RADIATOR 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 FC radiator 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
Removal/installation of millimeter wave radar sensor assembly Adjust millimeter wave radar sensor assembly

  • Dynamic radar cruise control system

  • Pre-crash safety system

Click here

PROCEDURE


  1. PRECAUTION

    Note


    • The coolant (Toyota genuine FC stack coolant) is an exclusive coolant.

    • The coolant (Toyota genuine FC stack coolant) cannot be reused, so when filling, be sure to fill with new coolant (Toyota genuine FC stack coolant).

    • To prevent degradation of coolant (Toyota genuine FC stack coolant) performance, do not add or fill any other substances such as tap water or battery electrolyte refill liquid.

    • Do not use cotton work gloves or other gloves that could shed fibers.

    • DO NOT use any container that has previously been used to fill substances such as oil.

    • To prevent foreign matter from contaminating the coolant (Toyota genuine FC stack coolant) passages, wash out the prepared container with tap water, then wipe away any water remaining inside the container before using it.

    • If the coolant (Toyota genuine FC stack coolant) passages are filled incorrectly, follow the countermeasures according to "Countermeasures when coolant (Toyota genuine FC stack coolant) passages are filled incorrectly".

      Click here

    • 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

    • 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 LUGGAGE TRIM SERVICE HOLE COVER

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  4. REMOVE FRONT BUMPER LOWER ABSORBER

    Click here

  5. REMOVE NO. 2 MOTOR UNDER COVER

    Click here

  6. REMOVE FRONT FLOOR COVER LH

    Click here

  7. REMOVE FRONT FLOOR COVER RH

    Click here

  8. REMOVE SUSPENSION MEMBER TO FRONT CROSSMEMBER BRACE SUB-ASSEMBLY

    Click here

  9. DRAIN COOLANT (FC STACK COOLANT)

    Click here

  10. REMOVE HEADLAMP ASSEMBLY LH

    Click here

  11. REMOVE HEADLAMP ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  12. REMOVE FRONT BUMPER ENERGY ABSORBER

    Click here

  13. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    Click here

  14. REMOVE MILLIMETER WAVE RADAR SENSOR ASSEMBLY

    Click here

  15. REMOVE AIR CLEANER INLET

    Click here

  16. REMOVE NO. 1 MOTOR UNDER COVER

    Click here

  17. REMOVE AIR CLEANER HOSE ASSEMBLY

    Click here

  18. REMOVE AIR CLEANER WITH ELEMENT ASSEMBLY

    Click here

  19. REMOVE NO. 1 RADIATOR AIR GUIDE RH


    1. A01MJE8

      Disengage the 2 claws.

    2. Disengage the guide to remove the No. 1 radiator air guide RH from the vehicle.

  20. REMOVE NO. 1 RADIATOR AIR GUIDE LH


    1. A01MFV2

      Disengage the 2 claws.

    2. Disengage the guide to remove the No. 1 radiator air guide LH from the vehicle.

  21. DISCONNECT FC RADIATOR INLET HOSE


    1. A01MHP1

      Slide the hose clip and disconnect the FC radiator inlet hose from the FC radiator assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.

      • Perform the work by hand. Do not use tools.

    2. A01MIZQC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the FC radiator inlet hose and FC radiator assembly with plastic bags.

  22. DISCONNECT NO. 1 FC RADIATOR OUTLET HOSE


    1. A01MGQL

      Slide the hose clip and disconnect the No. 1 FC radiator outlet hose from the FC radiator pipe.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator pipe portion.

      • Perform the work by hand. Do not use tools.

    2. A01MFHEC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 FC radiator outlet hose and FC radiator pipe with plastic bags.

  23. DISCONNECT FC SUB-RADIATOR INLET HOSE


    1. A01MJ05

      Slide the hose clip and disconnect the FC sub-radiator inlet hose from the FC radiator assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.

      • Perform the work by hand. Do not use tools.

    2. A01MJSBC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the FC sub-radiator inlet hose and FC radiator assembly with plastic bags.

  24. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY


    1. A01MIY9

      Disconnect the thermistor assembly connector.

    2. A01MJLP

      Disconnect the low pitched horn assembly connector.

    3. Disconnect the high pitched horn assembly connector.

    4. A01MHHL

      Disconnect the hood courtesy switch connector (hood lock assembly).

    5. A01MGE6

      Remove the 5 bolts and upper radiator support sub-assembly from the vehicle.

    6. A01MGEBC01
      *A for RHD
      *B for LHD

      Disengage the guide and disconnect the hood lock control cable assembly.

    7. A01MFTBC01
      *A for RHD
      *B for LHD

      Disengage the clamp to disconnect the hood lock control cable assembly.

  25. REMOVE FC RADIATOR ASSEMBLY


    1. A01MJNJ

      Disconnect the cooling fan with controller motor. (for Fan Side)


      1. Pull up the lever to disengage the lock and disconnect the cooling fan with controller motor connector.

    2. A01MG0Y

      Disconnect the cooling fan with controller motor. (for No. 2 Fan Side)


      1. Pull up the lever to disengage the lock and disconnect the cooling fan with controller motor connector.

    3. A01MJGQ

      Disengage the 7 clamps to separate the wire harness from the fan shroud.

    4. A01MFPE

      Remove the 6 bolts, and separate the radiator support sub-assembly and No. 2 radiator support sub-assembly together with the radiator assembly and cooler condenser assembly, as a single unit, from the FC radiator assembly.

    5. A01MFIB

      Remove the FC radiator assembly from the vehicle.

      Note

      During removal, make sure not to damage the radiator assembly or FC radiator assembly.

    6. A01MJXP

      Slide the hose clip and remove the No. 1 FC radiator outlet hose from the FC radiator assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.

      • Perform the work by hand. Do not use tools.

    7. A01MGC2C02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 FC radiator outlet hose and FC radiator assembly with plastic bags.

    8. A01MJC8

      Slide the hose clip and remove the radiator reservoir tank hose from the FC radiator assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or port of FC radiator assembly portion.

      • Perform the work by hand. Do not use tools.

    9. A01MFXMC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the radiator reservoir tank hose and FC radiator assembly with plastic bags.

    10. A01MI1N

      Remove the 4 bolts.

    11. A01MJOF

      Disengage the clamp.

    12. A01MK2P

      Disengage the 3 guides to remove the fan with motor from the FC radiator assembly.

  26. REMOVE RADIATOR SUPPORT CUSHION


    1. A01MHR5

      Remove the 2 radiator support cushions from the FC radiator assembly.

  27. REMOVE LOWER RADIATOR SUPPORT


    1. A01MJX8

      Remove the 2 lower radiator supports from the FC radiator assembly.