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On-Vehicle Inspection [12/2023 - ]: Procedure

  1. INSPECT HYDROGEN TANK ASSEMBLY FOR HYDROGEN GAS LEAK 

    Pre-procedure1

    • Remove the rear No. 4 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 2

    • Remove the rear No. 3 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 3

    • Remove the No. 2 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 4

    • Remove the No. 1 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 5

    • Remove the rear floor side member cover LH.

      HINT: 

      Refer to PROCEDURE - Step 6

    • Remove the rear floor side member cover RH.

      HINT: 

      Refer to PROCEDURE - Step 7

    • Remove the No. 1 floor under cover.

      HINT: 

      Refer to PROCEDURE - Step 8

    • Blow compressed air around the front compartment room and underside of the vehicle.
      GTY601758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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: 09401-62020 
      NOTE:
      • To perform the measurement, hold the tip of the hydrogen gas detector as shown in the illustration.
        GTY1004723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hydrogen Gas Detector Contact Location
        *b Hydrogen Gas Detector
      • 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.

      GTY1210242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Locations - -
      Illustration Item Measurement Location Measurement Method Specified Value
      A Boss Valve Side of Hydrogen Tank Assembly Measure the area near the boss or center of Hydrogen Tank Assembly. Less than 500 ppm
      B Boss End Side of Hydrogen Tank Assembly
      C Center of Hydrogen Tank Assembly
      (1 location in center of hydrogen tank assembly from underside of vehicle)

      If the specification is not met, replace the hydrogen tank assembly with a new one.

    Post-procedure1

    • Install the No. 1 floor under cover.
    • Install the rear floor side member cover RH.
    • Install the rear floor side member cover LH.
    • Install the No. 1 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 29

    • Install the No. 2 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 30

    • Install the rear No. 3 floor board sub-assembly.
    • Install the rear No. 4 floor board sub-assembly.
  2. INSPECT HYDROGEN TANK ASSEMBLY 

    Pre-procedure1

    • Check that the hydrogen tank assembly is not damaged.
      GTY1208861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hydrogen Tank Assembly Cutaway View *b GFRP (Glass Fiber Reinforced Plastic) Layer
      *c CFRP (Carbon Fiber Reinforced Plastic) Layer (Black) *d Resin Liner
      *e Pass *f CFRP (Carbon Fiber Reinforced Plastic) Layer (Black) is not exposed
      *g Reject *h CFRP (Carbon Fiber Reinforced Plastic) Layer (Black) is exposed
      Hydrogen Tank Assembly Inner Side Hydrogen Tank Assembly Outer Side

      OK

      The CFRP (Carbon Fiber Reinforced Plastic) Layer (Black) must not be exposed.

      HINT: 

      If the specification is not met, replace the hydrogen tank assembly with a new one.

    Post-procedure1

    • Install the No. 1 floor under cover.
    • Install the rear floor side member cover RH.
    • Install the rear floor side member cover LH.
    • Install the No. 1 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 29

    • Install the No. 2 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 30

    • Install the rear No. 3 floor board sub-assembly.
    • Install the rear No. 4 floor board sub-assembly.
  3. INSPECT FOR HYDROGEN GAS LEAK 
    NOTE:

    Perform the hydrogen gas leak inspection when the fuel remaining warning light is not illuminated.

    Pre-procedure1

    • Remove the rear No. 4 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 2

    • Remove the rear No. 3 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 3

    • Remove the No. 2 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 4

    • Remove the rear floor side member cover LH.

      HINT: 

      Refer to PROCEDURE - Step 6

    • Remove the No. 1 floor under cover.

      HINT: 

      Refer to PROCEDURE - Step 8

    • Remove the rear tire LH.

