Installation [06/2015 - ]: Procedure

INSTALL FC CONVERTER COOLING WATER INLET PIPE
HINT:

This procedure is only performed if the FC stack assembly was replaced with a new one.
1. Engage the 2 clamps to install the FC converter cooling water inlet pipe to the wire harness.

INSTALL NO. 1 FC STACK CAUTION LABEL

HINT:

This procedure is only performed if the FC stack assembly was replaced with a new one.

Install a new No. 1 FC stack caution label to the FC stack assembly in the location indicated in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not allow grease, oil or foreign matter to adhere to the FC stack assembly.
When peeling the No. 1 fuel stack caution label off of the backing paper, do not allow grease, oil or foreign matter to adhere to the adhesive portion of the No. 1 FC stack caution label.
Apply sufficient pressure when attaching the No. 1 FC stack caution label to ensure proper adhesion.
When applying the No. 1 FC stack caution label, be careful to avoid wrinkles or air bubbles.
When the No. 1 FC stack caution label is removed, it will be deformed and lose adhesive strength, so it cannot be reused.
If the area around the No. 1 FC stack caution label is extremely hot, then after applying the label, check for peeling, discoloration, deformation of lettering, dirtiness, etc., and if the visual appearance of the label is poor, replace it with a new No. 1 FC stack caution label.
Apply the No. 1 FC stack caution label in the label application area, and do not apply it onto rounded areas or protrusions.

INSTALL FC STACK ASSEMBLY

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	Front Side of Vehicle
	Attachment installation position

WARNING:

Wear insulated gloves.

Visually inspect the rear frame assembly.
1. Visually inspect the rear frame assembly to make sure there are no scratches or other damage.
  OK
  
  Make sure that there are no cracks, creases or uneven surfaces, and no scratches with depth of 1.0 mm (0.0394 in.) or more, or length of 60.0 mm (2.36 in.) or more.
  
  HINT:
  
  If the result is not as specified, replace the rear frame assembly.
Using the height adjustment attachment, set the rear frame assembly on the engine lifter.
NOTE:
Set so that the rear frame assembly is horizontal and level.

Install an eye bolt in the location shown in the illustration.

HINT:

Eye Bolt Installation Hole Size

Nominal Diameter [mm]	Pitch [mm]	Depth [mm]
M10	1.5	18

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Eye Bolt

Using an engine sling device, set it in the location shown in the illustration, and install the FC stack assembly to the rear frame assembly.

NOTE:

Do not hoist the FC stack assembly from locations other than those shown in the illustration.
Make sure that wire harnesses are not caught when hoisting.
To avoid damaging or deforming the FC stack assembly, be careful of the hoisting angle of the engine sling device.
Set the engine sling device so that the FC stack assembly is horizontal and level.

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Eye Bolt

Remove an eye bolt.
Install the 3 No. 2 FC stack mounts to the FC stack assembly.
Temporarily tighten the 3 bolts.
HINT:

Perform full tightening after installing the FC converter assembly.

INSTALL NO. 1 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY

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Apply TOYOTA Genuine FC Grease to 2 new O-rings.
To prevent contamination by foreign matter or water droplets, remove the plastic bag from the No. 1 hydrogen supply tube sub-assembly immediately before performing the procedure.
Install the 2 O-rings to the No. 1 hydrogen supply tube sub-assembly.
NOTE:
During installation, be careful not to damage the O-rings.

Temporarily install the No. 1 hydrogen supply tube sub-assembly to the rear frame assembly with the bolt A.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the bolt B.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
Fully tighten the bolt A.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
To prevent contamination by foreign matter or water droplets, remove the protective tape from the connecting portion of the FC stack assembly immediately before performing the procedure.
Connect the No. 1 hydrogen supply tube sub-assembly to the FC stack assembly with the bolt.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)

NOTE:
Make sure that the O-rings and engagement portions have no damage or foreign matter.

