T-SB-0093-20

T-SB-0093-20
September 22, 2020
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
2016 - 2020
Tacoma
VDS(s): AZ5CN, BZ5DN, CZ5AN, DZ5BN,
EZ5CN, FZ5DN, GZ5AN, HZ5BN, RZ5CN,
SZ5AN
Engine(s): 2GR
Transmission(s): 6AT
SUPERSESSION NOTICE
The information contained in this bulletin supersedes Service Bulletin No. T-SB-0063-18.
 The Applicability and Warranty Information sections have been updated.
Service Bulletin No T-SB-0063-18 is obsolete and any printed versions should be discarded.
Introduction
Some 2016 – 2020 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°F. Follow the Repair Procedure in the bulletin to
address this condition.
Warranty Information
OP CODE
AC1919
DESCRIPTION
Additional Cooling Kit
TIME
OFP
T1
T2
3.3
88450-04012
88460-04200
88460-04201
88450-04011
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.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Parts Information
PART NUMBER
PART NAME
QTY
88590-35050
Blower Assy, W/Shroud
1
90080-87026
Relay
1
90119-A0078
Bolt, W/Washer
1
36869-04010
1
36869-04030
Cover, Packing
36869-04040
1
1
36867-04040
Seal, Packing
1
82112-04050
Wire, Engine Room No. 2
1
82662-0E080
Cover, Relay Block, Upr
1
82683-35220
Label, Fuse Block Notice
1
08231-00045
Silicone Tape
1
NAPA Auto Parts P/N: NW 737305
or Equivalent
¼ in. Diameter Corrugated Tubing
1
82715-35F50
Bracket, Wire Harness Clamp
1
90080-11180
Bolt, W/Washer
2
82999-12020
Terminal, Joint Repair
3
90464-00345
Clamp
32
NOTE
 Repair components are NOT available as a kit.
 ALL parts MUST be ordered separately.
 The quantity amounts listed above are for repairing one vehicle.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
PART NUMBER
Techstream ADVi*
TSADVUNIT
Techstream 2.0
Techstream Lite
QTY
TS2UNIT
ADE
1
TSLITEPDLR01
Techstream Lite (Green Cable)
TSLP2DLR01
*Essential SST.
NOTE
 ONLY ONE of the Techstream units listed above is required.
 Software version 15.20.016 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Kit*
00002-06020-01
1
REQUIRED EQUIPMENT
PART NUMBER
QTY
K Tool International
8-in-1 Quick and Easy Wire Stripper
or Equivalent (Must Include INS Position)
KTI56207
Order Through www.walmart.com or
Several Other Websites
1
Eclipse Tools
CP-301G Pro'sKit Precision Wire Stripper,
30-20 AWG or Equivalent
CP-301G
Order Through www.amazon.com
–
*Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
REQUIRED TOOLS & MATERIAL
PART NUMBER
QTY
Silicone Sealer (Form-in-Place Gasket – Oil Pan)
00295-00103
1
Wire Coat Hanger
–
1
Isopropyl Rubbing Alcohol
–
As Needed
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure
NOTE
This procedure includes the installation of an additional condenser cooling fan. The installation of these
parts also requires the installation of an engine room sub-wire harness, passenger compartment
harnesses, and an additional relay block.
Does the vehicle A/C system shut OFF while stopped, idling in Drive for an extended period of
time during high ambient temperature (100°F+)?
CAUTION
 Ensure the parking brake is firmly applied and hold your foot on the brake pedal.
 Conduct activity in an open area away from obstacles.
NOTE
This condition may NOT be possible to duplicate if ambient temperature is below 100°F.

YES — Go to step 3.

NO — Continue to step 2.
If unable to duplicate the condition, confirm that the customer complaint 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.
Figure 1.
Remove the radiator grille.
A. Disconnect the battery.
2
1
B. Apply protective tape around the
radiator grille.
C. Remove the two screws holding the
grille in place.
1
D. Using a clip remover, remove the
two clips.
E. Disengage the 10 guides and remove
the radiator grille.
1
Clip
2
Screw
Guide
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Remove the left-hand radiator side deflector
by removing the clip and disengaging the
three claws.
Figure 2.
1
1
Clip
v
Remove the right-hand radiator side
deflector by removing the clip and
disengaging the three claws.
Claw
Figure 3.
1
Clip – Two Outer Attachments
1
v
© 2020 Toyota Motor Sales, USA
Claw
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Install the NEW condenser fan.
A. Slide the two bottom mounts of the
condenser fan over the sheet metal lip
of the radiator core support.
Figure 4.
1
B. Install the bolt into the top mount.
2
Locate the bolt holes on the driver side
inner fender. Attach the NEW bracket to
the inner fender with the bolts provided in
the kit.
1
Bolt
2
Bottom Mount
Figure 5.