      HINT: 

      Refer to PROCEDURE - Step 1

    • Detach the 3 clips and peel back the rear wheel house liner LH.
      GTY1003862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Blow compressed air around the front compartment room and underside of the vehicle.
      GTY601758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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: 09401-62020 
      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.
        GTY1002199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hydrogen Gas Detector Contact Location and Direction
        *b Side View
        *c Cutaway View
        *d Hydrogen Gas Detector
      • 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 measured value is outside of the specification, remove the hydrogen tank unit from the vehicle and replace the leaking component with a new one.
      GTY1004848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Locations - -
      Illustration Item Measurement Location Measurement Method Specified Value
      A Connection between Hydrogen Supply Primary Pipe Sub-assembly x Fuel Injector Assembly Measure the area near the piping, connecting portion, or sensor connecting portion. Less than 500 ppm
      B Connection between Hydrogen Supply Primary Pressure Sensor x Hydrogen Supply Secondary Pipe Sub-assembly
      C Connection between No. 1 Hydrogen Supply Tube x Hydrogen Supply Secondary Pipe Sub-assembly
      D Connection between No. 1 Hydrogen Supply Tube x No. 2 Hydrogen Supply Tube
      GTY1210013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Location - -
      Illustration Item Measurement Location Measurement Method Specified Value
      A Connection between No. 2 Hydrogen Tank Tube and No. 1 Hydrogen Tank Assembly Measure the area near the piping, connecting portion, or sensor connecting portion. Less than 500 ppm
      B Connection between No. 5 Hydrogen Tank Tube and No. 1 Hydrogen Tank Assembly
      C Connection between No. 3 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      D Connection between No. 1 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      E Connection between No. 4 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      F Connection between No. 2 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      G Connection between No. 6 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      H Connection between No. 8 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      I Connection between No. 7 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      J Connection between No. 5 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      K Connection between No. 7 Hydrogen Tank Tube and No. 3 Hydrogen Tank Assembly
      L Connection between No. 4 Hydrogen Tank Tube and No. 3 Hydrogen Tank Assembly
      M Connection between No. 2 Hydrogen Supply Tube Sub-assembly and No. 3 Hydrogen Supply Tube Sub-assembly
      N Connection between No. 6 Hydrogen Tank Tube and No. 2 Hydrogen Tank Assembly
      O Connection between No. 3 Hydrogen Tank Tube and No. 2 Hydrogen Tank Assembly
      P Connection between No. 8 Hydrogen Tank Tube and Hydrogen Supply Regulator
      Q Medium Pressure Port of Hydrogen Supply Regulator
      *1
      R Connection between No. 3 Hydrogen Supply Tube Sub-assembly and Hydrogen Supply Regulator
      S Connection between No. 1 Hydrogen Tank Tube and Hydrogen Inlet Receptacle
      *2
      T Filling Port of Hydrogen Inlet Receptacle Perform measurement with the tip of the hydrogen leak detector in direct contact with the filling port.
      *4, *5      		 1000 ppm or less
      1. *1: If the value is not as specified, replace the O-ring of the medium pressure port.
      2. *2: Measure from underneath the vehicle, with the rear wheel house liner LH peeled back.
      3. *3: Because there is a possibility of erroneously detecting hydrogen that has accumulated near the filling port, open the hydrogen inlet receptacle cap and wait for at least 3 minutes before performing the measurement.
      4. *4: When performing leak inspection of the hydrogen inlet receptacle assembly, hold the tip of the hydrogen leak detector in light contact with the area shown in the illustration.
        GTY1003091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hydrogen Leak Detector
        Contact Area for Hydrogen Leak Detector
      5. *5: To prevent damage to the O-ring, do not insert the tip of the hydrogen leak detector into the filling port of the hydrogen inlet receptacle assembly.
      GTY1003091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hydrogen Leak Detector
      Contact Area for Hydrogen Leak Detector

    Post-procedure1

    • Connect the hydrogen inlet receptacle cap and closed fuel lid.
    • Attach the 3 clips and install the rear wheel house liner LH.
    • Install the rear tire LH.