INSTALL NO. 1 FC EXHAUST PIPE
Refer to PROCEDURE - Step 1

INSTALL FC STACK AIR INLET HOSE

To prevent contamination by foreign matter or water droplets, remove the plastic bags from the connecting portions of the FC stack air inlet hose and FC stack assembly immediately before performing the procedure.

Install the FC stack air inlet hose to the FC stack assembly and tighten the hose clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	View A
*b	Upper Side of Vehicle
*c	RH Side of Vehicle
*d	Area of threaded portion of hose clamp: 90°
*e	Locations of hose tip and hose clamp
*f	Paint Mark (Yellow)
*g	Matchmark
*h	Distance between hose tip and hose clamp location: 2.0 to 5.0 mm (0.0787 to 0.197 in.)
*i	Distance between hose tip and FC stack assembly location: 0 to 2.0 mm (0 to 0.0787 in.)

Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)

NOTE:

Perform the installation with the hose and hose clamp at the correct angle.

INSTALL FC STACK COOLING WATER OUTLET HOSE

To prevent contamination by foreign matter, remove the plastic bags from the connecting portions of the FC stack cooling water outlet hose and FC stack assembly immediately before performing the procedure.

Install the FC stack cooling water outlet hose to the FC stack assembly and slide the hose clip to secure it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	View A
*b	Upper Side of Vehicle
*c	RH Side of Vehicle
*d	Area of claw of hose clip: 45°
*e	Locations of hose tip and hose clip
*f	Paint Mark (White)
*g	Matchmark
*h	Distance between hose tip and hose clip location: 2.0 to 5.0 mm (0.0787 to 0.197 in.)
*i	Distance between hose tip and FC stack assembly location: 0 to 2.0 mm (0 to 0.0787 in.)

NOTE:

Perform the installation with the hose and hose clip at the correct angle.

HINT:

When connecting, if it is difficult to insert the FC stack cooling water outlet hose, coat it with new coolant (Toyota genuine FC stack coolant (Pre-mixed))

INSTALL FC CONVERTER ASSEMBLY

WARNING:

Wear insulated gloves.

To prevent contamination by foreign matter or water droplets, remove the protective tape from the opening of the FC converter assembly immediately before performing the procedure.
Install a new rear FC converter gasket to the FC converter assembly.
NOTE:
- Do not allow foreign matter to adhere to the surface of the rear FC converter gasket.
- Perform the procedures by hand. Do not use any tools.
- Securely press the rear FC converter gasket into the groove of the FC converter assembly to install it.
To prevent contamination by foreign matter or water droplets, remove the protective tape from the opening of the FC stack assembly immediately before performing the procedure.

To avoid damaging the No. 1 FC stack caution label, protect the No. 1 FC stack caution label using protective tape or similar.

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*a	Protective Tape

HINT:

This procedure is only performed if the FC stack assembly was replaced with a new one. (When the FC stack assembly is not replaced, it is performed during the FC stack assembly removal procedure.)

Using the rough guide, align the FC converter assembly with the installation position, lower the FC converter assembly vertically and securely engage the assembly guide pin.

NOTE:

Do not hold the FC converter assembly by its pipe portion.
Be careful not to drop the rear FC converter gasket.
Be careful that foreign matter or water droplets do not enter the FC stack assembly and FC converter assembly.
If the FC converter assembly has been dropped, damaged or subjected to a strong impact, replace it with a new one.

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*a	Rough Guide
*b	Assembly Guide Pin
	Lower Vertically

Install the 6 bolts in the order shown in the illustration.

Fig 1: FC Converter Assembly Bolts Tightening Sequence
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Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf)
Remove the protective tape or similar from the No. 1 FC stack caution label.
Install the 2 No. 2 FC stack mounts to the FC converter assembly.
Install the 2 bolts.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
To prevent contamination by foreign matter or water droplets, remove the protective tape from the opening of the FC converter assembly immediately before performing the procedure.
Using an insulated tool, install the 2 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Install a new rear FC converter service hole gasket to the rear FC converter service hole cover.
NOTE:
- Do not allow foreign matter to adhere to the rear FC converter service hole gasket.
- Perform the procedures by hand. Do not use any tools.
- Securely press the rear FC converter service hole gasket into the groove of the rear FC converter service hole cover to install it.
Install the rear FC converter service hole cover to the FC converter assembly with the 2 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
NOTE:
- Be careful that foreign matter or water droplets do not enter the FC converter assembly.
- Be careful not to drop the rear FC converter service hole gasket.