Torque: 9.8 – 18.1 N*m
(100 – 185 kgf*cm, 7.5 – 13ft*lbf)
Figure 6.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Install the NEW notice label on the inside of
the NEW relay block relay cover.
Figure 7.
Install the NEW relay into the “CDS FAN”
location as indicated on the notice label.
Figure 8.
Attach the relay block to the bracket
installed in step 7.
Figure 9.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Remove the left-hand and right-hand
front door scuff plates by disengaging
the 10 claws and two guides.
Figure 10.
Remove the left-hand and right-hand
cowl side trim board.
Figure 11.
A. Remove the clip.
B. Disengage the two clips and guide to
remove the cowl side trim board.
Figure 12.
HINT
Repeat the same removal process for the
right-hand side.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Disconnect the hood lock control lever
sub-assembly by disengaging the claw and
three guides.
Figure 13.
Remove the instrument panel lower finish
panel sub-assembly.
Figure 14.
A. Remove the bolt.
B. Remove the two screws.
C. Disengage the 11 clips and four claws.
D. Disconnect the connectors and remove
the instrument panel lower finish panel
sub-assembly.
2
1
1
Bolt
2
Screw
Clip
v
© 2020 Toyota Motor Sales, USA
Claw
2
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Remove the right-hand instrument side
panel by disengaging the four claws, three
clips, and three guides.
Figure 15.
Remove the glove box compartment plate
by disengaging the five clips.
Figure 16.
Remove the lower No. 2 instrument panel
airbag assembly.
Figure 17.
CAUTION
 Wait AT LEAST 90 seconds AFTER the
ignition switch is turned to the LOCK
position and the negative (–) terminal
cable is disconnected from the battery.
 The SRS is equipped with a backup
power source, so if work is started
within 90 seconds AFTER
disconnecting the negative (–) terminal
cable of the battery, the SRS
may be deployed.
A. Remove the three bolts.
B. Use a screwdriver with its tip wrapped in
protective tape to release the airbag
protector lock.
1
1
© 2020 Toyota Motor Sales, USA
Protective Tape
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
C. Disconnect the airbag connector and remove the No. 2 instrument panel airbag assembly.
NOTICE
When handling the airbag connector, take care not to damage the wire harness.
Remove the instrument lower panel
assembly by removing the five screws.
Figure 18.
Remove the passenger side foot air duct by
removing the screw.
Figure 19.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Route the battery+ and pusher fan sub-wire harnesses from the relay block attached in
step 10 through the engine compartment.
Figure 20.
1
2
3
4
1
Engine Room Sub-wire Harness
2
Pusher Fan Sub-wire Harness
3
Battery+ Sub-wire Harness
4
Relay Block
5
A/C ECU Pigtail and Driver J/B
Sub-wire Harness
6
A/C ECU Sub-wire Harness
7
Passenger Compartment Sub-wire Harness
F
Driver J/B
G
Driver J/B Sub-wire Harness
H
Grommet
I
Brake Booster
J
A/C ECU Pigtail
K
TSB-Added Relay Block
L
Engine Room Relay Block
M
Battery (+) Sub-wire Harness
N
Battery
O
Pusher Fan Sub-wire Harness
P
Radiator
Q
TSB Pusher Fan
R
Front
S
Driver Side
T
Rear
U
Passenger Side
5
7
6
Figure 21.
F
B
A
G
E
C
H
D
I
J
T
G
K
S
U
R
L
M
N
O
P
Q
A
A/C ECU
B
Passenger Compartment
C
Evaporator Case
D
Engine Compartment
E
A/C ECU Sub-wire Harness
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
A. Remove the bolt from the engine room
relay block bracket and route the NEW
sub-wire harness behind the bracket.
Figure 22.
1
B. Loop and bring the NEW A/C ECU
pigtail and driver J/B sub-wire
harnesses back behind the bracket,
which will later be routed into the
passenger compartment.
2
C. Apply a tie band at the marked location
on the sub-wire harness, attach it to the
engine room relay block bracket, and
cut off the excess.
D. Reinstall the engine room relay block
bracket bolt.
1
A/C ECU Pigtail and Driver J/B
Sub-wire Harnesses
2
Engine Room Relay Block Bracket Bolt
Figure 23.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
E. Route the battery+ sub-wire harness
between the engine room relay block
and the battery.
Figure 24.
1
2
F. Unscrew the nut from the stud bolt on
the positive battery cable.
1
Vehicle Battery+ Cable
2
Battery+ Sub-wire Harness
Figure 25.
G. Put the ring terminal from the NEW
sub-wire harness (white) onto the stud
bolt flange side up.
H. Tighten the nut.
Torque: 9.8 – 15.7 N*m
(103 – 159 kgf*cm, 7.5 – 11.5 ft*lbf)
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
I.
Apply tie bands at the marked locations
on the NEW sub-wire harness, attach it
to the bottom side of the negative (–)
battery cable between the engine room
relay block and the battery, and cut off
the excess.
