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

CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS
NOTE:
- Do not allow foreign matter to enter the opening of the connector.
- Do not touch the connector terminals.
- Do not turn the power switch on (READY) before filling the coolant (for inverter).
- When turning power switch on (IG), do not also turn the power switch on (READY).
- Do not attempt to repair the connector terminal or the threads of the aluminum case.
- Be careful not to drop parts, damage parts with tools, or allow interference or impacts with surrounding components.
- Do not apply excessive force to the wire harnesses.
- Do not apply oil or grease to the bolts.
CAUTIONS FOR COMPRESSED HYDROGEN GAS
Refer to PRECAUTION [06/2015 - ]
CAUTIONS FOR COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed))
Refer to PROCEDURE - Step 1
REMOVE FRONT BUMPER LOWER ABSORBER
Refer to PROCEDURE - Step 7
REMOVE NO. 3 RADIATOR AIR GUIDE
Refer to PROCEDURE - Step 9
REMOVE NO. 2 MOTOR UNDER COVER
Refer to PROCEDURE - Step 1
REMOVE FRONT FLOOR COVER LH
Refer to PROCEDURE - Step 2
REMOVE FRONT FLOOR COVER RH
Refer to PROCEDURE - Step 3
REMOVE SUSPENSION MEMBER TO FRONT CROSSMEMBER BRACE SUB-ASSEMBLY
See step 17
REMOVE FRONT FLOOR CENTER COVER LH
Refer to PROCEDURE - Step 4
REMOVE FRONT FLOOR CENTER COVER RH
Refer to PROCEDURE - Step 5
REMOVE NO. 2 FLOOR UNDER COVER
Refer to PROCEDURE - Step 6
REMOVE NO. 1 FLOOR UNDER COVER
Refer to PROCEDURE - Step 7

PRESSURE RELEASE OPERATION

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)

Courtesy 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.

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)

Courtesy 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.

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.

Perform the depressurization procedure.

Make sure that the manual valves of the No. 1 hydrogen tank assembly and No. 2 hydrogen tank assembly are closed.

Apply paint marks to the hydrogen supply regulator union and the body of the hydrogen supply regulator assembly as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Hydrogen Supply Regulator Union
*a	Body
*b	Paint Mark

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.

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.

Courtesy 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Manual Valve Open

When performing depressurization, do not perform procedures by hand without wearing protective glasses and gloves.

Courtesy 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.

Blow compressed air around the underside of the vehicle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

Remove the O-ring from the hydrogen supply regulator union.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protective Tape

Check that the hydrogen supply regulator union has not been loosened.

Courtesy 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.

Procedures for when the hydrogen supply regulator union has been loosened:

Remove the hydrogen supply regulator union.

Courtesy 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.

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protective Tape

Remove the O-ring from the hydrogen supply regulator union.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

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

Clean and degrease the threaded portion of the hydrogen supply regulator union.

To prevent the O-ring from being damaged during installation, apply protective tape as shown in the illustration.

Courtesy 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.

Coat a new O-ring with TOYOTA Genuine FC Grease.

Install the O-ring to the hydrogen supply regulator union.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Make sure not to damage the O-ring.
Make sure the O-ring is not twisted.

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.

Coat the O-ring and the threaded portion of the hydrogen supply regulator union with TOYOTA Genuine FC Grease.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
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.

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.

Apply TOYOTA Genuine FC Grease to a new O-ring and to the threaded portion of the hydrogen supply regulator union.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the O-ring to the hydrogen supply regulator union.
NOTE:
During installation, make sure not to damage the O-ring.

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

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE SERVICE PLUG GRIP (for EV)
Refer to REMOVAL [06/2015 - 11/2018]
REMOVE FC STACK SERVICE PLUG GRIP
Refer to REMOVAL [06/2015 - 11/2018]

SEPARATE WIRE HARNESS

Remove the bolt to separate the wire harness from the vehicle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE INVERTER COVER
Refer to PROCEDURE - Step 27
REMOVE INVERTER TERMINAL COVER
See step 5

CHECK TERMINAL VOLTAGE

WARNING:

Wear insulated gloves.

NOTE:

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

Using a voltmeter, measure the voltage between the 2 terminals.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Voltage

0 V

HINT:

Use a measuring range of DC 750 V or more on the voltmeter.