Fully tighten the 3 bolts.

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Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)

INSTALL FC STACK COOLING WATER INLET HOSE

To prevent contamination by foreign matter, remove the plastic bags from the connecting portions of the FC stack cooling water inlet hose and FC stack assembly immediately before performing the procedure.

Install the FC stack cooling water inlet hose to the FC stack assembly and slide the hose clip to secure it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	View A
*b	Upper Side of Vehicle
*c	RH Side of Vehicle
*d	Area of claw of hose clip: 45°
*e	Locations of hose tip and hose clip
*f	Paint Mark (Yellow)
*g	Matchmark
*h	Distance between hose tip and hose clip location: 2.0 to 5.0 mm (0.0787 to 0.197 in.)
*i	Distance between hose tip and FC stack assembly location: 0 to 2.0 mm (0 to 0.0787 in.)

NOTE:

Perform the installation with the hose and hose clip at the correct angle.

HINT:

When connecting, if it is difficult to insert the FC stack cooling water inlet hose, coat it with new coolant (Toyota genuine FC stack coolant (Pre-mixed))

CONNECT FC STACK COOLING WATER INLET PIPE
1. Connect the FC stack cooling water inlet pipe to the FC converter assembly with the 2 bolts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the wire harness clamp bracket to the FC stack assembly with the bolt.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
2. Engage the 3 clamps to install the 3 wire harness clamp brackets to the wire harness.

CONNECT WIRE HARNESS

WARNING:

Wear insulated gloves.

Engage the 2 clamps to connect the wire harness to the wire harness clamp bracket.
To prevent contamination by foreign matter, remove the plastic bags from the connecting portions of the FC converter cooling water inlet hose and FC converter assembly immediately before performing the procedure.

Connect the FC converter cooling water inlet hose to the FC converter assembly and slide the hose clip to secure it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	View A
*b	Upper Side of Vehicle
*c	Front Side of Vehicle
*d	Area of claw of hose clip: 45°
*e	Locations of hose tip and hose clip
*f	Paint Mark (Yellow)
*g	Matchmark
*h	Distance between hose tip and hose clip location: 2.0 to 5.0 mm (0.0787 to 0.197 in.)
*i	Distance between hose tip and FC converter assembly location: 0 to 2.0 mm (0 to 0.0787 in.)

NOTE:

Perform the installation with the hose and hose clip at the correct angle.

Install the wire harness clamp bracket to the FC converter assembly with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Connect the FC converter cooling water inlet pipe, together with the wire harness, to the FC converter assembly with the 2 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Connect the connector.

Engage the 7 clamps to connect the wire harness to the wire harness clamp bracket.

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Install the 3 wire harness clamp brackets to the FC converter assembly and FC stack assembly with the 3 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Engage the 7 clamps to connect the wire harness and connector to the FC converter assembly and FC stack assembly.

INSTALL REAR FRAME ASSEMBLY

Check that the FC stack with FC converter assembly, together with the rear frame assembly, are set level and horizontal on an engine lifter.

Operate the engine lifter, and with the 14 bolts, install the rear frame assembly, together with the FC stack with FC converter assembly, to the vehicle.

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Bolt A

Torque: 82 N*m (836 kgf*cm, 60 ft.*lbf)

Bolt B

Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf)

NOTE:

To prevent them from falling over, securely support the FC stack with FC converter assembly together with the rear frame assembly.
Be careful of the wire harnesses and hoses when installing.

Bolt Length

Item	Length
Bolt A	79 mm (3.11 in.)
Bolt B	39 mm (1.54 in.)

INSTALL FRAME REAR CROSSMEMBER EXTENSION RH

Install the frame rear crossmember extension RH to the vehicle with the 10 bolts.