J. Remove the ground terminal from the
engine room harness.
Figure 26.
1
2
1
Tie Bands
2
Negative (–) Battery Cable
Figure 27.
(1) Attach the ring terminal from the
NEW sub-wire harness white wire.
1
(2) Reinstall the ground terminal into
the original position.
Torque: 7 – 9.8 N*m
(71 – 100 kgf*cm, 5 – 7.2 ft*lbf)
2
1
Engine Room Harness Ground Terminal
2
Sub-wire Harness Ground Ring Terminal
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
K. Continue to route the pusher fan
sub-wire harness forward along the side
of the battery and up the side of the
radiator, attach it to the engine room
harness at the marked locations with tie
bands, and cut off the excess.
Figure 28. Battery
1
1
1
Tie Bands
Figure 29. Radiator
1
1
© 2020 Toyota Motor Sales, USA
Tie Bands
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
L. Remove the radiator support frame seal
by removing the seven clips and the
frame seal.
Figure 30.
M. Continue to route the pusher fan
sub-wire harness over the top driver
side of the radiator, attach it to the
engine room harness at the marked
locations with tie bands, and cut off
the excess.
Figure 31. Radiator (Driver Side)
1
1
© 2020 Toyota Motor Sales, USA
Tie Bands
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
N. Route the pusher fan sub-wire harness
through the top front of the radiator.
Figure 32.
O. Attach the pusher fan sub-wire harness
to the bottom of the hood latch with a tie
band and cut off the excess.
P. Connect the sub-wire harness pusher
fan connector to the NEW pusher
fan included.
1
2
The A/C ECU pigtail and driver J/B sub-wire
harnesses from the engine compartment
will be routed into the passenger
compartment through the engine
compartment bulk head grommet located
next to the power brake booster.
1
Tie Band
2
Sub-wire Harness Pusher Fan Connector
Figure 33.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
The A/C ECU pigtail and driver J/B sub-wire
harnesses will be routed into the passenger
compartment through the bottom of the
grommet that will require modification.
Figure 34.
1
1
Sub-wire Harness Grommet Passage
Modify the bulk head grommet by using scissors or equivalent and cut off the rubber end
of the passage at the indent mark to expose the passage through to the
passenger compartment.
Figure 35.
Figure 36.
1
1
2
1
Grommet Indent Mark
1
Cut at Grommet Indent Mark
2
Modified Grommet
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Confirm the orientation of the grommet
passage is between the 6 and 8 o’clock
positions, viewing it from the engine
compartment side.
Figure 37.
If the grommet is NOT in this orientation,
rotate the bulk head grommet so the
passage is in the proper orientation.
Using the diagonal cutters, remove and
discard the connector end from the
A/C ECU pigtail sub-wire harnesses
BEFORE routing it through the engine
compartment grommet.
Figure 38.
1
1
© 2020 Toyota Motor Sales, USA
Cut Connector End Off
T-SB-0093-20
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Remove the vinyl tube protecting the pin on
the end of the driver J/B sub-wire harness
by removing the black tape and vinyl tube
exposing the pin.
Figure 39.
Cut the bottom straight portion of a wire
coat hanger approximately 30 cm in length
and bend one end of it backward
onto itself.
Figure 40.
Place the ends of the driver J/B sub-wire
harness and A/C ECU pigtail into the bent
end of the coat hanger wire.
Figure 41.
Using silicone tape, measure a 40 mm
length, cut with scissors, and snugly wrap
the bent end of the wire coat hanger and
two wire ends with the silicon tape.
Figure 42.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Using scissors, cut the corner of a used
parts bag enough to cover the end of the
bent wire coat hanger and wire ends.
Figure 43.
Wrap the bent end of the wire coat
hanger with the cut corner of the plastic
parts bag and dip the end in isopropyl
rubbing alcohol.
Figure 44.
HINT
This step aides in passing the wire coat
hanger and the attached wires through the
rubber grommet passage.
From the engine compartment side, gently
insert the bent end of the wire coat hanger
through the bulk head grommet passage
previously made in step 23.
Figure 45.
HINT
The wire coat hanger assists sending the
wires through the passage to the passenger
compartment side of the grommet.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Insert the bent wire coat hanger all the way
through into the passenger side so the
plastic is free of the grommet.
Figure 46.
Gently remove the plastic and the silicone tape, taking care to not damage the wire ends, and
free the wires from the wire coat hanger. Gently pull the remaining length of the wire coat
hanger through the passage and discard.
From the passenger compartment, pull the A/C ECU pigtail and driver J/B sub-wire harnesses
through the grommet until the corrugated wire harness covers meet up against the grommet
on the engine compartment side.
Figure 47.
Figure 48.
1
c
1
c
1
Passenger Compartment – Sub-wire Harnesses
Pulled Through Grommet
1
© 2020 Toyota Motor Sales, USA
Engine Compartment – Corrugated Sub-wire
Harness Covers
T-SB-0093-20
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
From the engine compartment, route the
A/C ECU pigtail and driver J/B sub-wire
harnesses along the engine room harness,
attach with tie bands, and cut off
the excess.
