LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2021 >> Mirai XLE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Converters and Controllers >> Fuel Cell (FC) Control System - Service Information (6 Of 7) >> Hydrogen Injector >> Installation [11/2020 - 12/2023] >> Procedure

Installation [11/2020 - 12/2023]: Procedure

  1. INSTALL FUEL INJECTOR ASSEMBLY 
    1. GTY1209619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
      1. Apply TOYOTA Genuine FC Grease to the O-ring and insulator.
      2. Install the O-ring and insulator to the fuel injector assembly.
        NOTE:

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

      3. Install the 3 fuel injector assemblies to the hydrogen supply secondary pipe sub-assembly.
      4. Install the hydrogen supply secondary pipe sub-assembly with the 2 bolts.

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

  2. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  3. INSTALL HYDROGEN SUPPLY PRESSURE REGULATOR ASSEMBLY 
    1. GTY1208974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Pull down Shift
      1. Apply TOYOTA Genuine FC Grease to the 2 new O-rings.
      2. Install the 2 O-rings to the No. 1 hydrogen supply tube sub-assembly.
        NOTE:

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

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

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

      5. Connect the No. 1 hydrogen tube and No. 1 hydrogen supply tube sub-assembly to the hydrogen supply puressure regulator assembly and install the hydrogen supply puressure regulator assembly with the 3 bolts.

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

      6. Install the 2 bolts and 2 nuts.

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

      7. Connect the No. 1 hydrogen detector bracket with the bolt.

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

      8. Connect the 5 connectors and attach the 2 clamps.
  4. INSTALL FC STACK COVER BRACKET 

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

  5. INSPECT FOR HYDROGEN GAS LEAK (for Medium Pressure) 

    HINT: 

    Use the GTS, perform a hydrogen leak inspection when replacing or removing and installing medium-pressure hydrogen-replated parts (medium pressure port of hydrogen supply regulator, hydrogen primary pressure sensor and fuel injector), and removing and installing medium-pressure hydrogen-related piping (No. 1 hydrogen supply tube, No. 2 hydrogen supply tube, and No. 3 hydrogen supply tube).

    1. GTY1002275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Manual Valve Closed *b Manual Valve Open
      *c Adjustment Bolt *d Counterclockwise
      1. Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 1 hydrogen tank assembly manual valve.
        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.

        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
    2. GTY1001752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Manual Valve Closed *b Manual Valve Open
      *c Adjustment Bolt *d Counterclockwise
      1. Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 2 hydrogen tank assembly manual valve.
        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.

        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
    3. GTY1002094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Manual Valve Closed *b Manual Valve Open
      *c Adjustment Bolt *d Counterclockwise
      1. for 3 Hydrogen Tank:

        Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 3 hydrogen tank assembly manual valve.

        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.

        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
    4. GTY1003409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Blow compressed air around the front compartment room and underside of the vehicle.

        HINT: 

        To enable accurate detection of hydrogen gas leaks from the piping, blow compressed air from the front of the vehicle towards the rear.

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

      Powertrain > EV > Utility 

      Tester Display
      Leak Check
    8. GTY1004653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Following the display on the GTS, check for hydrogen gas leaks.
    9. GTY1003822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Select mid-high pressure point leak check.
    10. GTY1004977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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.
        • 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.
        • The GTS may stop during a check when repeatedly used to perform leak checks. In this case, wait for 30 minutes and then perform the check again.
        GTY1004536Courtesy 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 around the connection. Less than 500ppm
        B Connection between Hydrogen 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
        GTY1004467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Hydrogen Tank-side Measurement Location - -
        Illustration Item Measurement Location Measurement Method Specified Value
        A Connection between No. 1 Hydrogen Supply Tube x No. 2 Hydrogen Supply Tube Measure the area around the connection. Less than 500ppm
        B Connection between No. 2 Hydrogen Supply Tube Sub-assembly and No. 3 Hydrogen Supply Tube Sub-assembly
        C Medium Pressure Port of Hydrogen Supply Regulator
        *1
        D Connection between No. 3 Hydrogen Supply Tube Sub-assembly and Hydrogen Supply Regulator

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

    11. GTY1004927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. The check for hydrogen gas leaks (for medium pressure) is complete.
  6. INSPECT FOR HYDROGEN GAS LEAK (for Low Pressure) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    Check for hydrogen gas leaks (for low pressure) is performed after check for hydrogen gas leaks (for medium pressure) has found no leaks.

