TECHNICAL INSTRUCTIONS
FOR
26TE03
ELECTRIC HEATER SUB-ASSEMBLY REPLACEMENT
CERTAIN 2021 - 2024
MIRAI

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this
repair are required to successfully complete the most current version of the E-Learning course “Safety Recall and
Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly, technicians
performing this repair are required to complete the following courses:
•

TIC309A - EPV Repair
TEN021B - Mirai
It is the dealership’s responsibility to select technicians who have completed the above course to
perform this repair. Carefully review your resources, the technician skill level, and ability before
assigning technicians to this repair. It is important to consider technician days off and vacation
schedules to ensure there are properly trained technicians available to always perform this repair.

1

OPERATION FLOW CHART
The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL steps
as outlined in the full technical instructions to confirm the campaign is completed correctly.

IDENTIFICATION OF AFFECTED VEHICLES
1.

CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a) Compare the vehicles VIN to the VIN listed in the Repair Order to ensure they match.
b) Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this CSP, HINT:
TMNA warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were
previously completed, even by another dealer.

2

PREPARATION
A. PARTS
1

Part Number
04004‐73162

Part Name
HEATER SUB-ASSY, ELECTRIC

Quantity
1

*The set above includes the following parts.
Part Number
Part Name
Quantity
Electric Heater Sub87101-62021
1
assembly
B. TOOLS, SUPPLIES & EQUIPMENT
• GTS+
• Insulated Tool Set
• Radiator Cap Tester
Adapter Set C

• Standard Hand Tools
• Toyota Electrical Tester Set

• Torque wrench
• Radiator Cap Tester

C. MATERIALS
Part Number
04005-15162
• Brake Cleaner
• light
• Protective Gloves

Part Name
COOLANT, FC STACK 0.3L
• Shop Cloth
• Protective Tape
• Insulated Gloves

Quantity
1 bottle

• Container
• Protective Eyewear
• Insulating Tape

3

WORK PROCEDURE TABLE OF CONTENTS
BACKGROUND ·································································································
COMPONENTS ·································································································
REMOVE THE ELECTRIC HEATER SUB-ASSEMBLY ·············································
INSTALL THE NEW ELECTRIC HEATER SUB-ASSEMBLY ······································
RESTORE VEHICLE ··························································································
APPENDIX ·······································································································

SECTION V.
SECTION VI.
SECTION VII.
SECTION VIII.
SECTION IX.
SECTION X.

BACKGROUND

4

COMPONENTS

5

REMOVE THE ELECTRIC HEATER SUB-ASSEMBLY
Always remember “SAFETY FIRST”.

1.

CHECK FOR DTCs
If the DTC is output, perform troubleshooting first.
If you troubleshoot without checking the diagnostic code, there is a risk of electric shock due to
electric leakage.

a) Be sure to check the diagnostic code before removing and installing parts of high-voltage systems.
DTC:
•
DTC P0AA649 (Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure)
•
P1C7C49 (Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure)
•
P1C7D49 (Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure)
•
P1C7E49 (Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure)
•
P1C7F49 (Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure)
•
P1EEC49 (Hybrid/EV Battery Voltage System Isolation (FC Air Compressor Area) Internal Electronic Failure)
•
P1EED49 (Hybrid/EV Battery Voltage System Isolation (FC Area) Internal Electronic Failure)
•
P1EEE49 (Hybrid/EV Battery Voltage System Isolation (Hydrogen Pump Area) Internal Electronic Failure)
•
P1EEF49 (Hybrid/EV Battery Voltage System Isolation (FC Coolant Pump Area) Internal Electronic Failure) is
not output
•
P1F0A (High Voltage Electric Heater Circuit (A/C Area)
•

If DTC is present: Proceed with replacing electric heater assembly.

2.

CHECK THE SOC
b) Using the GTS+, check if the SOC is 40% or higher.
Powertrain > EV > Data List
HINT:
If the SOC is lower than 40%, READY ON and wait until the SOC becomes 40% or higher.
3. REMOVE SERVICE PLUG GRIP
PRECAUTION
NOTICE:
After turning the ignition switch is turned off, wait 2 minutes before disconnecting the
negative (-) auxiliary battery terminal.

a)
b)

Disconnect cable from negative Auxiliary Battery Terminal
Remove NO.8 EV Battery Shield Panel

6

CAUTION:

•
•

Be sure to wear insulated gloves.
Do not inspect or service the high voltage system with the service plug grip and FC converter
power outlet cable (inverter with converter assembly) installed.