Figure 49.
1
c
1
Once the A/C ECU pigtail and driver J/B
sub-wire harnesses are properly placed in
the passenger compartment, install the
¼ in.-diameter corrugated tubing to both
sub-wire harnesses.
A/C ECU Pigtail and Driver J/B Sub-wire
Harnesses
Figure 50.
1
c
2
NOTE
 The ¼ in.-diameter corrugated tubing is
NOT included. It can be sourced through
NAPA Auto Parts P/N: NW 737305 or
equivalent.
 Corrugated tube length for A/C ECU
pigtail sub-wire harness =
Maximum of ~160 mm or less.
 Corrugated tube length for driver J/B
sub-wire harness = Maximum of ~560 mm
or less.
1
A/C ECU Pigtail Sub-wire Harness
2
Driver J/B Sub-wire Harness
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
A. Slide the corrugated tube over the A/C
ECU pigtail sub-wire harness so the
wire protrudes 60 mm from the
corrugated tube.
Figure 51.
2
1
B. Wrap the entire length of the corrugated
tube with electrical tape.
1
60 mm
2
Corrugated Tube
Figure 52.
Begin at the section of wire protruding
closest to the end of the corrugated
tube as shown.
Figure 53.
Figure 54.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
C. Slide the corrugated tube over the
driver J/B sub-wire harness so the
wire protrudes 60 mm from the
corrugated tube.
Figure 55.
1
D. Wrap the entire length of the corrugated
tube with electrical tape as shown.
1
60 mm
2
Corrugated Tube
Figure 56.
Figure 57.
Figure 58.
© 2020 Toyota Motor Sales, USA
2
c
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
In the driver side J/B, locate connector 1F
(32 pin), pull open the connector lock lever,
and remove the connector.
Figure 59.
NOTE
Connector 1F applies to both manual and
automatic air conditioning systems.
Remove the black, plastic lock lever from the connector.
Figure 60.
Figure 61.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Remove the electrical tape from the
connector harness and pull back the wire
harness cover to expose the wires.
Figure 62.
NOTICE
 The connection of the NEW driver J/B sub-wire harness to the driver side J/B 1F
connector will depend on whether there is a pin in pin location 16 of the 1F connector.
 For both manual and automatic A/C, the connection at the driver J/B will be made at pin
location 16 of connector 1F.
Is there a pin and wire in pin location 16 of the 1F connector?

YES — Continue to step 41 for the wire splice connection procedure.

NO — Go to step 42 for the pin insertion procedure.
Figure 63.
Figure 64.
Confirm there is a pin and wire in pin
location 16 in connector 1F. The connection
will be made with a wire splice procedure.
Figure 65.
A. From the back side of connector 1F,
locate and isolate the pin 16 wire.
B. Measure 60 mm along the pin 16 wire
from the base of connector 1F and mark
the wire.
C. Using the diagonal cutters, cut the pin
16 wire at the 60 mm mark.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
D. Using the wire stripper (P/N CP-301G;
use 24 AWG/0.5 mm to strip insulation
from wire), strip 11 mm of the wire
insulation from the end of pin 16 wire.
Figure 66.
CAUTION
 Due to the small gauge of the
pin 16 wire, be very careful NOT
to cut off ANY strands of the wire
while stripping the wire insulation,
or the integrity of the wire will
be compromised.
 If strands of wire are cut off during
the wire stripping process, cut off
the stripped wire and repeat the
process. Be careful not to cut the
wire too short, or the splice
process will be difficult.
Figure 67.
E. Locate the NEW driver J/B sub-wire harness and using the diagonal cutters, cut off and
discard the pin at the end of the harness.
F. Using the wire stripper, strip 11 mm of
wire insulation from the end of the wire.
Figure 68.
CAUTION
 Be very careful NOT to cut off ANY
strands of the wire while stripping
the wire insulation, or the integrity
of the wire will be compromised.
 If strands of wire are cut off during
the wire stripping process, cut off
the stripped wire and repeat the
process. Be careful not to cut the
wire too short, or the splice
process will be difficult.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
G. Join the stripped end of the NEW driver
J/B sub-wire harness to the stripped
end of the pin 16 wire in connector 1F.
Figure 69.
H. Twist the two stripped wire ends
together uniformly.
Figure 70.
CAUTION
Due to the wire gauge size differences
between the two wires, ensure the
wire ends twist around each
other evenly.
1
c
1
Wires Twisted Together Uniformly – Good
Figure 71.
1
1
I.
Slide the NEW blue joint terminal over
the twisted wire ends so the stripped
portion of the wires are positioned in the
middle of the joint terminal pressure
contact section.
Thin Wire Twisted Around Thick Wire –
Not Good
Figure 72.