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Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)

Bolt Length

Item	Length
Bolt A	50 mm (1.97 in.)
Bolt B	28 mm (1.18 in.)

INSTALL FRAME REAR CROSSMEMBER EXTENSION LH

Install the frame rear crossmember extension LH to the vehicle with the 10 bolts.

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Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)

NOTE:

Be careful of the brake tube when installing.

Bolt Length

Item	Length
Bolt A	50 mm (1.97 in.)
Bolt B	28 mm (1.18 in.)

CONNECT NO. 1 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY
Refer to PROCEDURE - Step 32 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 32 [11/2018 - ]
CONNECT NO. 2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY
Refer to PROCEDURE - Step 33 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 33 [11/2018 - ]
CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY
1. Connect the No. 3 parking brake cable assembly to the vehicle with the bolt.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)

INSTALL NO. 2 FC EXHAUST PIPE

To prevent contamination by foreign matter, remove the plastic bag from the connecting portion of the No. 1 FC exhaust pipe immediately before performing the procedure.

Connect the No. 2 FC exhaust pipe to the No. 1 FC exhaust pipe.

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*a	No. 2 FC Exhaust Pipe Triangle Mark
*b	No. 1 FC Exhaust Pipe Groove

NOTE:

Make sure not to scratch or damage the No. 1 FC exhaust pipe and No. 2 FC exhaust pipe.
Check that the rubber portion of the No. 1 FC exhaust pipe connecting portion (No. 2 FC exhaust pipe connecting side) is not folded to the inside, is securely assembled, and covers the entire circumference.

HINT:

As shown in the illustration, align the triangle mark of the No. 2 FC exhaust pipe with the position of the groove of the No. 1 FC exhaust pipe.

Connect the No. 2 FC exhaust pipe to the No. 3 FC exhaust pipe.

NOTE:

Make sure not to scratch or damage the No. 2 FC exhaust pipe and No. 3 FC exhaust pipe.
Check that the rubber portion of the No. 2 FC exhaust pipe connecting portion (No. 3 FC exhaust pipe connecting side) is not folded to the inside, is securely assembled, and covers the entire circumference.

HINT:

As shown in the illustration, align the triangle mark of the No. 3 FC exhaust pipe with the position of the groove of the No. 2 FC exhaust pipe.

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*a	No. 3 FC Exhaust Pipe Triangle Mark
*b	No. 2 FC Exhaust Pipe Groove

Temporarily install the No. 2 FC exhaust pipe to the vehicle body with the 2 bolts.

Fig 2: No. 2 FC Exhaust Pipe To Vehicle Body Bolts Tightening Sequence

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*a	View A
*b	View B
*c	Upper Side of Vehicle
*d	Right Side of Vehicle
*e	Front Side of Vehicle
*f	Clamp bolt must be within this range (90°)
*g	Clamp bolt flange surface must be within this range (10°)
*h	No. 2 FC Exhaust Pipe Groove
*i	No. 1 FC Exhaust Pipe Protrusion

Fully tighten the 2 bolts in the order shown in the illustration.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
Tighten the 2 clamps.
Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf)
NOTE:
- If the clamp is damaged or rusty, replace it with a new one.
- Align the clamp with the position shown in the illustration, and install the clamp.
Try to move the clamp by hand and confirm that it does not rotate.

CONNECT FC STACK COOLING WATER OUTLET PIPE

Connect the FC stack cooling water outlet pipe to the vehicle with the bolt.

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Detent

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

NOTE:

After installing, check that the detent of the FC stack cooling water outlet pipe is contacting the vehicle body.

CONNECT FC STACK AIR INLET HOSE

To prevent contamination by foreign matter or water droplets, remove the plastic bags from the connecting portions of the FC stack air inlet hose and No. 2 FC air compressor outlet pipe immediately before performing the procedure.

Connect the FC stack air inlet hose to the No. 2 FC air compressor outlet pipe and tighten the hose clamp.

