Installation [11/2020 - 12/2022]: Procedure

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Shackle (A) (09943-01020)

   *b

   Chain (09941-01010)

   1. Set up SST and the chain block as shown in the illustration.
      • SST: 09940-78010 
        1. 09941-01010
        2. 09943-01020
      NOTE:

      • Set up SST and the chain block so that the FC converter is level.
      • Do not hoist the FC converter from points other than those shown in the illustration.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Knock Pin

   *b

   Pin Hole

   1. Install a new gasket to the FC stack assembly.
   2. Install the FC stack by aligning the knock pin on the FC converter assembly side with the pin hole on the FC stack side.
   3. Temporarily install the 3 bolts.

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

      NOTE:

      Temporarily install the bolts in the order of 4 → 7 → 10.

   4. Install the FC stack assembly with the 13 bolts.

      Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

      NOTE:

      Make sure to tighten the bolts in the order.

3. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the bolt.

      Torque: 14 N.m (143 kgf/cm, 10 ft.lbf) 

   2. Connect the connector.
   3. Install the bolt.

      Torque: 14 N.m (143 kgf/cm, 10 ft.lbf) 

      NOTE:

      Using the paper from the removal procedure, install the paper as shown in the illustration before installing the bolts.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an E5 "TORX" socket wrench, install the stud bolts to the FC converter assembly.

      HINT: 

      This is used as a jig when installing the FC converter vent cover.

      Stud bolt

      90116-06048

   2. Remove the peeling paper of a new FC converter vent cover and install the FC converter vent cover to the FC converter assembly.
   3. Using an E5 "TORX" socket wrench, remove the stud bolts from the FC converter assembly.
   4. Install the FC converter vent cover with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 FC Stack Case Plug	-	-
   *a	Cylinder	-	-

   1. Remove the peeling paper of a new No. 1 FC stack case plug and install the No. 1 FC stack case plug to the FC converter assembly.
      NOTE:

      • Install within 60 minutes of removing the peeling paper.
      • Clean and degrease the installation surface of the No. 1 FC stack case plug.
      • The No. 1 FC stack case plug must not stick out from the column of the FC converter assembly.

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Shackle (A) (09943-01020)

   *b

   Chain (09941-01010)

   1. Set up SST and the chain block as shown in the illustration.
      • SST: 09940-78010 
        1. 09941-01010
        2. 09943-01020
      NOTE:

      • Set up SST and the chain block so that the FC stack assembly with FC converter is level.
      • Do not hoist the FC stack assembly with FC converter from points other than those shown in the illustration.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the FC stack assembly with FC converter to the FC stack frame assembly with the 4 bolts.
      NOTE:

      Perform this procedure with the FC stack frame in a level position.

      Torque: 60 N.m (612 kgf/cm, 44 ft.lbf) 

   2. Install the FC stack frame support bracket with the 6 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Apply TOYOTA Genuine FC Grease to the 2 new O-rings.
   2. Install the 2 O-rings to the No. 2 hydrogen tube.
      NOTE:

      Keep the O-ring and O-ring fitting surfaces free of foreign matter.

   3. Install the No. 2 hydrogen tube with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Apply TOYOTA Genuine FC Grease to the new O-ring.
   2. Install the O-ring to the No. 1 hydrogen tube.
      NOTE:

      Keep the O-ring and O-ring fitting surfaces free of foreign matter.

   3. Install the No. 1 hydrogen tube with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

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

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

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

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

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

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

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

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

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

Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

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

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

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

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

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Apply TOYOTA Genuine FC Grease to the 2 new O-rings.
   2. Install the 2 O-rings to the No. 3 hydrogen tube.
      NOTE:

      Keep the O-ring and O-ring fitting surfaces free of foreign matter.

   3. Install the No. 3 hydrogen tube with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the FC air compressor breather assembly with the 3 bolts.

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

      NOTE:

      Temporarily tighten the bolt (A), and then install the 3 bolts in the order of (B), (C) and (A).