      HINT: 

      Refer to PROCEDURE - Step 1

    • Install the No. 1 floor under cover.
    • Install the rear floor side member cover LH.
    • Install the No. 2 floor board sub-assembly.

      HINT: 

      Refer to PROCEDURE - Step 30

    • Install the rear No. 3 floor board sub-assembly.
    • Install the rear No. 4 floor board sub-assembly.
  4. FIRST LEAK CHECK 

    HINT: 

    • When replacing or removing and installing any high pressure hydrogen system component (hydrogen inlet receptacle assembly, hydrogen tank tube joint assembly, hydrogen tank assembly, hydrogen supply regulator, or hydrogen tank tube), perform the primary leak inspection.
    • The primary leak inspection is performed using nitrogen gas.
    • When performing the primary leak inspection, remove the floor covers and rear wheel house liner so that the high pressure and medium pressure hydrogen system components and high pressure and medium pressure hydrogen system pipes are visible during inspection.
    WARNING:
    • When performing the primary leak inspection, do not perform procedures without wearing protective glasses and gloves.
    • High pressure nitrogen gas could cause a serious accident.
    GTY1002175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    After performing the primary leak inspection and confirming that there are no leaks, perform secondary leak inspection.

    Pre-procedure1

    • Using an 8 mm socket hexagon wrench, apply the specified tightening torque to the adjustment bolt to make sure the manual valve of the No. 1 hydrogen tank assembly is closed.

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

      GTY1004378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Manual Valve Closed
      *b Adjustment Bolt
      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.
      • To prevent nitrogen gas from flowing into the hydrogen tank assembly, do not open the manual valve until after the primary leak inspection is completed.
    • Using an 8 mm socket hexagon wrench, apply the specified tightening torque to the adjustment bolt to make sure the manual valve of the No. 2 hydrogen tank assembly is closed.

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

      GTY1004740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Manual Valve Closed
      *b Adjustment Bolt
      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. 2 hydrogen tank assembly must be replaced.
      • To prevent nitrogen gas from flowing into the hydrogen tank assembly, do not open the manual valve until after the primary leak inspection is completed.
    • Using an 8 mm socket hexagon wrench, apply the specified tightening torque to the adjustment bolt to make sure the manual valve of the No. 1 hydrogen tank assembly is closed.

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

      GTY1004453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Manual Valve Closed
      *b Adjustment Bolt
      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.
      • To prevent nitrogen gas from flowing into the hydrogen tank assembly, do not open the manual valve until after the primary leak inspection is completed.
    • Prepare SST (10 MPa leak inspection tool).
      1. Check that the injection valve and discharge valve of SST (port assembly) are closed.
        GTY1018557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly)
        *b Discharge Valve Closed Condition
        *c Injection Valve Closed Condition
        • SST: 09402-62010 
          1. 09402-06020
      2. Select an adapter (SST) that matches the standard of the nitrogen cylinder and install it.
        • SST: 09761-0504009761-0505009761-0506009761-05070 

        HINT: 

        The adapter (SST) is not required for JIS standards.

