 

    See step  1

  2. REMOVE SERVICE PLUG GRIP (for EV) 

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

  3. REMOVE FC STACK SERVICE PLUG GRIP 

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

  4. REMOVE INVERTER COVER 

    Refer to PROCEDURE - Step 27

  5. REMOVE INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow foreign matter or water droplets to enter the inverter with converter assembly.

    1. Disconnect the 4 connectors.
      GTY555817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to separate the wire harnesses from the inverter terminal cover.
      GTY555820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.
      NOTE:
      • The inverter terminal cover has an interlock connector, so pull it up vertically.
      • Do not touch the rubber seal of the inverter terminal cover.
      GTY541444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
  6. CHECK TERMINAL VOLTAGE 

    See step  20

  7. DISCONNECT FC CONVERTER POWER OUTLET CABLE 
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow foreign matter or water droplets to enter the inverter with converter assembly.

    1. Using an insulated tool, remove the 3 bolts.
      GTY555802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an insulated tool, remove the 2 bolts to disconnect the FC converter power outlet cable from the inverter with converter assembly.
      GTY555801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not touch the rubber seal or terminal portion of the FC converter power outlet cable.
      • Do not touch the rubber seal or terminal portion of the FC converter power outlet cable.
      • Do not scratch or damage the FC converter assembly with the terminal portion of the FC converter power outlet cable.
      • Insulate the terminal portion of the FC converter power outlet cable by wrapping it with insulating tape.
    3. To prevent foreign matter or water droplets from entering the inverter with converter assembly, temporarily install the inverter terminal cover to the inverter with converter assembly with the 11 bolts.
      NOTE:
      • Check that the rubber seal is installed to the inverter terminal cover, and install the inverter terminal cover to the inverter with converter assembly.
      • Do not touch the rubber seal of the inverter terminal cover.
      • Do not install the inverter terminal cover while pressing down on the connector bracket.
      • Securely connect the interlock connector.
      GTY604915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      *2 Connector Bracket
    4. To prevent contamination by foreign matter or water droplets, cover the openings of the inverter with converter assembly with protective tape.
      GTY594657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
  8. REMOVE WINDSHIELD WIPER MOTOR AND LINK 

    Refer to REMOVAL [06/2015 - ]

  9. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 8

  10. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 9

  11. REMOVE COWL BODY MOUNTING REINFORCEMENT RH 

    Refer to PROCEDURE - Step 10

  12. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  13. SEPARATE FC CONVERTER POWER OUTLET CABLE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp to separate the FC converter power outlet cable from the FC cooling water valve bracket.
      GTY555803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 2 MOTOR UNDER COVER 

    Refer to PROCEDURE - Step 1

  15. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 2

  16. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 3

  17. REMOVE SUSPENSION MEMBER TO FRONT CROSSMEMBER BRACE SUB-ASSEMBLY 
    1. Remove the 5 bolts and suspension member to front crossmember brace sub-assembly from the vehicle.
      GTY595497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FC CONVERTER POWER OUTLET CABLE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp to separate the FC converter power outlet cable from the FC converter power outlet bracket.
      GTY555804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to separate the FC converter power outlet cable from the FC stack cooling water outlet bracket.
      GTY555805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and front FC converter service hole cover from the FC converter assembly.
      NOTE:
      • The front FC converter service hole cover has an interlock connector, so pull it down straight.
      • Make sure not to drop the gasket of the front FC converter service hole cover.
      GTY573300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
    4. Using an insulated tool, remove the 2 bolts.
      GTY555812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using an insulated tool, remove the 2 bolts and FC converter power outlet cable from the FC converter assembly.
      NOTE:
      • The FC converter power outlet cable has an interlock connector, so pull it out straight.
      • Do not touch the rubber seal or terminal portion of the FC converter power outlet cable.
      • Do not apply any impacts to the terminal portion of the FC converter power outlet cable.
      • Do not scratch or damage the FC converter assembly with the terminal portion of the FC converter power outlet cable.
      • Insulate the terminal portion of the FC converter power outlet cable by wrapping it with insulating tape.
      GTY603624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
    6. To prevent contamination by foreign matter or water droplets, cover the openings of the FC converter assembly with protective tape.
      GTY588378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
scientia non olet · About LEMON Manuals