   2. Connect the No. 1 FC air compressor breather hose to the FC air compressor with motor assembly, and slide the clip to secure it.
   3. Attach the claw and connect the connector to the FC air compressor breather assembly.
   4. Attach the clamp and connect the wire harness to the wire harness clamp bracket.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the radiator reserve tank bracket with the 2 bolts.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

      NOTE:

      Temporarily tighten the bolt (A), and then install the 2 bolts in the order of (B) and (A).

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the No. 2 hydrogen pump bracket with the 2 bolts.

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

      NOTE:

      Temporarily tighten the bolt (A), and then install the 2 bolts in the order of (B) and (A).

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

Refer to PROCEDURE - Step 4

Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

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

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 6

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Green-colored Lock

   -

   -

   1. As shown in the illustration, connect the connector push in the green-colored lock to securely fix it in place.
   2. Attach the 3 clamps.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Green-colored Lock

   -

   -

   1. As shown in the illustration, connect the connector push in the green-colored lock to securely fix it in place.
   2. Attach the 4 clamps.

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt		Nut
   	Attachments	-	-

   1. Set the FC converter with FC stack assembly with front frame assembly on an engine lifter.
      WARNING:

      • The FC converter with FC stack assembly with front frame assembly is a heavy component. Make sure that it is supported securely.
      • If it is not supported securely, it could fall and result in a serious accident.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      Using height adjustment attachments and plate lift attachments, keep the FC converter with FC stack assembly with front frame assembly level.

   2. Install the FC converter with FC stack assembly with front frame assembly with the 2 bolts and 2 nuts.

      Torque: 170 N.m (1734 kgf/cm, 125 ft.lbf) 

      NOTE:

      • Perform this procedure with several people supporting the FC converter with FC stack assembly with front frame assembly so that it does not tilt or fall.
      • Remove while paying attention to the wire harnesses and steering shaft.

for bolt 

Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

for hose clamp 

Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

Refer to PROCEDURE - Step 9

1. Perform the same procedure as for the LH side.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Apply TOYOTA Genuine FC Grease to the 2 new O-rings.
   2. Install the 2 O-rings to the No. 2 hydrogen supply tube sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surfaces free of foreign matter.

   3. Connect the No. 2 hydrogen supply tube sub-assembly with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

Refer to PROCEDURE - Step 1

1. Use the same procedure described for the front upper No. 1 suspension arm assembly LH.

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 3

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

Refer to PROCEDURE - Step 15

Refer to PROCEDURE - Step 17

Refer to INSTALLATION [11/2020 - ]

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

1. Perform the same procedure as for the LH side.

Refer to INSTALLATION [11/2020 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   for bolt A 

   Torque: 31 N.m (316 kgf/cm, 23 ft.lbf) 

   for bolt B 

   Torque: 14 N.m (143 kgf/cm, 10 ft.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   for bolt A 

   Torque: 31 N.m (316 kgf/cm, 23 ft.lbf) 

   for bolt B 

   Torque: 14 N.m (143 kgf/cm, 10 ft.lbf) 

Torque: 5.5 N.m (56 kgf/cm, 49 in.lbf) 

Torque: 5.5 N.m (56 kgf/cm, 49 in.lbf) 

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

Refer to INSTALLATION [11/2020 - 11/2021] , or refer to INSTALLATION [11/2021 - 12/2022]

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 3

Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING: Wear insulated gloves.

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

Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

Refer to PROCEDURE - Step 12

Refer to PROCEDURE - Step 2

Refer to INSTALLATION [11/2020 - 12/2022]

Refer to WORK PROCEDURE [11/2020 - 12/2022]

HINT: 

When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

Refer to AUTOMATIC LEARNING CHART [11/2020 - 11/2021] , or refer to AUTOMATIC LEARNING CHART [11/2021 - 12/2023]

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 5

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to ADJUSTMENT [11/2020 - ]

Refer to TEST MODE PROCEDURE [11/2020 - ]

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 9

Torque: 7.0 N.m (71 kgf/cm, 62 in.lbf) 

Torque: 7.9 N.m (81 kgf/cm, 70 in.lbf) 

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 5

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 9

Refer to PROCEDURE - Step 12

HINT: 

• Remove the two radiator support cushions before installing a new lower radiator air deflector.
• When installing a new lower radiator air deflector, it is not necessary to install the radiator support cushions.