      3. Connect SST (regulator assembly) to a nitrogen cylinder.
        • SST: 09402-62010 
          1. 09402-06010
        GTY1018601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Regulator Assembly)
        NOTE:
        • Wrap the threaded portion with seal tape.
        • Securely tighten so that nitrogen gas will not leak out.
    • Connect the nitrogen cylinder and SST (10 MPa leak inspection tool) to the hydrogen inlet receptacle.
      • SST: 09402-62010 
        1. 09402-06010
        2. 09402-06020
      NOTE:
      • Leave the nitrogen regulator valve closed.
      • The internal volume from the cylinder to the nozzle should be 130 cc or less.
      GTY1004591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Port Assembly) *b SST (Regulator Assembly)
      *c Nitrogen Cylinder - -
    • Slowly open the nitrogen cylinder valve.
      GTY1018572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Open the Nitrogen Cylinder Valve
    • Slowly open the injection valve of SST (port assembly).
      GTY1018598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Port Assembly)
      *b Slowly Open
      • SST: 09402-62010 
        1. 09402-06020
    • Slowly rotate the handle of SST (regulator assembly) in the clockwise direction to open the valve, and let the pressure rise to 10 MPa (102.0 kgf/cm2 , 1450 psi).
      • SST: 09402-62010 
        1. 09402-06010
      GTY1018575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Regulator Assembly)
      *b Open the Nitrogen Cylinder Valve
      NOTE:
      • Raise the pressure to 10 MPa (102.0 kgf/cm2 , 1450 psi) over a period of 5 to 20 seconds.
      • If there is a hissing sound of nitrogen gas leaking out when the SST (regulator assembly) valve is opened, close the SST (regulator assembly) valve, and after determining the location of the leak, replace the leaking component with a new one.
      • Even when it seems like the leaking sound is only coming from one location, it may be drowning out leaking sounds from other locations, so make sure to perform leakage point identification for all connecting portions.
    • Connect a battery charger to the auxiliary battery, and put the auxiliary battery into a charging state.
      GTY1003432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Auxiliary Battery
      *a Battery Charger

      HINT: 

      This is done to prevent the auxiliary battery from becoming discharged, as the tank shut valve of the hydrogen tank assembly will be forced to operate for 30 minutes.

    • Using the GTS, enter the following menus: Body Electrical / Power Source Control / Utility / Auto Power OFF Cancel

      Body Electrical > Power Source Control > Utility 

      Tester Display
      Auto Power OFF Cancel
    • Using the GTS, enter the following menus: Powertrain / EV / Utility / Temporary Leak Check

      Powertrain > EV > Utility 

      Tester Display
      Temporary Leak Check
    • Following the display on the GTS, select to next.
      GTY1166812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Open the tank shut valves of the hydrogen tank assembly.
      GTY1167097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If there is a hissing sound of nitrogen gas leaking out when the tank shut valves are opened, close both tank shut valves, and after determining the location of the leak, replace the leaking component with a new one.
      • Even when it seems like the leaking sound is only coming from one location, it may be drowning out leaking sounds from other locations, so make sure to perform leakage point identification for all connecting portions.

      HINT: 

      If the tank shut valve does not open, check that all of the hydrogen tank assembly manual valves are closed, and perform the primary leak inspection again.

      GTY1160806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • When the tank shut valve has been opened, if the pressure has gone below 10 MPa (102.0 kgf/cm2 , 1450 psi), increase the pressure to 10 MPa (102.0 kgf/cm2 , 1450 psi).
    • Close the nitrogen cylinder valve.
      GTY1004954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Close the Nitrogen Cylinder Valve
    • Rotate the handle of SST (regulator assembly) in the counterclockwise direction to close the valve.
      • SST: 09402-62010 
        1. 09402-06010
      GTY1004626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Regulator Assembly)
      *b Close the SST (Regulator Assembly) Valve
    • After closing the nitrogen cylinder valve and the SST (regulator assembly) valve, wait for 10 minutes to allow the pressure in the piping to stabilize.

      HINT: 

      When nitrogen has just been filled, the temperature inside the piping is increased, causing pressure to increase. Afterwards, when the temperature in the piping decreases, the pressure decreases. For this reason, pressure is not stable immediately after nitrogen filling.

    • After checking that the high-range hydrogen pressure and medium-range hydrogen pressure has stabilized, wait an additional 30 minutes, and then check the pressure decrease.
      GTY1167092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

      Less than 200 kPa (2.0 kgf/cm2 , 29 psi)

      • Less than 200 kPa (2.0 kgf/cm2 , 29 psi):

        Go to "Depressurize the nitrogen gas"

      • 200 kPa (2.0 kgf/cm2 , 29 psi) or more:

        Go to "Inspect for nitrogen gas leak"

    Post-procedure1

    • Depressurize the nitrogen gas:
      1. Select to next.
        GTY1167093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Slowly open the discharge valve of SST (port assembly) to depressurize the nitrogen gas.
        • SST: 09402-62010 
          1. 09402-06020
        GTY972226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly)
        *b Open the Discharge Valve of SST (Port Assembly)
        NOTE:

        Keep your hands and face away from the discharge port.