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*a	View A
*b	Upper Side of Vehicle
*c	LH Side of Vehicle
*d	Area of threaded portion of hose clamp: 45°
*e	Locations of hose tip and hose clamp
*f	Paint Mark (White)
*g	Distance between hose tip and hose clamp location: 2.0 to 5.0 mm (0.0787 to 0.197 in.)

Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)

NOTE:

Perform the installation with the hose and hose clamp at the correct angle.

CONNECT WIRE HARNESS

WARNING:

Wear insulated gloves.

Engage the clamp to connect the wire harness to the wire harness clamp bracket.

Connect the 5 connectors.

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NOTE:

Do not touch the connector terminals.
Because there are multiple connectors, make sure to connect them to their original locations.

HINT

Connector	Connector Color	Connector Pin Count
A	Black	13P
B	Gray	6P
C	Black	10P
D	Gray	13P
E	Gray	8P

Connect the connector and press in the green lock to securely fix the connector in place as shown in the illustration.

NOTE:

Do not touch the connector terminals.
Check that the connector is securely connected.

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*1	Green-colored Lock

CONNECT NO. 2 EV WATER HOSE CONNECTOR

To prevent contamination by foreign matter, remove the plastic bags from the connecting portions of the No. 2 EV water hose connector and FC converter assembly immediately before performing the procedure.

Connect the No. 2 EV water hose connector together with the FC converter cooling water outlet hose.

NOTE:

If the 2 O-rings on the inner side of the No. 2 EV water hose connector are damaged or falling out, replace the No. 2 EV water hose connector with a new one.

Align the No. 2 EV water hose connector with the connecting portion of the FC converter assembly, and press it in as a single unit.

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Insert Slowly

NOTE:

Securely insert the No. 2 EV water hose connector all the way into the connecting portion of the FC converter assembly.

Push up the retainer of the No. 2 EV water hose connector and lock it.

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*1	Retainer
	Push Up

HINT:

The retainer of the No. 2 EV water hose connector is designed so that it cannot be locked unless the No. 2 EV water hose connector is securely inserted into the FC converter assembly.

Pull on the No. 2 EV water hose connector and check that it is securely connected.

CONNECT NO. 2 INVERTER COOLING OUTLET HOSE

To prevent contamination by foreign matter, remove the plastic bags from the connecting portions of the No. 2 inverter cooling outlet hose and FC converter cooling water inlet pipe immediately before performing the procedure.

Connect the No. 2 inverter cooling outlet hose to the FC converter cooling water inlet pipe and slide the hose clip to secure it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	View A
*b	Lower Side of Vehicle
*c	RH Side of Vehicle
*d	Area of claw of hose clip: 45°
*e	Locations of hose tip and hose clip
*f	Paint Mark (Yellow)
*g	Distance between hose tip and hose clip location: 2.0 to 5.0 mm (0.0787 to 0.197 in.)

NOTE:

Perform the installation with the hose and hose clip at the correct angle.

CONNECT FC CONVERTER POWER OUTLET CABLE

WARNING:

Wear insulated gloves.

To prevent contamination by foreign matter or water droplets, remove the protective tape from the openings of the FC converter assembly immediately before performing the procedure.

Connect the FC converter power outlet cable to the FC converter assembly.

NOTE:

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.
Securely connect the interlock connector.
Check that the terminal of the FC converter power outlet cable can be seen from the installation area of the front FC converter service hole cover.

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*1	Interlock Connector
*a	Terminal Portion

Using an insulated tool, install the 2 bolts.

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Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Using an insulated tool, install the 2 bolts.

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Install the front FC converter service hole cover to the FC converter assembly with the 2 bolts.

*1	Interlock Connector

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

NOTE:

Do not allow foreign matter to adhere to the surface of the gasket of the front FC converter service hole cover.
Securely connect the interlock connector.
Make sure not to drop the gasket of the front FC converter service hole cover.

INSTALL INVERTER COVER
Refer to PROCEDURE - Step 62

CONNECT WIRE HARNESS

Connect the wire harness to the vehicle with the bolt.

Detent

Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)

NOTE:

Install with the wire harness detent contacting as shown in the illustration.