1
CAUTION
Be very careful not to bend ANY of
the stripped wire strands backward
as the terminal joint slides over the
stripped wire ends.
2
1
Blue Joint Terminal
2
Pressure Contact Section
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Figure 73.
NOTE
For the following steps when the wire crimp tool
is required, use a crimp tool that includes
insulated terminal crimp features and INS.
2
1
1
Insulated Terminal Crimp (Blue)
2
INS Crimp
J. Using a wire crimp tool, place the joint
terminal into the blue dot position of the
crimp jaws and center the terminal.
Figure 74.
K. Squeeze the crimp tool until the ends of
the crimp tool come in contact with each
other, ensuring a good quality crimp.
Figure 75.
1
1
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Close Here
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
L. While holding the joint terminal, gently tug on the wires to ensure the crimp is good.
NOTICE
If the wires pull out of the joint terminal or the crimp fails, replace the joint terminal with a
NEW one and then crimp again.
M. Crimp both ends of the joint terminal
with the crimp tool at the INS position.
N. Using silicone tape, measure a
150-mm length piece of tape and cut it
with scissors.
Figure 76.
Figure 77.
NOTICE
Do NOT let the silicone tape fold or
touch itself as it is very difficult to
unstick once this has occurred.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
O. Wrap the joint terminal with the silicone
tape by placing the tape lengthwise
along the terminal so the end of the
tape hangs below the terminal,
approximately the width of the tape.
Figure 78.
NOTICE
During the wrapping process of the
joint terminal with the silicone tape,
keep the silicone tape in tension
(stretched) at ALL times.
P. Fold the silicone tape over the top of the
joint terminal and down the opposite
side of the terminal, adhering the tape
to itself over the terminal area.
Figure 79.
Q. Continue to wrap the terminal from the
bottom up to the top of the terminal, and
ensure the tape is adhered to itself.
Figure 80.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
R. Fold the wire back onto itself from the
opposite end of the pin 16 wire, which
remains, and using electrical tape, tape
the wire back into the harness.
Figure 81.
Figure 82.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
S. Place the splice connection along the
wire harness, fold back the driver J/B
sub-wire harness along the connector
harness, and completely wrap with
electrical tape.
Figure 83.
Figure 84.
Figure 85.
T. Go to step 43.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Confirm that there is no pin or wire in cavity
location 16 in connector 1F. The connection
will be made with a pin insertion procedure.
Figure 86.
A. Using a small screwdriver, raise the pin
lock retainer from connector 1F.
Figure 87.
B. Locate the NEW driver J/B sub-wire
harness and insert the pin from the end
of the harness into cavity location 16 in
connector 1F until the pin locks into the
cavity and cannot be pulled out.
Figure 88.
2
CAUTION
BEFORE inserting the pin into the
connector, ensure the pin locking
feature is facing the side of the
connector with the pin lock retainer.
1
1
Pin Locking Feature
2
Connector Pin Lock Retainer
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
C. Close the pin lock retainer at the top of connector 1F.
D. Hold the driver J/B sub-wire harness along the driver side J/B harness and completely
wrap the wire harnesses together with electrical tape (similar to the procedure in
step 41, substep S).
Reapply the driver side J/B wire harness
cover previously pulled back in step 40 and
completely wrap with electrical tape.
Figure 89.
Figure 90.
Figure 91.
Reinstall the black plastic lock lever to connector 1F.
Reconnect connector 1F to the driver side J/B.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Locate the NEW A/C ECU pigtail and slide
the NEW joint terminal over the end of
the wire.
Figure 92.
1
1
Using the wire stripper, strip 11 mm of wire
insulation from the end of the A/C ECU
pigtail wire.
A/C ECU Pigtail
Figure 93.
CAUTION
 Be very careful not to cut off ANY
strands of the wire while stripping the
wire insulation, or the integrity of the
wire will be compromised.
 If strands of wire are cut off during the
wire stripping process, cut off the
stripped wire and repeat the process.
Be careful not to cut the wire too
short, or the splice process
will be difficult.
Figure 94.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Locate the NEW A/C ECU sub-wire
harness, and using the diagonal cutters,
cut the plastic connector off and discard
the connector.
Figure 95.
1
1
Using the wire stripper, strip 11 mm of wire
insulation from the end of the A/C ECU subwire harness where the plastic connector
was previously cut off in step 48.
Cut Connector End Off From the A/C ECU
Sub-harness
Figure 96.
CAUTION
 Be very careful not to cut off ANY
strands of the wire while stripping
the wire insulation, or the integrity of
the wire will be compromised.
 If strands of wire are cut off during
the wire stripping process, cut off the
stripped wire and repeat the process.
Be careful not to cut the wire too
short, or the splice process will
be difficult.
Overlap the two stripped wire ends from the
NEW A/C ECU pigtail and the NEW A/C
ECU sub-wire harness.
