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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 87.

Figure 88.

© 2018 Toyota Motor Sales, USA

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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 89.

Figure 90.

Figure 91.

T. Go to step 44.

© 2018 Toyota Motor Sales, USA

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

43. 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 92.

A. Using a small screwdriver, raise the pin
lock retainer from connector 1F.

Figure 93.

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 94.

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

© 2018 Toyota Motor Sales, USA

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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 42.S).
44. Reapply the driver side J/B wire harness
cover previously pulled back in step 41 and
completely wrap with electrical tape.

Figure 95.

Figure 96.

Figure 97.

45. Reinstall the black plastic lock lever to connector 1F.

46. Reconnect connector 1F to the driver side J/B.

© 2018 Toyota Motor Sales, USA

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

47. Locate the NEW A/C ECU pigtail and slide
the NEW joint terminal over the end of
the wire.

Figure 98.
1

1

48. 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 99.

CAUTION
 Be very careful during the stripping of
the wire insulation not to cut off ANY
strands of the wire, otherwise 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 100.

© 2018 Toyota Motor Sales, USA

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

49. Locate the NEW A/C ECU sub-wire
harness, and using the diagonal cutters,
cut the plastic connector off and discard
the connector.

Figure 101.

1

1

50. 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 49.

Cut Connector End Off From the A/C ECU
Sub-Harness

Figure 102.

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

51. Overlap the two stripped wire ends from the
NEW A/C ECU pigtail and the NEW A/C
ECU sub-wire harness.

Figure 103.

© 2018 Toyota Motor Sales, USA

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

52. 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 104.

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 105.
2

1

3

1

Blue Joint Terminal

2

Stripped Wires

3

Pressure Contact Section

Figure 106.

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 Crim p

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

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

Figure 107.

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

Figure 108.

1

1

55. While holding the joint terminal, gently tug
on the wires to ensure the crimp is good.

Close Here

Figure 109.

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.

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

56. Crimp both ends of the joint terminal with
the crimp tool at the INS position.

Figure 110.

57. Using silcone tape, measure a 150 mm
length piece of tape and cut it with scissors.

Figure 111.

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

58. 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 112.
1

1

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10 m m

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

59. Continue to wrap the tape around the joint
terminal, ensuring good adhesion until the
terminal is completely wrapped.

Figure 113.

Figure 114.

60. Repeat the same joint terminal wrapping
process as used in steps 57 – 59, using
electrical tape.

Figure 115.

61. 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 116.

1

1

© 2018 Toyota Motor Sales, USA

Tie Band

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

62. 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 117.

1

1

63. 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 118.

1
c

CAUTION
Make sure the NEW harness does NOT
interfere with the steering shaft or ANY
other moving parts in this location.
1

© 2018 Toyota Motor Sales, USA

Tie Band

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

64. Wire-tie the NEW A/C ECU sub-wire
harness to the HVAC harness and cut off
the excess.

Figure 119.

65. Route the A/C ECU sub-harness over the
heater core pipes, providing enough slack
in the harness to avoid contacting
the pipes.

66. 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

67. 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 120.

1

1

© 2018 Toyota Motor Sales, USA

Tie Band

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

68. 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 121.

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.
(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

Manual A/C

2

Autom atic A/C

Figure 122. Manual A/C Connect A14

1

1

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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.
(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.

Figure 123. Automatic A/C Connect A35

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.

69. At the A/C ECU, disconnect the A35
connector (A14 connector for manual A/C).

Figure 124.

1

1

© 2018 Toyota Motor Sales, USA

A35 Connect (Automatic A/C)

T-SB-0063-18