26. 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 43.

Figure 44.

1

1

© 2018 Toyota Motor Sales, USA

Cut Connector End Off

T-SB-0063-18

July 19, 2018

Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)

27. 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 45.

28. 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 46.

29. 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 47.

30. 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 48.

© 2018 Toyota Motor Sales, USA

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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)

31. 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 49.

32. 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 50.

HINT
This step aides in passing the wire coat
hanger and the attached wires through the
rubber grommet passage.

33. 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 24.

Figure 51.

HINT
The wire coat hanger assists sending the
wires through the passage to the passenger
compartment side of the grommet.

© 2018 Toyota Motor Sales, USA

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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)

34. Insert the bent wire coat hanger all the way
through into the passenger side so the
plastic is free of the grommet.

Figure 52.

35. Gently remove the plastic and the silicone tape not to 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.
36. 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 53.

Figure 54.

1
c
1
c

1

Passenger Compartment – Sub-Wire
Harnesses Pulled Through Grommet

1

© 2018 Toyota Motor Sales, USA

Engine Com partment – Corrugated Sub-Wire
Harness Covers

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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)

37. 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 55.

1
c

1

38. 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 56.

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.

1

A/C ECU Pigtail Sub-Wire Harness

2

Driver J/B Sub-Wire Harness

 Corrugated tube length for driver J/B
sub-wire harness = Maximum of ~560 mm
or less.

© 2018 Toyota Motor Sales, USA

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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 57.

2

1

B. Wrap the entire length of the corrugated
tube with electrical tape.
Begin at the section of wire protruding
closest to the end of the corrugated
tube as shown.

1

60 m m

2

Corrugated Tube

Figure 58.

Figure 59.

Figure 60.

© 2018 Toyota Motor Sales, USA

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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 61.

1

D. Wrap the entire length of the corrugated
tube with electrical tape as shown.

1

60 m m

2

Corrugated Tube

Figure 62.

Figure 63.

Figure 64.

© 2018 Toyota Motor Sales, USA

2
c

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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)

39. In the driver side J/B, locate connector 1F
(32 pin), pull open the connector lock lever,
and remove the connector.

Figure 65.

NOTE
Connector 1F applies to both manual and
automatic air conditioning systems.

40. Remove the black, plastic lock lever from the connector.
Figure 66.

Figure 67.

© 2018 Toyota Motor Sales, USA

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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)

41. Remove the electrical tape from the
connector harness and pull back the wire
harness cover to expose the wires.

Figure 68.

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 42 for the wire splice connection procedure.


NO — Go to step 43 for the pin insertion procedure.

Figure 69.

Figure 70.

42. 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 71.

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 pin16 wire.

Figure 72.

CAUTION
 Due to the small gauge of the pin 16
wire, be very careful during the
stripping of the wire insulation
NOT to cut off ANY strands of the
wire, or it will compromise the
wire integrity.
 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 otherwise making the
splice process will be difficult.

Figure 73.

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 74.

CAUTION
 Be very careful during the stripping
of the wire insulation NOT to cut off
ANY strands of the wire, or it will
compromise the wire integrity.
 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 otherwise making the
splice process will be difficult.

© 2018 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 75.

H. Twist the two stripped wire ends
together uniformly.

Figure 76.

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 77.

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 78.
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

© 2018 Toyota Motor Sales, USA

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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Figure 79.

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 Crim p

J. Using a wire crimp tool, place the joint
terminal into the blue dot position of the
crimp jaws and center the terminal.

Figure 80.

K. Squeeze the crimp tool until the ends of
the crimp tool come in contact with each
other, ensuring a good quality crimp.

Figure 81.
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 82.

Figure 83.

NOTICE
Do NOT let the silicone tape fold or
touch itself as it is very difficult to
unstick once this has occurred.

© 2018 Toyota Motor Sales, USA

T-SB-0063-18

July 19, 2018

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 84.

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 85.

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 86.

© 2018 Toyota Motor Sales, USA

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