REGULATOR ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the hydrogen supply regulator assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedure Effects/Inoperative when not Performed Link
Remove/install height control sensor RR

  • Vehicle information registration for the headlight light control ECU sub-assembly LH

  • Initialization of the headlight light control ECU sub-assembly LH

 Automatic headlight beam level control system

Click here

Remove/install rear axle beam

  1. Clear zero point calibration data

  2. Perform yaw rate and acceleration sensor zero point calibration

 VSC malfunctioning

Click here

Adjust lane departure warning camera Lane departure alert system does not operate correctly.

Click here

Note

When removing or installing the rear disc brake caliper assembly, if the piston of the brake caliper is pushed in, the clearance between the brake pad and rear disc will become large. In this condition, depressing the brake pedal may cause DTC C1214 (Hydraulic Control System Malfunction) to be stored, so check and clear DTCs after the procedure is complete.

CAUTION:


  • B006JCR

    Work procedures must be performed in an area with good ventilation (airflow) where hydrogen gas will not accumulate, and flames or other things that could act as ignition sources must not be present.

  • Accumulated hydrogen gas could ignite, resulting in a serious accident.

  • B006JFPC03
    *a When inside of piping is pressurized

    Do not install or remove any hydrogen system components without first performing depressurization procedures.

  • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.

  • B006JLTC19
    *a Manual Valve Open

    Do not perform depressurization procedures when the manual valve of the hydrogen tank assembly is open.

  • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.

  • B006JBL

    When performing depressurization, do not perform procedures by hand without wearing protective glasses and gloves.

  • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.

  • B006JJ9C04
    *a After depressurization procedures, the high pressure piping union nut that is loosened first.

    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.

  • B006JKHC08
    *a Heavy load exceeding the weight limits or size limits of the engine lifter

    Because the hydrogen tank unit is extremely heavy, make sure to follow the work procedures described in the repair manual.

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the engine lifter could drop and components could fall down.

PROCEDURE


  1. PRECAUTION

    Note


    • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

      Click here

    • 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.)

      B006JJCE01
      *1 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.)

    • 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 hydrogen system components (hydrogen tank assembly, high pressure hydrogen piping, hydrogen inlet receptacle, hydrogen tube joint, hydrogen tank pressure sensor or hydrogen supply regulator assembly), to prevent strain such as twisting from being applied to the high pressure hydrogen piping, use the hydrogen tank installation and removal guide tool and remove the hydrogen tank unit from the vehicle before performing procedures.

    • Even when replacing only the No. 1 hydrogen tank assembly, or only the No. 2 hydrogen tank assembly, to prevent strain from being applied to the high pressure hydrogen piping, use the tank positioning attachment of the hydrogen tank installation and removal tool, and perform positioning of the No. 1 hydrogen tank assembly and No. 2 hydrogen tank assembly.

    • 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.

    • Do not reuse high pressure hydrogen piping after it has been removed, because the coupling portions will not maintain their airtightness.

    • When reusable parts such as the hydrogen tank assembly valve portion, hydrogen inlet receptacle, hydrogen tube joint and hydrogen supply regulator assembly 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.

    • B006JHHC10
      *a Protective Tape
      *b Seal Portion
      *c Threaded Portion

      Protect seal portions and threaded portions as shown in the illustration.

    • 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 hydrogen system components, first perform primary leak inspection with low pressure nitrogen gas, and then fill pressurized hydrogen gas at a hydrogen station to perform secondary leak inspection. When performing secondary leak inspection, the vehicle cannot be driven to the hydrogen station under its own power, so transport it using a car carrier, etc.

    • B006JKNC04
      *a Exhaust Tube
      *b Atmosphere Ventilation Hole Cap

      Do not insert any sharp objects into the exhaust tube of the hydrogen supply regulator assembly release valve.

    • Do not remove the atmosphere ventilation hole cap of the hydrogen supply regulator assembly.

    • When the vehicle is parked with the power 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 power switch off (not on (IG) or on (READY)), disconnect the cable from the negative (-) auxiliary battery terminal before performing work.

  2. REMOVE NO. 2 MOTOR UNDER COVER

    Click here

  3. REMOVE FRONT FLOOR COVER LH

    Click here

  4. REMOVE FRONT FLOOR COVER RH

    Click here

  5. REMOVE FRONT FLOOR CENTER COVER LH

    Click here

  6. REMOVE FRONT FLOOR CENTER COVER RH

    Click here

  7. REMOVE NO. 2 FLOOR UNDER COVER

    Click here

  8. REMOVE NO. 1 FLOOR UNDER COVER

    Click here

  9. REMOVE FC EXHAUST TAIL PIPE ASSEMBLY

    Click here

  10. REMOVE NO. 3 EXHAUST PIPE

    Click here

  11. REMOVE NO. 2 EXHAUST PIPE

    Click here

  12. PRESSURE RELEASE OPERATION

    Click here

  13. DISABLE BRAKE CONTROL

    Click here

  14. REMOVE REAR WHEEL HOUSE FRONT PLATE LH


    1. A00266Z

      Remove the screw, 2 clips and rear wheel house front plate LH from the vehicle.