•

To reduce the risk of electric shock, make sure to remove the service plug grip and FC converter
power outlet cable (inverter with converter assembly) to cut off the high voltage circuit before
servicing the vehicle.
Make sure to remove the service plug grip first and then remove the FC converter power outlet
cable (inverter with converter assembly).
To reduce the risk of electric shock, make sure to wait at least 10 minutes after removing the
service plug grip and FC converter power outlet cable (inverter with converter assembly) to fully
discharge the high voltage capacitor inside the inverter with converter assembly.

•
•

•

Keep the removed service plug grip in your pocket to prevent other technicians from accidentally
installing it while you are servicing the vehicle.

NOTICE:

•
•
•

After removing the service plug grip and FC converter power outlet cable (inverter with converter
assembly), turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the
ignition switch to ON (READY) unless instructed by the repair manual.
Do not touch the terminals of the service plug grip and FC converter power outlet cable (inverter
with converter assembly).
If the service plug grip has been struck or dropped, replace it.

HINT:
Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the
inverter with converter assembly.

7

c) While wearing insulated PPE gloves, rotate the handle of the service plug grip and remove the service plug
grip as indicated by the arrows in the order shown in the illustration.

4.

REMOVE UPPER RADIATOR SUPPORT SEAL

5.

REMOVE FC STACK COVER SUB-ASSEMBLY

6.

REMOVE CONNECTOR COVER ASSEMBLY
CAUTION:
Wear insulated gloves.
NOTICE:

•
•
•

Make sure to pull the connector cover assembly straight up, as a connector is connected to the
bottom of the cover.
Do not touch the connector cover assembly waterproofing rubber.
Do not allow any foreign matter or water to enter the inverter with converter assembly.

8

7.

CHECK TERMINAL VOLTAGE
CAUTION:
Wear insulated gloves.
NOTICE:
Do not allow any foreign matter or water to enter the inverter with converter assembly.
a) Using a voltmeter, measure the voltage
between the terminals of the 2 phase connectors.
Standard Voltage:
0V
HINT:
Use a measuring range of DC 750 V or more on the
voltmeter.

8.

TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

9.

DISCONNECT FC CONVERTER POWER OUTLET CABLE (INVERTER WITH CONVERTER ASSEMBLY)
Refer to TIS for instructions on Engine / Hybrid System> HYBRID / BATTERY CONTROL>INVERTER WITH
CONVERTER>REMOVAL
10. REMOVE RESERVE TANK CAP
a) Cover the reserve tank cap with shop cloth and remove the reserve
tank cap.
CAUTION:
Slowly open the cap since fluid and steam may spray out due to high
pressure, possibly resulting in burns.
HINT:
If the reserve tank cap is not removed, coolant may leak from the water
hoses when disconnecting them.
11. DISCONNECT WATER HOSE SUB-ASSEMBLY C
a) Remove the water hose set No. 2.
b) Using pliers, grip the claws of the clip and slide the clip to
disconnect the water hose sub-assembly C.
NOTICE:
•
DO NOT apply excessive force to the water hose sub-assembly
C.
•
Prepare a container or cloth in case the coolant leaks.
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c)

Remove a cap from the new electric heater and install the cap to
the water hose B port of the old electric heater to prevent coolant
from leaking when removing the electric heater.
HINT:
Either cap can be installed since the cap size is the same for both
hoses.

12. DISCONNECT WATER HOSE SUB-ASSEMBLY B
a) Using pliers, grip the claws of the clip and slide the clip to
disconnect the water hose sub-assembly B.
NOTICE:
•
DO NOT apply excessive force to the water hose sub-assembly
B.
•
Prepare a container or cloth in case the coolant leaks.

b)

Remove a cap from the new electric heater and install the cap to
the water hose C port of the old electric heater to prevent coolant
from leaking when removing the electric heater.
HINT:
Either cap can be installed since the cap size is the same for both
hoses.

13. REMOVE ELECTRIC HEATER SUB-ASSEMBLY
a) Slide the green-colored lock of the connector (A) as shown in the illustration to release it and disconnect the
connector.
CAUTION:
Make sure to wear insulating gloves.
NOTICE:
Insulate the disconnected terminals and connector (A) with Insulating tape.
b) Disconnect the connector (B).
NOTICE:
Cover the disconnected terminals and connector (B) with protective tape to prevent coolant from entering.