Figure 97.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Slide the NEW blue joint terminal over the
stripped portion of the wires so that they are
positioned in the middle of the joint terminal
pressure contact section.
Figure 98.
CAUTION
Be very careful not to bend ANY of the
stripped wire strands backward as the
terminal joint slides over the stripped
wire ends.
Figure 99.
2
1
3
1
Blue Joint Terminal
2
Stripped Wires
3
Pressure Contact Section
Figure 100.
NOTE
For the following steps when using the wire
crimp tool is required, use a crimp tool that
includes insulated terminal crimp features
and INS.
2
1
1
Insulated Terminal Crimp (Blue)
2
INS Crimp
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Using a crimp tool, place the joint terminal
into the blue dot position of the crimp jaws
and center the terminal.
Figure 101.
Squeeze the crimp tool until the ends of the
crimp tool come in contact with each other,
ensuring a good-quality crimp.
Figure 102.
1
1
While holding the joint terminal, gently tug
on the wires to ensure the crimp is good.
Close Here
Figure 103.
NOTICE
If the wires pull out of the joint terminal or
the crimp fails, replace the joint terminal
with a NEW one and then crimp again.
© 2020 Toyota Motor Sales, USA
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Crimp both ends of the joint terminal with
the crimp tool at the INS position.
Figure 104.
Using silcone tape, measure a 150-mm
length piece of tape and cut it with scissors.
Figure 105.
NOTICE
Do NOT let the silicone tape fold or touch
itself as it is very difficult to unstick once
this has occurred.
Wrap the joint terminal with the silicone
tape by placing the tape about 10 mm from
the end of the joint terminal on the wire and
wrap the wire three or more times, keeping
the silcone tape in tension.
Figure 106.
1
1
© 2020 Toyota Motor Sales, USA
10 mm
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Continue to wrap the tape around the joint
terminal, ensuring good adhesion until the
terminal is completely wrapped.
Figure 107.
Figure 108.
Repeat the same joint terminal wrapping
process as used in steps 56 – 58, using
electrical tape.
Figure 109.
At the splice location on the NEW A/C ECU
sub-wire harness, gently fold the A/C ECU
sub-wire harness onto itself, join it with the
NEW driver J/B sub-wire harness, wire-tie
both harnesses to the I/P harness, and cut
off the excess from the tie band.
Figure 110.
1
1
© 2020 Toyota Motor Sales, USA
Tie Band
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Continue to route the A/C ECU sub-wire
harness up the I/P harness, attaching it with
a tie band and cutting off the excess.
Figure 111.
1
1
Continue to route the A/C ECU sub-wire
harness over the pedal cluster assembly
and steering column, and attach it to the
I/P harness with a tie band and cut off
the excess.
Tie Band
Figure 112.
1
c
CAUTION
Make sure the NEW harness does NOT
interfere with the steering shaft or ANY
other moving parts in this location.
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)
Wire-tie the NEW A/C ECU sub-wire
harness to the HVAC harness and cut off
the excess.
Figure 113.
Route the A/C ECU sub-harness over the
heater core pipes, providing enough slack
in the harness to avoid contacting
the pipes.
Route the A/C ECU sub-wire harness along
the outside of the evaporator case and
wire-tie the harness to the evaporator case
loop hole.
1
2
Route the NEW A/C ECU sub-wire harness
under the evaporator case through to the
passenger compartment foot well area,
wire-tie the harness to the HVAC harness,
and cut off the excess.
1
Tie Bands
2
Evaporator Case Loop Hole
Figure 114.
1
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)
The connection of the NEW A/C ECU
sub-wire harness to the A/C ECU connector
will depend on whether the vehicle has
manual or automatic A/C.
Figure 115.
1
2
A. Manual A/C vehicles will ONLY have
one connector (A14) at the A/C ECU.
(1) If connector A14, pin 16 has a
pin/wire, the connection of the NEW
A/C ECU sub-wire harness to
connector A14 will be made by a
wire splice process.
1
Manual A/C
2
Automatic A/C
Figure 116. Manual A/C Connect A14
(2) If connector A14, pin 16 does NOT
have a pin/wire, the connection of
the NEW A/C ECU sub-wire harness
to connector A14 will be made by a
pin insertion process.
1
1
© 2020 Toyota Motor Sales, USA
Affected Pin Location (16)
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
B. Automatic A/C vehicles will have two
connectors to the A/C ECU. The
connection of the A/C ECU sub-wire
harness to the A/C ECU will be made
through connector A35.
Figure 117. Automatic A/C Connect A35
(1) If connector A35, pin 8 has a
pin/wire, the connection of the NEW
A/C ECU sub-wire harness to
connector A35 will be made by a
wire splice process.
(2) If connector A35, pin 8 does NOT
have a pin/wire, the connection of
the NEW A/C ECU sub-wire harness
to connector A35 will be made by a
pin insertion process.