INSTALL INVERTER TERMINAL COVER

WARNING:

Wear insulated gloves.

NOTE:

To prevent foreign matter or water droplets from entering the inverter with converter assembly, install the inverter terminal cover after "CHECK TERMINAL VOLTAGE".

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.

Fig 1: Inverter Terminal Cover Bolts Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Interlock Connector
*2	Connector Bracket

Tighten the 11 bolts in the order shown in the illustration.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Engage the 2 clamps to connect the wire harness to the inverter terminal cover.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Connect the 4 connectors.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DRAIN COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed))
Refer to PROCEDURE - Step 7
DRAIN COOLANT (for Inverter)
Refer to PROCEDURE - Step 3

DISCONNECT FC CONVERTER POWER OUTLET CABLE

WARNING:

Wear insulated gloves.

Remove the 2 bolts and front FC converter service hole cover from the FC converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Interlock Connector

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.

Using an insulated tool, remove the 2 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an insulated tool, remove the 2 bolts and disconnect 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Interlock Connector

To prevent contamination by foreign matter or water droplets, cover the openings of the FC converter assembly with protective tape.

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*a	Protective Tape

DISCONNECT NO. 2 INVERTER COOLING OUTLET HOSE

Slide the hose clip and disconnect the No. 2 inverter cooling outlet hose from the FC converter cooling water inlet pipe.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Disconnect slowly to prevent coolant (for inverter) from splattering.

To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter cooling outlet hose and FC converter cooling water inlet pipe with plastic bags.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plastic Bag

DISCONNECT NO. 2 EV WATER HOSE CONNECTOR

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Retainer
*a	Protective Tape
	Press Down

Disconnect the No. 2 EV water hose connector.

NOTE:

Before disconnecting the No. 2 EV water hose connector, check that there is no mud or other contaminant on the connecting portions of the No. 2 EV water hose connector and FC converter assembly, and clean away any contaminants.

Using a screwdriver with its tip wrapped in protective tape, press down the retainer of the No. 2 EV water hose connector to release the lock.

Disconnect the No. 2 EV water hose connector, together with the FC converter cooling water outlet hose, from the FC converter assembly.

NOTE:

Perform the procedures by hand. Do not use any tools.
Do not forcefully bend, fold, or twist the No. 2 EV water hose connector and FC converter cooling water outlet hose.
Disconnect slowly to prevent coolant (for inverter) from splattering.
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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect Slowly

After disconnecting the No. 2 EV water hose connector, check that there is no mud or other contaminant on the connecting portions of the FC converter assembly, and clean away any contaminants.

To prevent contamination by foreign matter, cover the connecting portions of the No. 2 EV water hose connector and FC converter assembly with plastic bags.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plastic Bag

SEPARATE WIRE HARNESS

WARNING:

Wear insulated gloves.

Pull out the green lock of the connector and disengage the connector as shown in the illustration.

NOTE:

Do not touch the connector terminals.
Insulate the opening of the connector by wrapping it with insulating tape.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Green-colored Lock

Disconnect the 5 connectors.

NOTE:

Do not touch the connector terminals.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disengage the clamp to separate the wire harness from the wire harness clamp bracket.

NOTE:

When disengaging the clamp, be careful not to damage the clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT FC STACK AIR INLET HOSE

Loosen the hose clamp and disconnect the FC stack air inlet hose from the No. 2 FC air compressor outlet pipe.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

To prevent contamination by foreign matter or water droplets, cover the connecting portions of the FC stack air inlet hose and No. 2 FC air compressor outlet pipe with plastic bags.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plastic Bag

SEPARATE FC STACK COOLING WATER OUTLET PIPE

Remove the bolt and separate the FC stack cooling water outlet pipe from the vehicle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE NO. 2 FC EXHAUST PIPE

Loosen the 2 clamps.

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Remove the 2 bolts and No. 2 FC exhaust pipe from the No. 1 FC exhaust pipe, No. 3 FC exhaust pipe and vehicle body.