INSTALL FC STACK SERVICE PLUG GRIP
Refer to INSTALLATION [06/2015 - 11/2018] , or refer to INSTALLATION [11/2018 - ]
INSTALL SERVICE PLUG GRIP (for EV)
Refer to INSTALLATION [06/2015 - 11/2018] , or refer to INSTALLATION [11/2018 - ]

CHECK FOR HYDROGEN GAS LEAK

Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 1 hydrogen tank assembly manual valve.

*a	Adjustment Bolt
*b	Manual Valve Closed
*c	Manual Valve Open
*d	Counterclockwise

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 is damaged, it will be impossible to operate the adjustment bolt.
Do not rotate the adjustment bolt more than 4 rotations.
Rotating the adjustment bolt more than 4 rotations could damage the manual valve.
If the manual valve is damaged, it will be necessary to replace the No. 1 hydrogen tank assembly.

HINT:

When the manual valve is opened, the protrusion of the adjustment bolt is 3.5 mm (0.138 in.) or less.

*a	Adjustment Bolt
*b	Protrusion

Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 2 hydrogen tank assembly manual valve.

*a	Adjustment Bolt
*b	Manual Valve Closed
*c	Manual Valve Open
*d	Counterclockwise

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 is damaged, it will be impossible to operate the adjustment bolt.
Do not rotate the adjustment bolt more than 4 rotations.
Rotating the adjustment bolt more than 4 rotations could damage the manual valve.
If the manual valve is damaged, it will be necessary to replace the No. 2 hydrogen tank assembly.

HINT:

When the manual valve is opened, the protrusion of the adjustment bolt is 3.5 mm (0.138 in.) or less.

*a	Adjustment Bolt
*b	Protrusion

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.
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.

HINT:

This is done to fill the hydrogen piping with hydrogen gas.
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.

Blow compressed air around the underside of the vehicle.

HINT:

To enable accurate detection of hydrogen gas leaks from the piping, blow compressed air from the front of the vehicle towards the rear.

If there are water droplets, etc. adhering to any of the measurement locations, wipe them away before performing the procedures.
NOTE:
If measurements are performed while water droplets, etc. are adhered, the hydrogen gas detector may be damaged.

Using SST and a hydrogen gas detector, measure each of the measurement locations for approximately 10 continuous seconds per location.

SST: 09401-62010

NOTE:

To perform the measurement, hold the tip of the hydrogen gas detector as shown in the illustration (*c), in contact with a single location from any one of the directions shown.

*a	Hydrogen Gas Detector
*b	Side View
*c	Cutaway View

Hold the tip in light contact with the location so that the tip does not deform.

HINT:

Immediately after the measurement starts, the measured value may be unstable.
If the value is outside the specified range, replace the leaking component with a new one, and perform the hydrogen gas leak check again.

Measurement Location and Direction

Illustration Item	Measurement Location	Measurement Method	Specified Value
A	Connection between FC Stack Assembly and No. 1 Hydrogen Supply Tube Sub-assembly	Measure the area near the piping, connecting portion, or sensor connecting portion.	300 ppm or less
B	Connection between No. 1 Hydrogen Supply Tube Sub-assembly and No. 2 Hydrogen Supply Tube Sub-assembly
C	Medium Pressure Port of Hydrogen Supply Regulator Assembly *1

*1: If the value is not as specified, replace the O-ring of the medium pressure port.

CONNECT NO. 2 FC COOLING WATER PUMP OUTLET HOSE

Connect the No. 2 FC cooling water pump outlet hose (with FC water hose connector).

Remove the plastic bags that are protecting the connecting portions of the No. 2 FC cooling water pump outlet hose (with FC water hose connector) and FC stack cooling water inlet pipe.

Line up the No. 2 FC cooling water pump outlet hose (with FC water hose connector) and FC stack cooling water inlet pipe in a row, and push them in as a single unit.