  15. REMOVE REAR BUMPER SIDE SEAL LH

    Click here

  16. REMOVE REAR WHEEL HOUSE LINER LH


    1. B006JKLC03
      *a Hexagon Screw

      Using a 4 mm socket hexagon wrench, remove the hexagon screw.

    2. Remove the 12 clips and rear wheel house liner LH from the vehicle.

  17. REMOVE LUGGAGE COMPARTMENT FLOOR MAT

    Click here

  18. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

    Click here

  19. REMOVE NO. 2 LUGGAGE COMPARTMENT TRIM HOOK

    Click here

  20. REMOVE FRONT LUGGAGE COMPARTMENT TRIM COVER

    Click here

  21. REMOVE REAR FLOOR FINISH PLATE

    Click here

  22. REMOVE ROPE HOOK

    Click here

  23. REMOVE LUGGAGE COMPARTMENT TRIM COVER ASSEMBLY LH

    Click here

  24. REMOVE FUEL LID WITH MOTOR LOCK ASSEMBLY

    Click here

  25. DISCONNECT HYDROGEN INLET RECEPTACLE CAP


    1. A0026H1

      Disconnect the hydrogen inlet receptacle cap from the hydrogen inlet receptacle assembly.

  26. REMOVE FUEL TANK CAP COVER

    Click here

  27. REMOVE FUEL TANK FILLER PIPE SHIELD

    Click here

  28. REMOVE FUEL FILLER OPENING LID SUB-ASSEMBLY

    Click here

  29. REMOVE REAR AXLE BEAM ASSEMBLY

    Click here

  30. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY

    Click here

  31. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY

    Click here

  32. SEPARATE NO. 3 FLOOR WIRE

    Click here

  33. SEPARATE NO. 2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY

    Click here

  34. DISCONNECT NO. 1 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY

    Click here

  35. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  36. DISCONNECT HYDROGEN TANK TUBE CLAMP BRACKET

    Click here

  37. DISCONNECT HYDROGEN TANK TUBE ASSEMBLY


    1. B006JFQ

      Remove the bolt and disconnect the bracket of the hydrogen tank tube assembly from the vehicle.

      Note

      When loosening the bolt, to prevent the high pressure hydrogen piping from rotating together and being strained, hold the bracket portion in place by hand while performing the procedure.

  38. DISCONNECT HYDROGEN INLET RECEPTACLE BRACKET SUB-ASSEMBLY


    1. A0026NZ

      Disengage the clamp and separate the wire harness clamp from the hydrogen inlet receptacle bracket sub-assembly.

    2. Disconnect the hydrogen fuel control transmitter connector.

    3. A0026KN

      Remove the 5 bolts and disconnect hydrogen inlet receptacle bracket sub-assembly from the vehicle.

  39. REMOVE HYDROGEN TANK UNIT

    CAUTION:


    • Because the hydrogen tank unit is extremely heavy, make sure to follow the work procedures described in the repair manual.

    • If work is not performed according to the procedures described in the repair manual, there is a danger that the engine lifter could drop and components could fall down.

    B006JKHC10
    *a Heavy load exceeding the weight limits or size limits of the engine lifter

    1. B006JH9C02
      *a SST (Hydrogen Tank Stand)
      *b Belt

      Set the SST (hydrogen tank stand) on the engine lifter and secure it with the belt.

      SST
      09403-62010   ( 09403-06010, 09403-06020, 09403-06030, 09403-06040, 09403-06050, 09403-06060, 09403-06070, 09403-06080, 09403-06090, 09403-06100, 09403-06110 )

      Note

      Set the SST (hydrogen tank stand) in the middle of the engine lifter and secure the center portion with the belt.

    2. B006JDTC05
      *a SST (Support No. 5)
      *b SST (Support No. 6)
      *c SST (Nut)

      Remove the SST (nuts) and each tank support type SST.

      SST
      09403-62010   ( 09403-06050, 09403-06060, 09403-06090 )
    3. B006JCPC05
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)

      Remove the SST (bolts) and each SST (tank belt fixture).

