July 19, 2018

Page 50 of 63

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

70. Remove the electrical tape from the connector harness to expose the wires.
Figure 125.

Figure 126.

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 71 for the wire splice connection procedure.


NO — Go to step 72 for the pin insertion procedure.

71. 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).
B. Measure 60 mm along the pin 8 wire
from the base of connector A35 and
mark the wire.

Figure 127.

C. Using the diagonal cutters, cut the pin 8
wire (pin 16 wire for manual A/C) at the
60 mm mark.

Figure 128.

© 2018 Toyota Motor Sales, USA

T-SB-0063-18

July 19, 2018

Page 51 of 63

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 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 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.
Figure 129.
F. Using the wire stripper, strip 11 mm of
the wire insulation from the NEW A/C
ECU sub-wire harness.
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 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 130.

© 2018 Toyota Motor Sales, USA

T-SB-0063-18

July 19, 2018

Page 52 of 63

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

H. Twist the two stripped ends
together uniformly.

Figure 131.

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 132.

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 133.
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

T-SB-0063-18

July 19, 2018

Page 53 of 63

Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Figure 134.

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 135.

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

Figure 136.

© 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)

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

Figure 137.

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 138.

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 139.

© 2018 Toyota Motor Sales, USA

Page 54 of 63

T-SB-0063-18

July 19, 2018

Page 55 of 63

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 140.

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 141.

1

1

Rem aining Pin 8 Wire to Harness to Fold Back

Figure 142.

1

1

© 2018 Toyota Motor Sales, USA

Rem aining Electrical Tape (Pin 8 Wire
to Harness)

T-SB-0063-18

July 19, 2018

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 143.

Figure 144.

Figure 145.

R. Go to step 73.
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 146.

© 2018 Toyota Motor Sales, USA

Page 56 of 63

T-SB-0063-18

July 19, 2018

Page 57 of 63

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 147.

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 148.
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).

© 2018 Toyota Motor Sales, USA

T-SB-0063-18

July 19, 2018

Page 58 of 63

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

73. 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 149.

1

1

74. 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 150.
1

2

3

1

Upper LH Body Plug

2

Low er LH Body Plug

3

RH Body Plug

4

Skid Plate Seal

© 2018 Toyota Motor Sales, USA

4

T-SB-0063-18

July 19, 2018

Page 59 of 63

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

A. Install the two NEW LH body plugs in
the indicated locations on the left side of
the radiator core support.

Figure 151.

Some vehicles may require modification
to the upper LH body plug to allow
clearance for the metal tab.

Figure 152.

1

2

1

Metal Tab

2

Metal Tab Clearance Modification

Figure 153.

1

2

1

Upper LH Body Plug

2

Low er LH Body Plug

© 2018 Toyota Motor Sales, USA

T-SB-0063-18

July 19, 2018

Page 60 of 63

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

B. Install the NEW RH body plug in the
indicated locations on the right side of
the radiator core support.

Figure 154.

Figure 155.

1

1

C. Remove the No. 1 engine under cover
sub-assembly by removing the
four bolts.

RH Body Plug

Figure 156.

© 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)

D. Install the NEW skid plate seal in the
position as shown.

Figure 157.

E. Reinstall the No. 1 engine under cover sub-assembly with the four bolts.
Torque: 30 N*m (306 kgf*cm, 22 ft*lbf)

75. Reinstall the passenger side foot air duct
removed in step 20.

Figure 158.

76. Reinstall the instrument lower panel
assembly removed in step 19.

Figure 159.

© 2018 Toyota Motor Sales, USA

Page 61 of 63

T-SB-0063-18

July 19, 2018

Page 62 of 63

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

77. Reinstall the lower No. 2 instrument panel
airbag assembly.
A. Connect the airbag connector.

Figure 160.

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)

78. Reconnect the negative (–) battery terminal.
Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf)

79. Start the vehicle, turn the air conditioner ON, and set the blower speed and temperature to the
lowest setting.
80. 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.

© 2018 Toyota Motor Sales, USA

T-SB-0063-18

July 19, 2018

Page 63 of 63

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

81. Reinstall ALL previously removed interior trim panels, air deflectors, frame seal, and grille.
82. Seal the wire harness passage end to
prevent water entry.
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.

Figure 161.

1

1

83. Verify installation and air conditioning operation.

© 2018 Toyota Motor Sales, USA

Silicone Sealer Application