*a	No Identification Markings
	Slowly Insert

NOTE:

The No. 2 FC cooling water pump outlet hose (with FC water hose connector) and FC stack cooling water inlet pipe do not have identification markings.
If the O-ring on the inner side of the FC water hose connector is damaged or falls out, replace the FC water hose connector with a new one.
Do not rotate or tilt the No. 2 FC cooling water pump outlet hose (with FC water hose connector) when pushing it in.
Securely and fully insert the No. 2 FC cooling water pump outlet hose (with FC water hose connector) all the way into the FC stack cooling water inlet pipe.

Push up the retainer of the FC water hose connector and lock it.

Push Up

HINT:

The retainer of the FC water hose connector is designed so that it cannot be locked if the No. 2 FC cooling water pump outlet hose (with FC water hose connector) is not securely inserted into the FC stack cooling water inlet pipe.

After connecting the No. 2 FC cooling water pump outlet hose (with FC water hose connector), firmly pull on the FC water hose connector and FC stack cooling water inlet pipe to check that they are securely connected.

CONNECT NO. 2 FC COOLING WATER VALVE INLET HOSE

Connect the No. 2 FC cooling water valve inlet hose (with FC water hose connector).

Remove the plastic bags that are protecting the connecting portions of the No. 2 FC cooling water pump inlet hose (with FC water hose connector) and FC stack cooling water outlet pipe.

Line up the No. 2 FC cooling water valve inlet hose (with FC water hose connector) and FC stack cooling water outlet pipe in a row, and push them in as a single unit.

*a	Identification Markings (White)
	Slowly Insert

NOTE:

Align the white identification markings of the No. 2 FC cooling water valve inlet hose (with FC water hose connector) and the FC stack cooling water outlet pipe.
If the O-ring on the inner side of the FC water hose connector is damaged or falls out, replace the FC water hose connector with a new one.
Do not rotate or tilt the No. 2 FC cooling water pump outlet hose (with FC water hose connector) when pushing it in.
Securely and fully insert the No. 2 FC cooling water pump inlet hose (with FC water hose connector) all the way into the FC stack cooling water outlet pipe.

Push up the retainer of the FC water hose connector and lock it.

Push Up

HINT:

The retainer of the FC water hose connector is designed so that it cannot be locked if the No. 2 FC cooling water pump inlet hose (with FC water hose connector) is not securely inserted into the FC stack cooling water outlet pipe.

After connecting the No. 2 FC cooling water pump inlet hose (with FC water hose connector), firmly pull on the FC water hose connector and FC stack cooling water outlet pipe to check that they are securely connected.

ADD COOLANT (for Inverter)
Refer to PROCEDURE - Step 4
ADD COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed))
Refer to PROCEDURE - Step 8
INSPECT FOR COOLANT LEAK (for Inverter)
Refer to PROCEDURE - Step 1
INSPECT FOR COOLANT (FC STACK COOLANT)
Refer to PROCEDURE - Step 2
INSTALL NO. 1 FLOOR UNDER COVER
Refer to PROCEDURE - Step 6
INSTALL NO. 2 FLOOR UNDER COVER
Refer to PROCEDURE - Step 7
INSTALL FRONT FLOOR CENTER COVER RH
Refer to PROCEDURE - Step 8
INSTALL FRONT FLOOR CENTER COVER LH
Refer to PROCEDURE - Step 9
INSTALL SUSPENSION MEMBER TO FRONT CROSSMEMBER BRACE SUB-ASSEMBLY
See step 2
INSTALL FRONT FLOOR COVER RH
Refer to PROCEDURE - Step 10
INSTALL FRONT FLOOR COVER LH
Refer to PROCEDURE - Step 11
INSTALL NO. 2 MOTOR UNDER COVER
Refer to PROCEDURE - Step 12
INSTALL NO. 3 RADIATOR AIR GUIDE
Refer to PROCEDURE - Step 5
INSTALL FRONT BUMPER LOWER ABSORBER
Refer to PROCEDURE - Step 38 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 38 [11/2018 - ]
INITIALIZATION
1. Perform the following procedures after replacing the FC stack assembly.
  1. Using the Techstream, perform the utility "FC Stack Shock History Clear".
    Refer to UTILITY [06/2015 - ]