Removal [12/2023 - ]: Procedure

Refer to PRECAUTION [11/2020 - ]

Refer to PRECAUTION [11/2020 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 9

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 8

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING: Since high voltage accumulates within the FC stack assembly with FC converter, never perform the work of separating this part into the FC converter assembly and FC stack assembly without first performing electrical charge discharge (forced electrical charge discharge or electrical charge self-discharge), because doing so is dangerous. HINT:  Forced electrical charge discharge involves injecting nitrogen to forcibly discharge the electrical charge within the FC stack assembly with FC converter, thereby reducing the voltage within the FC stack assembly with FC converter to a level where work can be performed safely. Electrical charge self-discharge involves removing parts such as the air pressure regulator assembly to discharge the electrical charge through self-discharge, thereby reducing the voltage within the FC stack assembly with FC converter to a level where work can be performed safely. hen the auxiliary components operate normally, forced electrical charge discharge can be performed. If any of the auxiliary components do not operate, forced electrical charge discharge cannot be performed. Perform electrical charge self-discharge.

1. Presence of vehicle external damage (accident)
   1. Check the FC stack assembly and area near the FC stack assembly for any damage that requires body repair or replacement.
   2. Check the FC stack assembly and area near the FC stack assembly for external damage.

      Refer to ON-VEHICLE INSPECTION [11/2020 - ]

      Result

      Result	Proceed to
      NG	Perform electrical charge self-discharge. (Perform after lowering the FC stack assembly with FC converter with front frame assembly from the vehicle. Perform the procedure up to "Perform Electrical Charge Self-discharge (When Forced Electrical Charge Discharge Not Possible)".)
      OK	Go to Check No. 1 Hydrogen Supply Tube Sub-assembly and No. 2 Hydrogen Supply Tube Sub-assembly Pipes

2. Check No. 1 hydrogen supply tube sub-assembly and No. 2 hydrogen supply tube sub-assembly pipes
   1. Check that the required pipes are not cracked, bent or damaged.

      Result

      Result	Proceed to
      NG	Perform electrical charge self-discharge. (Perform after lowering the FC stack assembly with FC converter with front frame assembly from the vehicle. Perform the procedure up to "Perform Electrical Charge Self-discharge (When Forced Electrical Charge Discharge Not Possible)".)
      OK	Go to Check HV/EV battery SOC

3. Check HV/EV battery SOC
   1. Connect the GTS to the DLC3.
   2. Turn the ignition switch to ON.
   3. Enter the following menus: Powertrain / EV / Data List / HV/EV battery SOC.

      Powertrain > EV > Data List 

      Tester Display
      Hybrid/EV Battery SOC

   4. Check the HV/EV battery SOC.

      Standard Percentage

      30 % or higher

      Result

      Result	Proceed to
      NG	Perform electrical charge self-discharge. (Perform after lowering the FC stack assembly with FC converter with front frame assembly from the vehicle. Perform the procedure up to "Perform Electrical Charge Self-discharge (When Forced Electrical Charge Discharge Not Possible)".)
      OK	Go to Perform Forced Electrical Charge Discharge Refer to Forced Electrical Charge Discharge Work [11/2020 - ]

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING: Since high voltage accumulates within the FC stack assembly with FC converter, never perform the work of separating this part into the FC converter assembly and FC stack assembly without first discharging the electrical charge (forced electrical charge discharge), because doing so is dangerous. Be sure to reduce the voltage within the FC stack assembly with FC converter to a level where work can be performed safely by performing forced electrical charge discharge.

1. Go to Perform Forced Electrical Charge Discharge

   Refer to Forced Electrical Charge Discharge Work [11/2020 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the bolt and No. 2 hydrogen supply tube sub-assembly.
   2. Remove the 2 O-rings from the No. 2 hydrogen supply tube sub-assembly.
   3. Cover the connection of the No. 2 hydrogen supply tube sub-assembly with plastic bags to prevent the foreign matter.
   4. Protect the openings of the No. 1 hydrogen supply tube sub-assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.