10

c)

Remove the 3 bolts and electric heater sub-assembly.

INSTALL THE NEW ELECTRIC HEATER SUB-ASSEMBLY
• Always remember “SAFETY FIRST”.

1.

INSTALL ELECTRIC HEATER SUB-ASSEMBLY
a) Temporarily install the electric heater subassembly with 3 bolts.
b) Install the electric heater sub-assembly with the 3 bolts in the order
shown in the illustration.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

c)
d)

Remove the protective tape from the connector (B) and then connect the connector (B).
Remove the insulating tape from the connector (A) and then connect the connector (A) and slide the greencolored lock as shown in the illustration to securely lock it.
CAUTION:
Make sure to wear insulating gloves.
NOTICE:
Make sure that the connector is connected securely.

2.

CONNECT WATER HOSE SUB-ASSEMBLY B
a) Connect the water hose with its marking facing upward and install the hose sub-assembly B clip within the
range shown in the illustration.
NOTICE:
DO NOT apply excessive force to the water hose sub-assembly B.

11

3.

CONNECT WATER HOSE SUB-ASSEMBLY C
a) Connect the water hose with its marking facing upward and install the hose sub-assembly C clip within the
range shown in the illustration.
b) Install the water hose set No. 2.
NOTICE:
DO NOT apply excessive force to the water hose sub-assembly C.

4.

CONNECT FC CONVERTER POWER OUTLET CABLE (INVERTER WITH CONVERTER ASSEMBLY)
CAUTION:
Wear insulated gloves.
NOTICE:
Before installing the service plug grip, check that no parts or tools remain and that the high
voltage terminals and connectors are connected securely.

(b) If the FC converter power outlet front holder and FC converter power outlet front gasket are removed,
install them using the following procedure.
12

(1) Install the FC converter power outlet front gasket to the housing.

HINT:
Install by aligning the protrusion of the FC converter power outlet front gasket with the housing groove.
(2) Install the FC converter power outlet front holder to the housing.
NOTICE:

c)

Push in the FC converter power outlet front holder until a "click" sound is heard. After pushing it in, check
that it is not removed.

(1) Connect the FC converter power outlet cable (inverter with converter assembly) to the FC stack assembly.
(2) Tighten the 2 bolts (A) and bolt (B) in the order shown in the illustration.
Torque:
8.0 N·m {82 kgf·cm, 71 in·lbf}
5.

INSTALL SERVICE PLUG GRIP
CAUTION:
Wear insulated gloves.
NOTICE:
Before installing the service plug grip, check that no parts or tools remain and that the high
voltage terminals and connectors are connected securely.

13

(1) While wearing insulated gloves, temporarily install the service plug grip as indicated by the arrow (1) shown
in the illustration.
(2) Rotate the handle of the service plug grip 90° toward the HV battery and slide it in the direction indicated by
the arrow (3) shown in the illustration until a click sound is heard to install the service plug grip.
2. INSTALL NO. 8 EV BATTERY SHIELD PANEL
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}

6.

ADD COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed))
•

COOLING: COOLANT: REPLACEMENT (Step 7 Only)

• Since FC coolant is not removed, it is unnecessary to add coolant with FC cooling water ion
exchanger element removed.
• DO NOT add coolant into the case of the ion exchanger, otherwise FC coolant will flow out.

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7.

INSPECT FOR COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed)) LEAK
•

COOLING: COOLING SYSTEM: ON-VEHICLE INSPECTION (Step 8 Only)

8.

INSTALL FC STACK COVER SUB-ASSEMBLY

9.

INSTALL FC STACK COVER SUB-ASSEMBLY

10. CHECK AND CLEAR DTCs

RESTORE VEHICLE
• Always remember “SAFETY FIRST”.

a)
b)

-

Restore the vehicle to Original Condition.
Complete the Repair Quality Check Sheet.

◄ VERIFY REPAIR QUALITY ►
No DTC’s are present.
Confirm Heater/ Defroster functions properly.
Confirm coolant reservoir tank is full.

If you have any questions regarding this update, please contact your regional representative.

15

APPENDIX
A. CAMPAIGN DESIGNATION DECODER

Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021

B. CAMPAIGN PARTS DISPOSAL
As required by Federal Regulations, please make sure all campaign parts (original parts) removed from the
vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery
return.

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