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Home >> Toyota >> 2019 >> Mirai >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Converters and Controllers >> Fuel Cell (FC) Control System - Service Information >> FC Inverter Input Junction Assembly >> Removal [06/2015 - 11/2018] >> Procedure

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

  1. CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS 

    See step  1

  2. CAUTIONS FOR INTAKE SYSTEM COMPONENTS 

    Refer to PROCEDURE - Step 3

  3. REMOVE SERVICE PLUG GRIP (for EV) 

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

  4. REMOVE FC STACK SERVICE PLUG GRIP 

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

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK 

    Refer to REMOVAL [06/2015 - ]

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

    Refer to PROCEDURE - Step 8

  7. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 9

  8. REMOVE COWL BODY MOUNTING REINFORCEMENT RH 

    Refer to PROCEDURE - Step 10

  9. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  10. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 1

  11. REMOVE AIR CLEANER INLET 

    Refer to PROCEDURE - Step 24

  12. REMOVE AIR CLEANER WITH ELEMENT ASSEMBLY 

    Refer to PROCEDURE - Step 25

  13. REMOVE AIR CLEANER SUPPORT 
    1. Remove the air cleaner support from the FC inverter input junction assembly.
      GTY559244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE INVERTER COVER 

    Refer to PROCEDURE - Step 27

  15. REMOVE INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 17

  16. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 18

  17. TEMPORARILY TIGHTEN INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 19

  18. SEPARATE FC WATER PUMP DRAIN HOSE ASSEMBLY 
    1. Remove the bolt and FC water pump drain hose assembly from the FC inverter input junction assembly.
      GTY598921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FC INVERTER INPUT JUNCTION COVER 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the FC inverter input junction cover connector.
      GTY544953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to separate the wire harness from the FC inverter input junction cover.
    3. Remove the 2 bolts and FC inverter input junction cover from the FC inverter input junction assembly.
      GTY589153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      NOTE:
      • Because the FC inverter input junction cover has an interlock connector, pull it straight out.
      • Do not touch the rubber seal of the FC inverter input junction cover.
  20. DISCONNECT FRAME WIRE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 4 bolts and disconnect the frame wire from the FC inverter input junction assembly.
      GTY599979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      NOTE:
      • Because the frame wire has an interlock connector, pull it out straight.
      • When disconnecting, do not damage the terminal portion, connector housing, or FC inverter input junction assembly.
      • Do not touch the rubber seal or terminal portion of the frame wire.
      • Insulate the terminal portion of the frame wire by wrapping it with insulating tape.
    2. To prevent contamination by foreign matter or water droplets, cover the openings of the FC inverter input junction assembly with protective tape.
      GTY590905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
  21. REMOVE INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 17

  22. REMOVE FC INVERTER INPUT JUNCTION ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Disengage the clamp to separate the wire harness from the FC inverter input junction assembly.
      GTY540950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Green-colored Lock
    2. Pull out the green lock of the connector and disconnect the connector from the FC water and hydrogen pump inverter assembly as shown in the illustration.
      NOTE:
      • Do not touch the connector terminals.
      • Insulate the opening of the connector by wrapping it with insulating tape.
    3. Pull out the green lock of the connector and disconnect the connector from the electric heater sub-assembly as shown in the illustration.
      GTY602651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Green-colored Lock
      NOTE:
      • Do not touch the connector terminals.
      • Insulate the opening of the connector by wrapping it with insulating tape.
    4. Using an insulated tool, remove the 5 bolts and FC inverter input junction assembly from the inverter with converter assembly.
      GTY563590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      NOTE:
      • Because the FC inverter input junction assembly has an interlock connector, pull it straight out.
      • When removing, do not damage the terminal portion, connector housing or inverter with converter assembly.
      • Do not touch the seal packing or terminal portion of the FC inverter input junction assembly.
      • If the seal packing of the FC inverter input junction assembly has any damage or deformation, replace it with a new one.
      • Insulate the terminal portion of the FC inverter input junction assembly by wrapping it with insulating tape.
    5. To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.
      GTY577412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
  23. TEMPORARILY TIGHTEN INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 19

  24. REMOVE PACKING SEAL 

    HINT: 

    Perform this procedure when the packing seal must be replaced.

    1. Remove the packing seal from the FC inverter input junction assembly.
      GTY602109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE HIGH VOLTAGE FUSE 
    NOTE:

    Do not allow foreign matter or water droplets to enter the FC inverter input junction assembly.

    HINT: 

    Perform this procedure when the high voltage fuse must be replaced.

    1. Remove the 9 bolts.
      GTY544957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped in protective tape, pry the 2 locations shown in the illustration and remove the junction block service cover from the FC inverter input junction assembly.
      NOTE:
      • Do not scratch or damage the sealing surface between the junction block service cover and FC inverter input junction assembly.
      • If the junction block service cover has any deformation, replace it with a new one.
      GTY595426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Remove the 4 nuts and 2 high voltage fuses from the FC inverter input junction assembly.
      GTY598918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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