Removal [11/2020 - 11/2021]: 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 [11/2020 - 11/2021]

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.)

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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.

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*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.

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*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

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Bolt

Screw

REMOVE REAR NO. 3 FLOOR BOARD SUB-ASSEMBLY

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	Screw		Nut
	Grommet	-	-

REMOVE NO. 2 FLOOR BOARD SUB-ASSEMBLY

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	Bolt		Nut
	Grommet	-	-

Remove the 3 bolts and nut, detach the 8 clips and loosen the 5 grommets.
Slide the cover and loosen the grommet and remove the No. 2 floor board sub-assembly.

REMOVE NO. 1 FLOOR BOARD SUB-ASSEMBLY

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	Bolt		Nut
	Grommet	-	-

Remove the 3 bolts and nut, detach the 8 clips and loosen the 5 grommets.
Slide the cover and loosen the grommet and remove the No. 2 floor board sub-assembly.

REMOVE REAR FLOOR SIDE MEMBER COVER LH

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REMOVE REAR FLOOR SIDE MEMBER COVER RH

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REMOVE NO. 1 FLOOR UNDER COVER (for 3 Hydrogen Tank)

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	Screw		Nut
	Grommet	-	-

REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
REMOVE REAR SUSPENSION BRACE COVER
REMOVE NO. 3 FC EXHAUST PIPE
Refer to PROCEDURE - Step 5
DISCHARGE COMPRESSED HYDROGEN GAS COMPRESSED HYDROGEN GAS (When replacing the hydrogen tank assembly)
Refer to DISCHARGE COMPRESSED HYDROGEN GAS [11/2020 - 12/2023]
PRESSURE RELEASE OPERATION
Refer to PROCEDURE - Step 9
DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL
Refer to REMOVAL [11/2020 - 11/2021]
REMOVE HYDROGEN TANK TUBE JOINT ASSEMBLY (for Inlet Side)
Refer to REMOVAL [11/2020 - 11/2021]
REMOVE HYDROGEN TANK TUBE JOINT ASSEMBLY (for Outlet Side)
Refer to REMOVAL [11/2020 - 11/2021]

REMOVE MOTOR CABLE

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REMOVE NO. 3 FLOOR WIRE

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REMOVE NO. 3 FUEL TUBE CLAMP

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REMOVE NO. 5 FUEL TUBE CLAMP

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Detach the 3 clamp and disconnect the connector and 2 No. 5 fuel tube clamps from the No. 1 hydrogen tank bracket.

DISCONNECT NO. 3 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY

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Remove the bolt and disconnect the No. 3 hydrogen supply tube sub-assembly 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.
Remove the 2 O-rings from the No. 3 hydrogen supply tube sub-assembly.
To prevent contamination by foreign matter, cover the connecting portions of the No. 3 hydrogen supply tube sub-assembly with plastic bags.
To prevent contamination by foreign matter, cover the openings of the hydrogen supply regulator with protective tape.
HINT:

When the hydrogen supply regulator will be replaced with a new one, it is not necessary to protect the openings with protective tape.

REMOVE NO. 2 HYDROGEN TANK ASSEMBLY

WARNING:

Because the hydrogen tank assembly is extremely heavy, make sure to follow the work procedures described in the appropriate service information .
If work is not performed according to the procedures described in the appropriate service information , there is a danger that the engine lifter could drop and components could fall down.

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*a	Heavy load exceeding the weight limits or size limits of the engine lifter

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*a	SST (Hydrogen Tank Stand No. 2)	*b	Belt
*c	SST (Support No. 1)	*d	SST (Set Bolt A)
*e	SST (Support No. 2)	-	-

Set SST (hydrogen tank stand No. 2) on the engine lifter and secure it with the belt.
- SST: 09403-62030
NOTE:
Set SST (hydrogen tank stand No. 2) in the middle of the engine lifter and secure the center portion with the belt.
Remove 2 SST (set bolt A) and SST (support No. 1).
- SST: 09403-62030
  1. 09403-06200
  2. 09403-06210
Remove 2 SST (set bolt A) and SST (support No. 2).
- SST: 09403-62030
  1. 09403-06210
  2. 09403-06220

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*a	Front side of vehicle	*b	SST (Support Rail No. 1)
*c	SST (Support No. 3)	*d	SST (Set Bolt C)
*e	SST (Set Bolt B)	*f	Scale surface: 692 mm (27.2 in.)
*g	Scale surface: 56 mm (2.20 in.)	*h	Scale surface: 88 mm (3.47 in.)
*i	Scale surface: 467 mm (18.4 in.)	*j	Front side of vehicle: 244 mm (9.61 in.) Rear side of vehicle: 265 mm (10.4 in.)