      SST
      09403-62010   ( 09403-06100, 09403-06110 )
    4. B006JD0C06
      *a SST (Support No. 1)
      *b SST (Support No. 2)
      *c SST (Support No. 3)
      *d SST (Support No. 4)
      *e SST (Bolt)
      *f Pin

      For each tank support type SST, disengage the 2 pins and loosen the 2 SST (bolts).

      Tech Tips

      This is done to align the SST (hydrogen tank stand) with the installation condition of the hydrogen tank unit on the vehicle.

      SST
      09403-62010   ( 09403-06010, 09403-06020, 09403-06030, 09403-06040, 09403-06080 )

    5. Operate the engine lifter, and set the SST (hydrogen tank stand) against the hydrogen tank frame.

      B006JENC05
      *a SST (Hydrogen Tank Stand) *b Pin
      *c Groove - -
      SST
      09403-62010

      Note


      • Align the pins of the each tank support type SST with the pin holes of the hydrogen tank frame.

      • Align the grooves of the each tank support type SST with the tank frame.

    6. B006JFLC01
      *a SST (Tank Belt Fixture)
      *b SST (Bolt)

      Using the SST (bolts), install each SST (tank belt fixture), and support the hydrogen tank frame.

      SST
      09403-62010   ( 09403-06100, 09403-06110 )

      Note


      • If the hydrogen tank unit is removed from the vehicle without attaching each SST (tank belt fixture), the hydrogen tank frame will spring back because of the spring force and the installation positions of parts will be misaligned.

      • Do not remove any of the tank frame installation bolts until each SST (tank belt fixture) are installed.

      Tech Tips

      If it is difficult to install each SST (tank belt fixture), loosen the tank frame installation bolts to a position where the tank frame support attachments can be installed.

    7. B006JDHC01
      *a SST (Support No. 1, Support No. 2, Support No. 3 and Support No. 4)
      *b SST (Bolt)

      Tighten the SST (bolts) of each tank support type SST.

      SST
      09403-62010   ( 09403-06010, 09403-06020, 09403-06030, 09403-06040, 09403-06080 )
    8. B006JDX

      Remove the 8 bolts.

    9. B006JHWC03
      *a Shift

      While shifting the hydrogen inlet receptacle assembly approximately 25 mm (0.98 in.) to the vehicle inner side, operate the engine lifter and slowly remove the hydrogen tank unit from the vehicle.

      Note


      • Do not apply excessive force to the high pressure hydrogen piping.

      • Make sure the hydrogen tank assembly and high pressure hydrogen piping do not interfere with the vehicle body or surrounding components.

    10. B006JDLC01
      *a SST (Support No. 7)

      Support the hydrogen tank tube assembly with the SST (support No. 7).

      Note


      • To prevent deformation of the hydrogen tank tube assembly, make sure the hydrogen tank tube assembly does not come off of the SST (support No. 7).

      • To prevent deformation of the hydrogen tank tube assembly, make sure that your body does not catch on it.

  40. REMOVE NO .2 HYDROGEN SUPPLY TUBE SUB-ASSEMBLY

    Click here

  41. REMOVE NO. 6 HYDROGEN TANK TUBE

    CAUTION:


    • 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.

    B006JJ9C15
    *a After depressurization procedures, the high pressure piping union nut that is loosened first.

    1. A00269R

      Using a 17 mm union nut wrench, loosen the 2 union nuts and remove the No. 6 hydrogen tank tube from the hydrogen supply regulator assembly and hydrogen tank tube joint.

      Note

      Do not reuse the No. 6 hydrogen tank tube.

    2. B006JIYC03
      *a Protective Tape

      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 tank tube joint and hydrogen supply regulator assembly with protective tape.

      Tech Tips


      • When replacing the hydrogen supply regulator assembly with a new one, it is not necessary to protect the seal portions and thread portions with protective tape.

      • When replacing the hydrogen tank tube joint with a new one, it is not necessary to protect the seal portions and thread portions with protective tape.

  42. SEPARATE HYDROGEN TANK TUBE JOINT SUPPLY BRACKET


    1. A0026D2

      Remove the 2 bolts and separate the hydrogen tank tube joint supply bracket from the front center hydrogen tank frame.

  43. REMOVE HYDROGEN SUPPLY REGULATOR ASSEMBLY


    1. B006JM9C03
      B006JEG Lift Upwards
      B006JKV Remove

      Remove the 4 bolts.

    2. While slightly lifting up the hydrogen tank tube joint supply bracket, remove the hydrogen supply regulator assembly from the hydrogen tank frame FR CTR.

      Note

      Do not damage or deform the No. 4 hydrogen tank tube or the No. 5 hydrogen tank tube.