    HINT: 

    Use the GTS, perform a hydrogen leak inspection when replacing or removing and installing low-pressure hydrogen- elated parts (fuel injector assembly, hydrogen secondary pressure sensor, hydrogen recirculation pump assembly, hydrogen recirculation separator assembly, and FC stack assembly, FC converter assembly), and removing and installing low-pressure hydrogen-related piping (No. 1 hydrogen tube, No. 2 hydrogen tube, and No. 3 hydrogen tube).

    1. GTY1003409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Blow compressed air around the front compartment room and underside of the vehicle.

        HINT: 

        To enable accurate detection of hydrogen gas leaks from the piping, blow compressed air from the front of the vehicle towards the rear.

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

      Powertrain > EV > Utility 

      Tester Display
      Leak Check
    5. GTY1004653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Following the display on the GTS, check for hydrogen gas leaks.
    6. GTY1003070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Select low pressure point leak check.
    7. GTY1004977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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.
        • 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.
        • The GTS may stop during a check when repeatedly used to perform leak checks. In this case, wait for 30 minutes and then perform the check again.
        GTY1004530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Measurement Locations *b Insertion Slot
        Illustration Item Measurement Location Measurement Method Specified Value
        A Connection between No. 1 Hydrogen Tube x Hydrogen supply Secondary Pipe Sub-assembly Measure the area near the piping, connecting portion, or sensor connecting portion. Less than 500ppm
        B Connection between Hydrogen Secondary Pressure Sensor x Hydrogen Supply Secondary Pipe Sub-assembly
        C Connection between Fuel Injector Assembly x Hydrogen Supply Secondary Pipe Sub-assembly
        D Connection between No. 2 Hydrogen Tube x FC Stack Hydrogen Inlet
        E Connection between No. 2 Hydrogen Tube x Hydrogen Recirculation Pump Assembly
        F Connection between Hydrogen Recirculation Pump Assembly x Hydrogen Recirculation Separator Assembly Remove SST (hydrogen gas detector adapter) and insert the hydrogen gas detector probe into the insertion slot to perform a measurement.
        G Connection between No. 1 Hydrogen Tube x FC Stack Hydrogen Inlet Measure the area near the piping, connecting portion, or sensor connecting portion.
        H Connection between No. 3 Hydrogen Tube x FC Stack Assembly
        I Connection between No. 3 Hydrogen Tube x Hydrogen Recirculation Separator Assembly
    8. GTY1004857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Perform the end processing, the check for hydrogen gas leaks (for low pressure) is complete.
  7. INSTALL FC STACK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 175 [11/2020 - 12/2022] , or refer to PROCEDURE - Step 175 [12/2022 - 12/2023]

  8. INSTALL NO. 3 FC EXHAUST PIPE 

    Refer to PROCEDURE - Step 4

  9. INSTALL NO. 1 FLOOR UNDER COVER (for 3 Hydrogen Tank) 
  10. INSTALL REAR FLOOR SIDE MEMBER COVER LH 
  11. INSTALL NO. 2 FLOOR BOARD SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 30 [11/2020 - 12/2022] , or refer to PROCEDURE - Step 30 [12/2022 - 12/2023]
  12. INSTALL REAR NO. 3 FLOOR BOARD SUB-ASSEMBLY 
  13. INSTALL REAR NO. 4 FLOOR BOARD SUB-ASSEMBLY 
scientia non olet · About LEMON Manuals