NO — Go to step 42 for the pin insertion procedure.

Figure 63.

Figure 64.

41. 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.
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 66.

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.

Draft - Confidential

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T-SB-0093-20

Rev1

September 22, 2020

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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.

Draft - Confidential

2

1

Blue Joint Terminal

2

Pressure Contact Section

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T-SB-0093-20

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Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Figure 73.

NOTE
For the f ollowing 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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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.

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T-SB-0093-20

Rev1

September 22, 2020

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)

42. 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.

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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).
43. 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.

44. Reinstall the black plastic lock lever to connector 1F.
45. Reconnect connector 1F to the driver side J/B.

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T-SB-0093-20

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September 22, 2020

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

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

Figure 92.
1

1

47. Using the wire stripper, strip 11 mm of wire
insulation from the end of the A/C ECU
pigtail wire.
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.

Draft - Confidential

A/C ECU Pigtail

Figure 93.

Figure 94.

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

48. 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

49. 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.

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

Draft - Confidential

Figure 97.

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T-SB-0093-20

Rev1

September 22, 2020

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

51. 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.