      3. Slowly rotate the handle of SST (regulator assembly) a small amount in the clockwise direction to open the valve.
        • SST: 09402-62010 
          1. 09402-06010
        GTY1018576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Regulator Assembly)
        *b Open the SST (Regulator Assembly) Valve

        HINT: 

        This is done to reduce the pressure of the nitrogen gas between the nitrogen cylinder and SST (regulator assembly).

      4. Close the injection valve of SST (port assembly).
        GTY972212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly)
        *b Close the Injection Valve of SST (Port Assembly)
        • SST: 09402-62010 
          1. 09402-06020
      5. Close the discharge valve of SST (port assembly).
        GTY972245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly)
        *b Close the Discharge Valve of SST (Port Assembly)
        • SST: 09402-62010 
          1. 09402-06020
      6. 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 nitrogen gas from the medium pressure leak check port of the hydrogen supply regulator.
        GTY1003377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        When depressurizing the nitrogen gas, only loosen the No. 1 hydrogen supply regulator plug. Do not remove it.

      7. Remove the No. 1 hydrogen supply regulator plug from the hydrogen supply regulator.
        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.

        GTY1003381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      8. Remove the O-ring from the hydrogen supply regulator.
        GTY1003019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      9. 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 with protective tape.
        GTY1003535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protective Tape
      10. 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 until immediately before performing work.
        GTY1004113Courtesy 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.

      11. Apply TOYOTA Genuine FC Grease to a new O-ring and to the threaded portion of the hydrogen supply regulator.
        GTY1004120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      12. Install the O-ring to the hydrogen supply regulator.
        NOTE:

        During installation, make sure not to damage the O-ring.

        GTY1003049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      13. Using SST install the No. 1 hydrogen supply regulator plug to the hydrogen supply regulator.
        GTY1003656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Torque Wrench Fulcrum Length
        • SST: 09922-10240 

        Torque

        Specified tightening torque 

        9.0 N*m (92 kgf*cm, 80 in.*lbf)

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [11/2020 - ]

        • When using SST (fulcrum length of 40 mm (1.57 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 7.2 N*m (73 kgf*cm, 64 in.*lbf)
      14. Disconnect the nitrogen cylinder and SST (10 MPa leak inspection tool) from the hydrogen inlet receptacle.
        • SST: 09402-62010 
          1. 09402-06010
          2. 09402-06020
        GTY1004591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly) *b SST (Regulator Assembly)
        *c Nitrogen Cylinder - -
      15. Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 1 hydrogen tank assembly manual valve.
        GTY1003611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Manual Valve Closed
        *b Manual Valve Open
        *c Adjustment Bolt
        *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.
        • Before opening the manual valve, check that the nitrogen gas contained in the hydrogen piping has been depressurized.

        HINT: 

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

        GTY1003391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Adjustment Bolt
        *b Protrusion
      16. Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 2 hydrogen tank assembly manual valve.
        GTY1004170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Manual Valve Closed
        *b Manual Valve Open
        *c Adjustment Bolt
        *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.
        • Before opening the manual valve, check that the nitrogen gas contained in the hydrogen piping has been depressurized.

        HINT: 

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

        GTY1003391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Adjustment Bolt
        *b Protrusion
      17. Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 3 hydrogen tank assembly manual valve.
        GTY1004001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Manual Valve Closed
        *b Manual Valve Open
        *c Adjustment Bolt
        *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. 3 hydrogen tank assembly.
        • Before opening the manual valve, check that the nitrogen gas contained in the hydrogen piping has been depressurized.