WARNING:

If the water remaining inside the No. 2 FC exhaust pipe is hot, do not touch the water directly.
Touching the water remaining inside the No. 2 FC exhaust pipe when it is hot could result in burns.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

If there are any scratches or other damage on the inner surface or insertion portions of the No. 2 FC exhaust pipe, or on the insertion portions of the No. 1 FC exhaust pipe or No. 3 FC exhaust pipe, replace the damaged part with a new one.
If the clamp is damaged or rusty, replace it with a new one.

To prevent contamination by foreign matter, cover the connecting portion of the No. 1 FC exhaust pipe with a plastic bag.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plastic Bag

SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY

Remove the bolt to separate the No. 3 parking brake cable assembly from the vehicle.

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SEPARATE NO. 2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY
Refer to PROCEDURE - Step 22
DISCONNECT NO. 1 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY
Refer to PROCEDURE - Step 23

REMOVE FRAME REAR CROSSMEMBER EXTENSION LH

Remove the 10 bolts and frame rear crossmember extension LH from the vehicle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Be careful of the brake tube when removing.

REMOVE FRAME REAR CROSSMEMBER EXTENSION RH

Remove the 10 bolts and frame rear crossmember extension RH from the vehicle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE REAR FRAME ASSEMBLY

Using a height adjustment attachment, set the engine lifter, together with the FC stack with FC converter assembly, to the rear frame assembly.

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	Front Side of Vehicle
	Attachment installation position

NOTE:

Set so that the rear frame assembly is horizontal and level.

Remove the 14 bolts, and remove the rear frame assembly, together with the FC stack with FC converter assembly, from the vehicle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Be careful of the wire harnesses and hoses when removing.

SEPARATE WIRE HARNESS

WARNING:

Wear insulated gloves.

Disengage the 7 clamps to separate the wire harness and connector from the FC converter assembly and FC stack assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

When disengaging the clamps, be careful not to damage the clamps.

Remove the 3 bolts to separate the 3 wire harness clamp brackets from the FC converter assembly and FC stack assembly.

NOTE:

Do not disengage the clamps before removing the wire harness clamp brackets.

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Disengage the 7 clamps to separate the wire harness from the wire harness clamp bracket.

NOTE:

When disengaging the clamps, be careful not to damage the clamps.
Do not remove the grommet.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Grommet

Disconnect the connector.

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Remove the 2 bolts to separate the FC converter cooling water inlet pipe, together with the wire harness, from the FC converter assembly.

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NOTE:

To avoid possibly damaging the clamp, do not disengage the wire harness clamp and FC converter cooling water inlet pipe when not replacing the FC stack assembly.

Remove the bolt and wire harness clamp bracket from the FC converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Slide the hose clip and disconnect the FC converter cooling water inlet hose from the FC converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

To prevent contamination by foreign matter, cover the connecting portions of the FC converter cooling water inlet hose and FC converter assembly with plastic bags.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plastic Bag

Disengage the 2 clamps to separate the wire harness from the wire harness clamp bracket.

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NOTE:

When disengaging the clamps, be careful not to damage the clamps.

REMOVE WIRE HARNESS CLAMP BRACKET

Disengage the 3 clamps to remove the 3 wire harness clamp brackets from the wire harness.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

When disengaging the clamps, be careful not to damage the clamps.

Remove the bolt and wire harness clamp bracket from the FC stack assembly.

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SEPARATE FC STACK COOLING WATER INLET PIPE

Remove the 2 bolts to separate the FC stack cooling water inlet pipe from the FC converter assembly.

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REMOVE FC STACK COOLING WATER INLET HOSE

Slide the hose clip and remove the FC stack cooling water inlet hose from the FC stack assembly.

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To prevent contamination by foreign matter, cover the connecting portions of the FC stack cooling water inlet hose and FC stack assembly with plastic bags.

*a	Plastic Bag

REMOVE FC CONVERTER ASSEMBLY

WARNING:

Wear insulated gloves.

To prevent contamination by foreign matter or water droplets, check that the area around the rear FC converter service hole cover has no foreign matter or water droplets, and clean away any foreign matter or water droplets found.
NOTE:
Do not allow foreign matter or water droplets to enter any other components.

Remove the 2 bolts and rear FC converter service hole cover from the FC converter assembly.

NOTE:

Be careful that foreign matter or water droplets do not enter the FC converter assembly.

Remove the rear FC converter service hole gasket from the rear FC converter service hole cover.