Refer to PROCEDURE - Step 2

Refer to REMOVAL [12/2023 - ]

Refer to PROCEDURE - Step 19

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 5

Refer to PROCEDURE - Step 4

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING: Wear insulated gloves.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Detach the clamp.
   2. Remove the 2 bolts and disconnect the FC junction cable from the FC converter assembly.
   3. Protect the openings of the FC converter assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, disconnect the No. 6 FC inverter cooling hose from the No. 4 FC inverter cooling pipe.
   2. Slide the clip, disconnect the No. 7 FC inverter cooling hose from the EV reserve tank assembly.
   3. Remove the 2 bolts and EV reserve tank assembly.
   4. Cover the connection of the EV reserve tank assembly, No. 6 FC inverter cooling hose, No. 7 FC inverter cooling hose and No. 4 FC inverter cooling pipe with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, disconnect the reserve tank inlet hose.
   2. Slide the clip, disconnect the radiator to reserve tank hose.
   3. Slide the clip, disconnect the reserve tank outlet hose.
   4. Remove the 2 bolts and FC radiator reserve tank assembly.
   5. Cover the connection of the FC radiator reserve tank assembly, reserve tank inlet hose, radiator to reserve tank hose and reserve tank outlet hose with plastic bags to prevent the foreign matter.

Refer to PROCEDURE - Step 15

Refer to PROCEDURE - Step 16

Refer to PROCEDURE - Step 17

Refer to PROCEDURE - Step 13

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Detach the 2 clamps.
   2. Slide the clip, disconnect the No. 13 FC inverter cooling hose.
   3. Cover the connection of the No. 13 FC inverter cooling hose and FC air compressor with motor assembly with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, disconnect the water hose sub-assembly C.
   2. Cover the connection of the water hose sub-assembly C and electric heater sub-assembly with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, disconnect the water hose sub-assembly E.
   2. Cover the connection of the water hose sub-assembly E and water hose sub-assembly D with plastic bags to prevent the foreign matter.

Refer to REMOVAL [12/2023 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to REMOVAL [12/2023 - ]

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 7

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

Refer to PROCEDURE - Step 7

Refer to REMOVAL [12/2023 - ]

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 44

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Loosen the 2 hose clamps.
   2. Remove the bolt and No. 1 FC exhaust pipe.
   3. Cover the connection of the No. 1 FC exhaust pipe and FC stack air outlet hose with plastic bags to prevent the foreign matter.

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:

      Place wooden blocks or plate lift attachments so that the FC converter with FC stack assembly with front frame assembly is level.

   2. Remove the 2 bolts and 2 nuts.
   3. Operate the engine lifter, then slowly remove the FC converter with FC stack assembly with front frame assembly from the vehicle.
      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.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Green-colored Lock

   -

   -

   1. Detach the 4 clamps.
   2. As shown in the illustration, pull out the green lock of the connector and disconnect the 2 connectors.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Green-colored Lock

   -

   -

   1. Detach the 3 clamps.
   2. As shown in the illustration, pull out the green lock of the connector and disconnect the connector.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 9

Refer to PROCEDURE - Step 13

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, remove the No. 6 FC radiator hose.
   2. Cover the connection of the No. 6 FC radiator hose and No. 4 FC radiator pipe with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Detach the 3 clamps.
   2. Slide the clip, remove the reserve tank inlet hose.
   3. Cover the connection of the reserve tank inlet hose and No. 4 FC radiator pipe with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, remove the No. 3 FC intercooler hose.
   2. Cover the connection of the No. 3 FC intercooler hose and No. 3 FC radiator pipe with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, disconnect the No. 4 FC radiator hose.
   2. Remove the 4 bolts, No. 3 FC radiator pipe and No. 4 FC radiator pipe.
   3. Cover the connection of the No. 4 FC radiator hose and FC stack water outlet with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Detach the clamp.
   2. Slide the 2 clips, disconnect the water hose sub-assembly B.
   3. Remove the bolt and water hose sub-assembly B.
   4. Cover the connection of the water hose sub-assembly B, hydrogen recirculation pump assembly with hydrogen recirculation separator assembly and electric heater sub-assembly with plastic bags to prevent the foreign matter.

Refer to PROCEDURE - Step 4

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, remove the No. 1 FC inverter cooling hose sub-assembly.
   2. Cover the connection of the No. 1 FC inverter cooling hose sub-assembly and FC converter assembly with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, remove the No. 5 FC inverter cooling hose.
   2. Cover the connection of the No. 5 FC inverter cooling hose and FC converter assembly with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, disconnect the No. 12 FC radiator hose.
   2. Remove the 2 bolts and No. 6 FC radiator pipe.
   3. Cover the connection of the No. 12 FC radiator hose and No. 6 FC radiator pipe with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Slide the clip, disconnect the No. 3 FC radiator hose.
   2. Cover the connection of the No. 3 FC radiator hose and FC stack air and water inlet with plastic bags to prevent the foreign matter.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 2 bolts and No. 3 hydrogen tube.
   2. Remove the 2 O-rings from the No. 3 hydrogen tube.
   3. Cover the connection of the No. 3 hydrogen tube with plastic bags to prevent the foreign matter.
   4. Protect the openings of the FC stack assembly and hydrogen recirculation pump assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING: Since high voltage accumulates within the FC stack assembly with FC converter, never perform the work of separating this part into the FC converter assembly and FC stack assembly without first discharging the electrical charge (electrical charge self-discharge), because doing so is dangerous. Be sure to reduce the voltage within the FC stack assembly with FC converter to a level where work can be performed safely by performing electrical charge self-discharge. (This work is unnecessary if forced electrical charge discharge has been completed.)