        HINT: 

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

        GTY1003391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Adjustment Bolt
        *b Protrusion
    • The primary leak inspection is complete.
      GTY1167094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Inspect for nitrogen gas leak:
      1. Using soapy water, check the connection points to determine the locations of the leaks.

        HINT: 

        If the soapy water on the part connection points is difficult to see, use a mirror and a light.

        GTY1004847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a FC Stack-side Leak Check Locations - -
        GTY1210335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hydrogen Tank-side Leak Check Locations - -
        GTY1004557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Nitrogen Regulator-side Leak Check Locations - -
      2. Slowly open the discharge valve of SST (port assembly) to depressurize the nitrogen gas.
        • SST: 09402-62010 
          1. 09402-06020
        GTY972226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly)
        *b Open the Discharge Valve of SST (Port Assembly)
        NOTE:

        Keep your hands and face away from the discharge port.

      3. Slowly rotate the handle of SST (regulator assembly) a small amount in the clockwise direction to open the valve.
        • SST: 09402-62010 
          1. 09402-06010

        HINT: 

        This is done to reduce the pressure of the nitrogen gas between the nitrogen cylinder and SST (regulator assembly).

        GTY1018576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Regulator Assembly)
        *b Open the SST (Regulator Assembly) Valve
      4. Close the injection valve of SST (port assembly).
        • SST: 09402-62010 
          1. 09402-06020
        GTY972212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly)
        *b Close the Injection Valve of SST (Port Assembly)
      5. Close the discharge valve of SST (port assembly).
        • SST: 09402-62010 
          1. 09402-06020
        GTY972245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly)
        *b Close the Discharge Valve of SST (Port Assembly)
      6. 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 nitrogen gas from the medium pressure leak check port of the hydrogen supply regulator.
        GTY1003377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        When depressurizing the nitrogen gas, only loosen the No. 1 hydrogen supply regulator plug. Do not remove it.

      7. Remove the No. 1 hydrogen supply regulator plug from the hydrogen supply regulator.
        GTY1003381Courtesy 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.

      8. Remove the O-ring from the hydrogen supply regulator.
        GTY1003019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      9. 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 with protective tape.
        GTY1003535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protective Tape
      10. 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 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.

        GTY1004113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      11. Apply TOYOTA Genuine FC Grease to a new O-ring and to the threaded portion of the hydrogen supply regulator.
        GTY1004120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      12. Install the O-ring to the hydrogen supply regulator.
        NOTE:

        During installation, make sure not to damage the O-ring.

        GTY1003049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      13. Using SST install the No. 1 hydrogen supply regulator plug to the hydrogen supply regulator.
        GTY1003656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Torque Wrench Fulcrum Length
        • SST: 09922-10240 

        Torque

        Specified tightening torque 

        9.0 N*m (92 kgf*cm, 80 in.*lbf)

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [11/2020 - ]

        • When using SST (fulcrum length of 40 mm (1.57 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 7.2 N*m (73 kgf*cm, 64 in.*lbf)
      14. Disconnect the nitrogen cylinder and SST (10 MPa leak inspection tool) from the hydrogen inlet receptacle.
        • SST: 09402-62010 
          1. 09402-06010
          2. 09402-06020
        GTY1004591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Port Assembly) *b SST (Regulator Assembly)
        *c Nitrogen Cylinder - -
      15. After replacing the leaking component with a new one, perform primary leak inspection again.
  5. SECOND LEAK CHECK 
    NOTE:
    • Secondary leak inspection is performed after primary leak inspection has found no leaks.
    • When replacing or removing and installing any high pressure hydrogen system component (the hydrogen inlet receptacle assembly, hydrogen tank tube joint assembly, hydrogen tank assembly, hydrogen supply regulator, or hydrogen tank tube), transport the vehicle to a hydrogen station such as on a car transporter and fill the tanks completely with compressed hydrogen gas.