NOTE:

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

Using an insulated tool, remove the 2 bolts.

NOTE:

Be careful that foreign matter or water droplets do not enter the FC converter assembly.

To prevent contamination by foreign matter or water droplets, cover the opening of the FC converter assembly with protective tape.

*a	Protective Tape

Remove the 2 bolts.

Remove the 2 No. 2 FC stack mounts from the FC converter assembly.

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

*a	Protective Tape

HINT:

This procedure is only performed when the FC stack assembly is not being replaced with a new one.

Remove the 6 bolts and FC converter assembly from the FC stack assembly.

NOTE:

Do not hold the FC converter assembly by its pipe portion.
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.

Ground the FC converter assembly in the location indicated by the illustration, and place the FC converter assembly on a piece of cardboard.

NOTE:

Do not place the bottom side of the FC converter assembly directly on the floor.
Do not place the FC converter assembly upside-down.
To avoid damaging or deforming the FC converter assembly, do not ground the FC converter assembly in a location other than the one shown in the illustration.
Set so that the FC converter assembly is horizontal and level.
To avoid damaging or deforming the FC converter assembly, place a piece of cloth or similar in the location shown in the illustration.

*a	Cardboard
*b	Cloth
	Front Side of Vehicle
	Grounding Location

To prevent contamination by foreign matter or water droplets, cover the opening of the FC stack assembly with protective tape.

*a	Protective Tape

Remove the rear FC converter gasket from the FC converter assembly.

NOTE:

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

To prevent contamination by foreign matter or water droplets, cover the opening of the FC converter assembly with protective tape.

*a	Protective Tape

REMOVE FC STACK COOLING WATER OUTLET HOSE

Slide the hose clip and remove the FC stack cooling water outlet hose from the FC stack assembly.

To prevent contamination by foreign matter, cover the connecting portions of the FC stack cooling water outlet hose and FC stack assembly with plastic bags.

*a	Plastic Bag

REMOVE FC STACK AIR INLET HOSE

Loosen the hose clamp and remove the FC stack air inlet hose from the FC stack assembly.

To prevent contamination by foreign matter or water droplets, cover the connecting portions of the FC stack air inlet hose and FC stack assembly with plastic bags.

*a	Plastic Bag

REMOVE NO. 1 FC EXHAUST PIPE
Refer to PROCEDURE - Step 12

REMOVE NO. 1 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY

Remove the bolt and disconnect the No. 1 hydrogen supply tube sub-assembly from the FC stack assembly.

To prevent contamination by foreign matter or water droplets, cover the connecting portion of the FC stack assembly with protective tape.

*a	Protective Tape

Remove the 2 bolts and No. 1 hydrogen supply tube sub-assembly from the rear frame assembly.

Remove the 2 O-rings from the No. 1 hydrogen supply tube sub-assembly.

To prevent contamination by foreign matter or water droplets, cover the No. 1 hydrogen supply tube sub-assembly with a plastic bag.

*a	Plastic Bag

REMOVE FC STACK ASSEMBLY

WARNING:

Wear insulated gloves.

Remove the 3 bolts.

Remove the 3 No. 2 FC stack mounts from the FC stack assembly.

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

Eye Bolt

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

Eye Bolt

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.

Using the height adjustment attachment, set it so that it contacts the FC stack assembly in the location shown in the illustration, and set the FC stack assembly on the height adjustment attachment.

NOTE:

To avoid damaging or deforming the FC stack assembly, do not attach the height adjustment attachment to the plastic portions or to the lower cover on the bottom surface of the FC stack assembly.
Set so that the FC stack assembly is horizontal and level.
Do not place the bottom side of the FC stack assembly directly on the floor.

*a	Plastic Portions
*b	Lower Cover

	Front Side of Vehicle
	Attachment installation position

Remove the eye bolt.

REMOVE FC CONVERTER COOLING WATER INLET PIPE

HINT:

This procedure is only performed when the FC stack assembly is being replaced with a new one.

Disengage the 2 clamps to remove the FC converter cooling water inlet pipe from the wire harness.

NOTE:

To avoid possibly damaging the clamp, do not disengage the wire harness clamp and FC converter cooling water inlet pipe when not replacing the FC stack assembly.