1
1
Affected Pin Location (8)
NOTICE
The following wire splice and pin insertion process of the A/C ECU sub-wire harness to the
A/C ECU connector is shown for an automatic A/C at connector A35. However, the process is the
same for manual A/C at connector A14.
At the A/C ECU, disconnect the A35
connector (A14 connector for manual A/C).
Figure 118.
1
1
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A35 Connect (Automatic A/C)
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Remove the electrical tape from the connector harness to expose the wires.
Figure 119.
Figure 120.
NOTICE
The connection of the NEW A/C ECU sub-wire harness to the A/C ECU A35 connector will
depend on whether there is a pin in pin location 8 of the A35 connector (or pin location 16 in
connector A14 for manual A/C).
Is there a pin and wire in pin location 8 in connector A35 (or pin location 16 in connector A14
for manual A/C)?

YES — Continue to step 70 for the wire splice connection procedure.

NO — Go to step 71 for the pin insertion procedure.
Confirm that there is a pin and wire in pin location 8 in connector A35 (or pin location 16 in
connector A14 for manual A/C).
A. From the back side of connector A35,
locate and isolate pin 8 wire (pin 16 in
connector A14 for manual A/C).
Figure 121.
B. Measure 60 mm along the pin 8 wire
from the base of connector A35 and
mark the wire.
C. Using the diagonal cutters, cut the pin 8
wire (pin 16 wire for manual A/C) at the
60 mm mark.
Figure 122.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
D. Using the wire stripper (P/N CP-301G; use 24 AWG/0.5 mm to strip insulation from wire),
strip 11 mm of wire insulation from the end of the pin 8 wire (pin 16 wire for manual A/C).
CAUTION
 Due to the small gauge of pin wire, be very careful not to cut off ANY strands of the
wire while stripping the wire insulation, or the integrity of the wire will be
compromised.
 If strands of wire are cut off during the wire stripping process, cut off the stripped
wire and repeat the process. Be careful not to cut the wire too short, or the splice
process will be difficult.
E. Locate the NEW A/C ECU sub-wire harness, and using the diagonal cutters, cut off and
discard the pin at the end of the harness.
F. Using the wire stripper, strip 11 mm of
the wire insulation from the NEW A/C
ECU sub-wire harness.
Figure 123.
CAUTION
 Be very careful not to cut off ANY
strands of the wire while stripping
the wire insulation, or the integrity of
the wire will be compromised.
 If strands of wire are cut off during
the wire stripping process, cut off
the stripped wire and repeat the
process. Be careful not to cut the
wire too short, or the splice process
will be difficult.
G. Join the stripped end of the NEW A/C
ECU sub-wire to the stripped end of the
pin 8 wire in connector in A35 (pin 16
wire in connector A14 for manual A/C).
Figure 124.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
H. Twist the two stripped ends
together uniformly.
Figure 125.
CAUTION
Due to the wire gauge size differences
between the two wires, ensure the wire
ends twist around each other evenly.
1
c
1
Wires Twisted Together Uniformly – Good
Figure 126.
1
1
I.
Slide the NEW blue joint terminal over
the twisted wire ends so that the
stripped portion of the wires are
positioned in the middle of the joint
terminal pressure contact section.
Thin Wire Twisted Around Thick Wire –
No Good
Figure 127.
1
CAUTION
Be very careful not to bend ANY of the
stripped wire strands backward as the
terminal joint slides over the stripped
wire ends.
2
1
Blue Joint Terminal
2
Pressure Contact Section
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Figure 128.
NOTE
For the following steps when the wire
crimp tool is required, use a crimp tool that
includes insulated terminal crimp
features and INS.
2
1
1
Insulated Terminal Crimp (Blue)
2
INS Crimp
J. Using a wire crimp tool, place the joint
terminal into the blue dot position of the
crimp jaws and center the terminal.
Figure 129.
K. Crimp both ends of the joint terminal
with the crimp tool at the INS position.
Figure 130.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
L. Using silicone tape, measure a 150 mm
length piece of tape and cut it
with scissors.
Figure 131.
NOTICE
Do NOT let the silicone tape fold or
touch itself as it is very difficult to
unstick once this has occurred.
M. Begin wrapping the NEW joint terminal
with silicone tape by placing the tape
lengthwise along the terminal so that
the end of the tape hangs below the
terminal, approximately the width of
the tape.
Figure 132.
NOTICE
During the wrapping process of the
joint terminal with the silicone tape,
keep the silicone tape in tension
(stretched) at ALL times.
N. Fold the silicone tape over the top of the
joint terminal and down the opposite
side of the terminal, adhering the tape
to itself over the terminal area.
Figure 133.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
O. Continue wrapping the terminal from the
bottom to the top of the terminal,
ensuring the tape is adhered to itself.
Figure 134.
P. Fold the wire back onto itself from the
opposite end of the pin 8 wire (pin 16
wire for manual A/C) which remains,
and using electrical tape, tape the wire
back into the harness.