Adjust SST (support No. 3), SST (support rail No. 1), and tighten SST (set bolt B), SST (set bolt C).
- SST: 09403-62030
  1. 09403-06230
  2. 09403-06250
  3. 09403-06240
  4. 09403-06260
HINT:

This is done to align SST (hydrogen tank stand No. 2) with the installation condition of the No. 2 hydrogen tank assembly on the vehicle.

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Protrusion

SST (Support No. 3)

Operate the engine lifter, and set SST (hydrogen tank stand No. 2) against the No. 2 hydrogen tank assembly.
NOTE:
Align the protrusions of each No. 2 hydrogen tank frame sub-assembly with the holes of SST (support No. 3).
When the gap between the No. 2 hydrogen tank frame sub-assembly and SST (support No. 3) is large, rotate SST (support No. 3) to adjust the height.

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Remove the 5 bolts.
Operate the engine lifter and slowly remove the No. 2 hydrogen tank assembly from the vehicle.
NOTE:
- Make sure that the No. 2 hydrogen tank assembly does not interfere with the hydrogen tank tube.
- Check the body paint near the mounting bolts of the No. 2 hydrogen tank frame sub-assembly, and if the paint is peeled off, apply paint.

REMOVE HYDROGEN DETECTOR

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REMOVE NO. 8 HYDROGEN TANK TUBE

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Refer to PROCEDURE - Step 16

REMOVE NO. 6 HYDROGEN TANK TUBE

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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.

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Detach the clamp and using a 19 mm union nut wrench, loosen the union nut and remove the No. 6 hydrogen tank tube from the No. 2 hydrogen tank assembly.
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 No. 2 hydrogen tank assembly with protective tape.
HINT:

When the No. 2 hydrogen tank assembly 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. 6 hydrogen tank tube with plastic bags.

REMOVE NO. 3 HYDROGEN TANK TUBE

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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.

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Detach the clamp and using a 19 mm union nut wrench, loosen the union nut and remove the No. 3 hydrogen tank tube from the No. 2 hydrogen tank assembly.
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 No. 2 hydrogen tank assembly with protective tape.
HINT:

When the No. 2 hydrogen tank assembly 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. 3 hydrogen tank tube with plastic bags.

REMOVE NO. 4 FUEL TUBE CLAMP

REMOVE HYDROGEN SUPPLY REGULATOR ASSEMBLY
Refer to PROCEDURE - Step 17

REMOVE NO. 1 HYDROGEN TANK BRACKET

REMOVE NO. 2 HYDROGEN TANK SPRING BOLT CUP

Remove the 2 bolts, 2 No. 2 hydrogen tank spring bolt cups and 2 compression springs.

REMOVE NO. 2 HYDROGEN TANK BAND SUB-ASSEMBLY

REMOVE NO. 2 HYDROGEN TANK ASSEMBLY

Wheel Chocks

Using an engine sling device and belts, remove the No. 2 hydrogen tank assembly from the No. 2 hydrogen tank frame sub-assembly.

WARNING:

When hoisting up the hydrogen tank assembly, do not hoist it when not properly balanced.

The hydrogen tank assembly could fall, resulting in a serious accident.

Place the No. 2 hydrogen tank assembly on wheel chocks or similar.

REMOVE NO. 2 HYDROGEN TANK FRAME SUB-ASSEMBLY

Remove the nut and harness bracket.
HINT:

This procedure is only performed when the harness bracket is being replaced.
Remove the 8 grommets.
HINT:

This procedure is only performed when the grommet is being replaced.
Remove the No. 2 hydrogen tank frame sub-assembly LH and No. 2 hydrogen tank frame sub-assembly RH.

REMOVE NO. 3 HYDROGEN TANK FRAME SEAT

HINT:
This procedure is only performed when the No. 3 hydrogen tank frame seat is being replaced.

REMOVE NO. 1 HYDROGEN TANK INFORMATION LABEL

HINT:
This procedure is only performed when the No. 1 hydrogen tank information label is being replaced.

NOTE:

There are 2 types of No. 1 hydrogen tank information labels (for Type A and for Type B). These labels are not interchangeable so replace with the No. 1 hydrogen tank information label applied to the original tank if damaged or if peeling occurs.

for Type A

for Type B

Label Cover Film

No. 1 Hydrogen Tank Information Label

Using a scraper peel off the No. 1 hydrogen tank information label from the No. 2 hydrogen tank assembly.
Using a solvent and cloth, clean the contact surfaces of the No. 1 hydrogen information label and No. 2 hydrogen tank assembly.