T-SB-0034-18-Rev

T-SB-0034-18
Rev1
May 11, 2018
Lack of A/C Performance at Idle in High Ambient
Temperature
Service
Category
Vehicle Interior
Section
Heating/Air Conditioning
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2015
Tacoma
VDS(s): JU4GN, KU4HN, LU4EN, MU4FN,
TU4GN, UU4EN
Engine(s): 1GR
Transmission(s): 5AT
REVISION NOTICE
February 13, 2019 Rev1:
 Applicability has been updated to include engine and transmission type.
 The Warranty Information section has been updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2015 model year Tacoma vehicles may exhibit a condition where the air conditioning
system shuts down and stops blowing cool air during periods of extended engine idle with
ambient temperatures greater than 100° Fahrenheit. Follow the Repair Procedure in this bulletin
to address this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
AC1901
Additional Cooling Kit
1.6
16410-0P030
7A
99
APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
© 2019 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Parts Information
PART NUMBER
PREVIOUS
NEW
N/A
04000-17235
PART NAME
QTY
SSP, Cooling Kit
1
Repair Procedure
NOTE
This procedure includes the installation of an additional condenser cooling fan and an updated A/C
pressure switch. The installation of these parts also requires the installation of a sub-wire harness and an
additional relay block.
1. Does the vehicle A/C system shut OFF while idling in Drive during high ambient temperature
(100°F+) for a prolonged period of time?
CAUTION
 Ensure that the parking brake is firmly applied and hold your foot on the brake pedal.
 Conduct activity in an open area away from obstacles.
NOTE
The condition may NOT be possible to duplicate if ambient temperature is below 100°F.

YES — Go to step 3.

NO — Continue to step 2.
2. If unable to duplicate the condition in step 1, confirm that the vehicle condition is similar to the
condition described in step 1.
Is the condition similar to the condition described in step 1?
 YES — Continue to step 3.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
3. Discharge the air conditioning system.
Refer to TIS, applicable model and model year Repair Manual:

2015 Tacoma:
Vehicle Interior – Heating/Air Conditioning – “Air Conditioning: Refrigerant: Replacement”
© 2019 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
4. Remove the radiator grille.
A. Disconnect and remove the battery.
B. Remove the two screws holding the
grille in place.
C. Using a clip remover, remove the
two clips.
D. Disengage the eight guides and remove
the radiator grille.
Figure 1.
1
1
1
Clip
2
Screw
Guide
5. Remove the hood lock release lever
protector shroud by removing the two bolts.
2
Figure 2.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
6. Modify the hood lock release lever protector.
A. Using sheet metal shears, trim the bottom of the protector which shares the attachment
with the pusher fan.
Figure 3. Measure 40 mm
Figure 4. Measure 10 mm
Figure 5. Trimmed Protector
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
B. Bend the locating tab up for
fan clearance.
Figure 6.
1
1
Bend Here
7. Modify the additional condenser fan for the automatic transmission oil cooler.
Figure 7.
Figure 8.
1
2
1
Fan Bracket
2
Autom atic Transmission Cooler Mount
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
8. Cut off the side bracket to eliminate
interference with the automatic
transmission cooler mount.
A. Gently hold the base mount of the
condenser fan in a vise.
Figure 9.
1
1
B. Using an abrasive cutting wheel or
similar cutting tool, cut off the right
side mount.
Side Bracket
Figure 10.
1
© 2019 Toyota Motor Sales, USA
Trim Here
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
C. Measure 25 mm from the top of
the mount and cut off the
remaining portion.
Figure 11.
1
1
D. Clean off ANY remaining plastic burrs
from the cut surface.
25 m m
Figure 12.
1
1
© 2019 Toyota Motor Sales, USA
Finished Mount Modification
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
9. Install the condenser fan and hood lock
release lever protector.
A. Slide the two bottom mounts of the
condenser fan over the sheet metal lip
of the radiator core support.
B. Remove the bolt from the rubber
grommet at the top mounting location.
C. Place the hood lock release lever
protector over the rubber grommet and
install the bolts as shown.
Figure 13.
1
2
1
Bolt
2
Bottom Mount
2
Figure 14.
1
2
1
Rubber Grommet
2
Bolt
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
10. Remove the engine room relay block cover.
Unplug the engine wire harness connector
EA1 and engine room main wire EB1.
Figure 15.
1
2
11. Pull the wire harness from the relay block
by sliding the connector up.
1
EA1 Connector
2
EB1 Connector
Figure 16.
© 2019 Toyota Motor Sales, USA
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Repair Procedure (continued)
12. Release the pin lock from the EA1
connector using a terminal removal tool.
Figure 17.
13. Remove pin No. 3 (purple wire) from the
EA1 connector.
Figure 18.
14. Remove the female terminal (purple wire)
from the 1 pin sub-wire harness connector
using the terminal removal tool.
Figure 19.
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Repair Procedure (continued)
15. Install the purple wire (that was removed
from the EA1 connector in step 13) into the
connector body that was removed from the
sub-wire harness in step 14.
Figure 20.
16. Connect the connector in the sub-wire
harness to the purple wire connector.
Figure 21.
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Repair Procedure (continued)
17. Install the purple wire that was removed in
step 14 from the sub-wire harness
connector (purple wire) into the EA1
connector pin No. 3. Ensure that the pin
lock is seated.
18. Route the harness into the relay block
and ensure that the wire harness is
NOT pinched.
19. Plug the connectors back into the relay
block. The sub-wire connector will sit in the
relay block between the connectors.
Figure 22.
Figure 23.
Figure 24.
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Repair Procedure (continued)
20. Unscrew the nut from the stud bolt on the
positive battery cable. Put the ring terminal
from the sub-wire harness (white) onto the
stud bolt. Tighten the nut.
Figure 25.
Torque: 9.8 – 15.7 N*m
(103 – 159 kgf*cm, 7.5 – 11.5 ft*lbf)
21. Locate the bolt holes on the driver side
inner fender. Attach the bracket included in
the kit to the inner fender with the bolts
included in the kit.
Figure 26.
Torque: 9.8 – 18.1 N*m
(100 – 185 kgf*cm, 7.5 – 13ft*lbf)
22. Install the supplied notice label on the
inside of the additional relay block
relay cover.
Figure 27.
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Repair Procedure (continued)
23. Install the relay included in the kit into the
CDS FAN location as indicated on the
Notice label.
Figure 28.
24. Attach the relay block to the bracket
installed in step 21.
Figure 29.
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Repair Procedure (continued)
25. Route the sub-wire harness as shown,
between the relay block and the body.
Figure 30.
26. Attach the sub-wire harness to the engine
room main wire harness with a tie band and
cut off the excess.
1
27. Secure the sub-wire harness to the relay
block as shown with a tie band and cut off
the excess.
Tie Band
Figure 31.
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Repair Procedure (continued)
28. Remove the ground terminal from the
engine room main harness.
A. Attach the ring terminal from the
sub-wire harness white wire.
B. Reinstall the ground terminal into the
original position.
Figure 32.
Torque: 7 – 9.8 N*m
(71 – 100 kgf*cm, 5 – 7.2 ft*lbf)
C. Attach the sub-wire harness to the
engine harness with the tie bands as
indicated and cut off the excess.
1
Tie Band
29. Remove the radiator support shroud by
disengaging the nine clips.
Figure 33.
30. Route the sub-wire harness along the
radiator support. Secure the harness with
tie bands and cut off the excess.
Figure 34.
1
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Tie Band
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
31. Connect the sub-wire harness connector to
the cooling fan added from the kit and
attached the sub-wire harness with a tie
band to the hood lock support brace and
cut off the excess.
32. Attach the sub-wire harness as shown.
Figure 35.
1
Tie Band
2
Connector
Figure 36.
33. Remove the 2-pin pressure switch and replace it with the 4-pin switch included with the kit.
© 2019 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
34. Connect the vehicle 2-pin connector to the
sub-wire harness 2-pin connector. Connect
the sub-wire 4-pin connector to the 4-pin
pressure switch installed in step 33.
Figure 37.
35. Attach the sub-wire harness to the leg of
the bracket under the power steering
reservoir tank with a tie band and cut
off excess.
Figure 38.
1
36. Attach the sub-wire harness to the engine
wire harness in front of the windshield
washer reservoir with a tie band and cut
off the excess.
Tie Band
Figure 39.
1
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Tie Band
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Repair Procedure (continued)
37. Remove the windshield washer reservoir and
attach the sub-wire harness ground terminal
to the ground point behind the reservoir.
Figure 40.
Torque: 7 – 9.8 N*m
(70 – 100 kgf*cm, 5 – 7.2 ft*lbf)
38. Reattach the windshield washer reservoir to the fender.
39. Confirm that the sub-wire harness is installed correctly.
40. Recharge the A/C system and inspect for any leaks.
Refer to the TIS, applicable model and model year Repair Manual:

2015 Tacoma:
Vehicle Interior – Heating/Air Conditioning – “Air Conditioning:
Refrigerant: Replacement”
41. Remove the four bolts holding the radiator
in place.
Figure 41.
42. Lift up and push back on the radiator,
releasing the hooks holding it in place.
Figure 42.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
43. Install the eight radiator core support body
plugs and seals included in the kit.
Figure 43.
3
6
5
1
4
2
7
8
1
Body Plug, Upper RH
2
Body Plug, Low er RH
3
Body Plug, Upper LH
4
Body Plug, Low er LH
5
Radiator Seal, LH
6
Radiator Seal, RH
7
Low er Radiator Seal
8
Skid Plate Seal
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Repair Procedure (continued)
A. Peel the adhesive backing off the LH
and RH foam radiator seals included in
the kit and install with the arrow pointing
down. The adhesive side should be
installed towards the radiator.
Figure 44.
1
NOTE
Foam seals have markings on them
distinguishing right from left and top
from bottom.
1
Foam Seal
B. Reinstall the four radiator support bolts.
C. Install the NEW body plugs included in
the kit in the indicated locations.
Reference step 43 for location positions.
Figure 45.
1
© 2019 Toyota Motor Sales, USA
Body Plug
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
D. Remove the No. 1 engine under the
cover sub-assembly.
Figure 46.
E. Install the lower radiator seal as shown.
Figure 47.
F. Install the skid plate seal included in the
kit in the position as shown.
Figure 48.
G. Reinstall the No. 1 engine under cover sub-assembly.
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Repair Procedure (continued)
44. Reinstall the radiator grille.
45. Reinstall the battery and ensure the sub-wire harness is NOT being pinched by the
battery cable.
Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf)
46. Verify installation and air conditioning operation.
© 2019 Toyota Motor Sales, USA