Figure 135.
1
1
Remaining Pin 8 Wire to Harness to Fold Back
Figure 136.
1
1
© 2020 Toyota Motor Sales, USA
Remaining Electrical Tape (Pin 8 Wire
to Harness)
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Q. Place the splice connection along the
wire harness and fold back the A/C
ECU sub-wire harness along the
connector harness and begin wrapping
with electrical tape until it is
completely wrapped.
Figure 137.
Figure 138.
Figure 139.
R. Go to step 72.
Confirm there is no pin or wire in cavity
location 8 in connector A35 (or pin location
16 in connector A14 for manual A/C).
Figure 140.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
A. Using a small screwdriver, raise the pin
lock retainer from connector A35.
Figure 141.
B. Locate the NEW A/C ECU sub-wire
harness and insert the pin from the end
of the harness into cavity location 8 in
connector A35 (cavity 16 in connector
A14 for manual A/C) until the pin locks
into the cavity and cannot be pulled out.
Figure 142.
1
CAUTION
BEFORE inserting the pin into the
connector, ensure the pin locking
feature is facing the side of the
connector with the pin lock retainer.
2
1
Connector Pin Lock Retainer
2
Pin Locking Feature
C. Close the pin lock retainer at the top of connector A35.
D. Reconnect connector A35 to the A/C ECU (connector A14 for manual A/C).
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Take the excess length of the NEW A/C
ECU sub-harness, loop it up and back
down alongside the blower motor case,
wire-tie it to the harness, and cut off
the excess.
Figure 143.
1
1
At the front of the radiator core support,
install the three NEW radiator core support
body plugs and the skid plate seal.
Tie Bands
Figure 144.
1
2
3
4
1
Upper Left-Hand Body Plug
2
Lower Left-Hand Body Plug
3
Right-Hand Body Plug
4
Skid Plate Seal
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
A. Install the two NEW left-hand body
plugs in the indicated locations on the
left side of the radiator core support.
Some vehicles may require modification
to the upper left-hand body plug to allow
clearance for the metal tab.
Figure 145.
Figure 146.
1
2
1
Metal Tab
2
Metal Tab Clearance Modification
Figure 147.
1
2
1
Upper Left-Hand Body Plug
2
Lower Left-Hand Body Plug
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
B. Install the NEW right-hand body plug in
the indicated locations on the right side
of the radiator core support.
Figure 148.
Figure 149.
1
1
C. Remove the No. 1 engine under cover
sub-assembly by removing the
four bolts.
Right-Hand Body Plug
Figure 150.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
D. Install the NEW skid plate seal in the
position as shown.
Figure 151.
E. Reinstall the No. 1 engine under cover sub-assembly with the four bolts.
Torque: 30 N*m (306 kgf*cm, 22 ft*lbf)
Reinstall the passenger side foot air duct
removed in step 19.
Figure 152.
Reinstall the instrument lower panel
assembly removed in step 18.
Figure 153.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Reinstall the lower No. 2 instrument panel
airbag assembly.
Figure 154.
A. Connect the airbag connector.
NOTICE
When handling the airbag connector,
take care not to damage the
wire harness.
B. Push in the airbag connector lock to
install the airbag connector.
C. Install the lower No. 2 instrument panel
assembly with the three bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
Reconnect the negative (–) battery terminal.
Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf)
Start the vehicle, turn the air conditioner ON, and set the blower speed and temperature to the
lowest setting.
Confirm the NEW pusher fan operation by gently sliding a piece of cardboard between the
condenser and radiator to block the airflow, then check that the pusher fan turns ON within
2 minutes.
CAUTION
Be careful that the engine does not overheat during the fan operation confirmation process.
A. Once proper pusher fan operation is confirmed, turn OFF the ignition and gently remove
the cardboard from between the condenser and radiator, then continue reassembly of
previously removed parts.
B. If the pusher fan does NOT turn on, turn OFF the ignition and gently pull out the cardboard
from between the condenser and radiator.
C. Confirm proper installation of pusher fan components.
 Confirm ALL connectors are fully connected and seated.
 Confirm ALL ground points are properly connected and secured.
 Confirm circuit integrity through ALL splice points.
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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Reinstall ALL previously removed interior trim panels, air deflectors, frame seal, and grille.
Seal the wire harness passage end to
prevent water entry.
Figure 155.
Dab silicone sealer on the end of your
finger and apply it to the wire harness
passage end on the engine compartment
side of the bulk head grommet.
1
1
Silicone Sealer Application
Verify installation and air conditioning operation.
Perform the millimeter wave radar sensor adjustment.
NOTE
For vehicles equipped with Toyota Safety System.
Refer to TIS, applicable model and model year Repair Manual:
 2018 – 2020 Tacoma:
Engine/Hybrid System – Cruise Control – “Cruise Control: Millimeter Wave Radar
Sensor: Adjustment”
© 2020 Toyota Motor Sales, USA