    HINT: 

    • When replacing or removing and installing the high pressure hydrogen system components, and when removing and installing medium pressure and high-pressure hydrogen pipes, perform the secondary leak inspection.
    • Hydrogen gas may stay near the hydrogen detector, detect hydrogen leaks, and output DTC. Perform the secondary leak inspection with the No. 3 FC exhaust pipe installed.

    Pre-procedure1

    • When replacing or removing and installing high pressure hydrogen system components:
      1. At the hydrogen station, fill the tanks completely with compressed hydrogen gas.
    • Blow compressed air around the front compartment room and underside of the vehicle.
      GTY601758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

    • Connect the GTS to the DLC3.
    • Turn the ignition switch on (IG).
    • Enter the following menus: Powertrain / EV / Utility / Leak Check

      Powertrain > EV > Utility 

      Tester Display
      Leak Check
    • Following the display on the GTS, check for hydrogen gas leak.
      GTY1003203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Select Mid-High Pressure Point Leak Check.
      GTY1003578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Using SST and a hydrogen gas detector, perform measurements for approximately 10 seconds at the locations where components were removed and installed during the replacement of components.
      GTY1004456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09401-62020 
      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.
        GTY1002199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hydrogen Gas Detector Contact Location and Direction
        *b Side View
        *c Cutaway View
        *d Hydrogen Gas Detector
      • 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 measured value is outside of the specification, replace the leaking component with a new one.
      GTY1004846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a FC Stack-side Measurement Location - -
      Illustration Item Measurement Location Measurement Method Specified Value
      A Connection between Hydrogen Supply Primary Pipe Sub-assembly x Fuel Injector Assembly Measure the area near the piping, connecting portion, or sensor connecting portion. Less than 500 ppm
      B Connection between Hydrogen Supply Primary Pressure Sensor x Hydrogen Supply Primary Pipe Sub-assembly
      C Connection between No. 1 Hydrogen Supply Tube x Hydrogen Supply Primary Pipe Sub-assembly
      D Connection between No. 1 Hydrogen Supply Tube x No. 2 Hydrogen Supply Tube
      GTY1209438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hydrogen Tank-side Measurement Location - -
      Illustration Item Measurement Location Measurement Method Specified Value
      A Connection between No. 2 Hydrogen Tank Tube and No. 1 Hydrogen Tank Assembly Measure the area near the piping, connecting portion, or sensor connecting portion. Less than 500 ppm
      B Connection between No. 5 Hydrogen Tank Tube and No. 1 Hydrogen Tank Assembly
      C Connection between No. 3 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      D Connection between No. 1 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      E Connection between No. 4 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      F Connection between No. 2 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Inlet Side)
      G Connection between No. 6 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      H Connection between No. 8 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      I Connection between No. 7 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      J Connection between No. 5 Hydrogen Tank Tube and Hydrogen Tank Tube Joint Assembly (for Outlet Side)
      K Connection between No. 7 Hydrogen Tank Tube and No. 3 Hydrogen Tank Assembly
      L Connection between No. 4 Hydrogen Tank Tube and No. 3 Hydrogen Tank Assembly
      M Connection between No. 2 Hydrogen Supply Tube Sub-assembly and No. 3 Hydrogen Supply Tube Sub-assembly
      N Connection between No. 6 Hydrogen Tank Tube and No. 2 Hydrogen Tank Assembly
      O Connection between No. 3 Hydrogen Tank Tube and No. 2 Hydrogen Tank Assembly
      P Connection between No. 8 Hydrogen Tank Tube and Hydrogen Supply Regulator
      Q Medium Pressure Port of Hydrogen Supply Regulator
      *1
      R Connection between No. 3 Hydrogen Supply Tube Sub-assembly and Hydrogen Supply Regulator
      S Connection between No. 1 Hydrogen Tank Tube and Hydrogen Inlet Receptacle

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

    Post-procedure1

    • The hydrogen gas leak check is complete.
      GTY1004642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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