Removal [12/2022 - 12/2023]: Procedure

PRECAUTION

NOTE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.
Refer to BEFORE DISCONNECTING BATTERY [12/2022 - 12/2023]

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.)

Courtesy 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 the hydrogen tank assembly, high pressure hydrogen piping, hydrogen inlet receptacle, hydrogen tank tube joint assembly or hydrogen supply regulator, to prevent strain such as twisting from being applied to the high pressure hydrogen piping.
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.
When reusable parts such as the hydrogen tank assembly valve portion, hydrogen inlet receptacle, hydrogen tank tube joint assembly and hydrogen supply regulator 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.

Courtesy 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 high pressure hydrogen system components, first perform primary leak inspection with low pressure nitrogen gas, and then perform secondary leak inspection.

Do not insert any sharp objects into the relief valve of the hydrogen supply regulator.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Atmosphere Ventilation Hole Cap
*b	Relief Valve

Do not remove the atmosphere ventilation hole cap of the hydrogen supply regulator.
When the vehicle is parked with the ignition 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 ignition switch off (not on (IG) or on (READY)), disconnect the cable from the negative (-) auxiliary battery terminal before performing work.
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 REAR NO. 4 FLOOR BOARD SUB-ASSEMBLY
Refer to PROCEDURE - Step 2
REMOVE REAR NO. 3 FLOOR BOARD SUB-ASSEMBLY
Refer to PROCEDURE - Step 3

REMOVE NO. 2 FLOOR BOARD SUB-ASSEMBLY

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 4

REMOVE REAR FLOOR SIDE MEMBER COVER LH
Refer to PROCEDURE - Step 6
REMOVE NO. 1 FLOOR UNDER COVER (for 3 Hydrogen Tank)
Refer to PROCEDURE - Step 8
REMOVE NO. 3 FC EXHAUST PIPE
Refer to PROCEDURE - Step 5
PRESSURE RELEASE OPERATION
Refer to PROCEDURE - Step 9
DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL
Refer to REMOVAL [12/2022 - 12/2023]
REMOVE FUEL FILLER OPENING LID SUB-ASSEMBLY
Refer to REMOVAL [11/2020 - ]
REMOVE HYDROGEN FUEL CONTROL TRANSMITTER
Refer to REMOVAL [11/2020 - ]

REMOVE ROCKER PANEL MOULDING PROTECTOR LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE REAR WHEEL HOUSE LINER LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT NO. 1 HYDROGEN TANK TUBE

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

Using a 19 mm union nut wrench, loosen the union nut and disconnect the No. 1 hydrogen tank tube from the hydrogen inlet receptacle while holding the hydrogen inlet receptacle part by wrench.
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 contamination by foreign matter, cover the openings of the hydrogen inlet receptacle with protective tape.
HINT:

When the hydrogen inlet receptacle will be replaced with a new one, it is not necessary to protect the openings with protective tape.
To prevent contamination by foreign matter, cover the connecting portions of the No. 1 hydrogen tank tube with plastic bags.

REMOVE HYDROGEN INLET RECEPTACLE BRACKET SUB-ASSEMBLY

REMOVE NO. 1 HYDROGEN INLET RECEPTACLE BRACKET CUSHION

REMOVE HYDROGEN INLET RECEPTACLE

Mount the No. 1 hydrogen inlet receptacle bracket in a vise between aluminum plates, and use a wrench turn clockwise to loosen the hydrogen inlet receptacle.