1. Go to Perform Electrical Charge Self-discharge (When Forced Electrical Charge Discharge Not Possible)

   Refer to Electrical Charge Self-discharge Work [11/2020 - ]

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the bolt and No. 1 hydrogen tube.
   2. Remove the O-ring from the No. 1 hydrogen tube.
   3. Cover the connection of the No. 1 hydrogen tube with plastic bags to prevent the foreign matter.
   4. Protect the openings of the FC stack hydrogen inlet with protective tape (non-residue type) to prevent the entry of foreign matter or water.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 2 bolts and No. 2 hydrogen tube.
   2. Remove the 2 O-rings from the No. 2 hydrogen tube.
   3. Cover the connection of the No. 2 hydrogen tube with plastic bags to prevent the foreign matter.
   4. Protect the openings of the FC stack hydrogen inlet and hydrogen recirculation pump assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the engine hanger with the 3 bolts as shown in the illustration.

      Torque: 32 N.m (326 kgf/cm, 24 ft.lbf) 

      HINT: 

      Engine Hanger	12282-28010
      Bolt	91552-K1025

2. 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.

3. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Put wooden blocks on the work table and place the FC converter with FC stack assembly on them.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a cloth, remove dirt and dust from the FC stack assembly with FC converter surface and around the bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Be sure to perform this work, because it may not be possible to retrieve the bolt if it falls inside the FC stack assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Paper	*b	Tape
   *c	Approximately 33 mm	*d	Approximately 110 mm

   1. Prepare paper of the size shown in the illustration, and roll up the paper so that it overlaps.
   2. Insert the rolled up paper into the FC converter assembly.
   3. Firmly secure the inserted paper to the FC converter assembly with tape.
      NOTE:

      • Be sure to perform this work, because it may not be possible to retrieve the bolt if it falls inside the FC stack assembly.
      • Store the rolled up paper because it will be used again during installation.

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. Remove the bolt.
   2. Disconnect the connector and remove the bolt.

3. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Protective tape

   -

   -

   1. Remove the 13 bolts.
   2. Using a screwdriver with its tip wrapped with protective tape, pry the points shown in the illustration and remove the FC stack assembly.
      NOTE:

      • Remove the FC stack assembly carefully in a perpendicular orientation while making sure not to subject it to any impacts, because there is an FC stack voltage sensor on the FC stack assembly side, and the gap between the FC stack voltage sensor and FC converter assembly is small.
      • Do not damage the contact surfaces of the FC stack assembly and FC converter assembly.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *1	FC Converter Assembly
      *2	FC Stack Assembly
      *3	FC Stack Voltage Sensor
      *a	Gap

   3. Remove the upper FC stack case gasket from the FC stack assembly.

4. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Put wooden blocks on the work table and place the FC converter assembly on them.
      NOTE:

      Use wooden blocks so that the protruding parts on the lower portion of the FC converter assembly does not make contact with the work table.

5. Clean FC converter vent cover installation surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Remaining Double-sided Tape
   *b	Scraper Made of Resin
   *c	Protect with Cloth, etc.

   1. Protect the FC converter assembly with a cloth, etc., to prevent dirt or foreign matter from entering it, as shown in the illustration.
   2. Use a scraper made of resin to remove the remaining double-sided tape from the FC converter vent cover installation surface.
      NOTE:

      Never remove using a screwdriver or scraper made of metal, etc., because doing so may cause damage that results in problems such as poor adhesion.

   3. Clean and degrease the installation surface of the FC converter vent cover using non-residue solvent and brake cleaner.
      NOTE:

      • Installing the FC converter vent cover with some double-sided tape remaining may cause poor adhesion. Remove the double-sided tape completely.
      • Never remove using a screwdriver or scraper made of metal, etc., because doing so may cause damage that results in problems such as poor adhesion.

      HINT: 

      After removing the tape with a scraper made of resin, spraying non-residue solvent and brake cleaner onto the tape remaining on the adhesional surface and rubbing it with a cloth, etc., makes it easy to remove the tape.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Remaining Double-sided Tape