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 f ollowing steps when using the wire
crimp tool is required, use a crimp tool that
includes insulated terminal crimp features
and INS.

2

1

Draft - Confidential

1

Insulated Terminal Crimp (Blue)

2

INS Crimp

© 2021 Toyota Motor Sales, USA

T-SB-0093-20

Rev1

September 22, 2020

Page 42 of 62

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

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

Figure 101.

53. 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

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

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.

Draft - Confidential

Close Here

© 2021 Toyota Motor Sales, USA

T-SB-0093-20

Rev1

September 22, 2020

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

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

Figure 104.

56. 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.

57. 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

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© 2021 Toyota Motor Sales, USA

10 mm

Page 43 of 62

T-SB-0093-20

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

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

Figure 107.

Figure 108.

59. Repeat the same joint terminal wrapping
process as used in steps 56 – 58, using
electrical tape.

Figure 109.

60. 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

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© 2021 Toyota Motor Sales, USA

Tie Band

Page 44 of 62

T-SB-0093-20

Rev1

September 22, 2020

Page 45 of 62

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

61. 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

62. 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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© 2021 Toyota Motor Sales, USA

Tie Band

T-SB-0093-20

Rev1

September 22, 2020

Page 46 of 62

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

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

Figure 113.

64. Route the A/C ECU sub-harness over the
heater core pipes, providing enough slack
in the harness to avoid contacting
the pipes.
65. Route the A/C ECU sub-wire harness along
the outside of the evaporator case and
wire-tie the harness to the evaporator case
loophole.

1

2

66. 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 Loophole

Figure 114.

1

1

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© 2021 Toyota Motor Sales, USA

Tie Band

T-SB-0093-20

Rev1

September 22, 2020

Page 47 of 62

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

67. 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

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© 2021 Toyota Motor Sales, USA

Affected Pin Location (16)

T-SB-0093-20

Rev1

September 22, 2020

Page 48 of 62

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 117. 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.

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

Figure 118.

1

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A35 Connect (Automatic A/C)

T-SB-0093-20

Rev1

September 22, 2020

Page 49 of 62

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

69. 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.

70. 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 121.

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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© 2021 Toyota Motor Sales, USA

T-SB-0093-20

Rev1

September 22, 2020

Page 50 of 62

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).

Draft - Confidential

Figure 124.

© 2021 Toyota Motor Sales, USA

T-SB-0093-20

Rev1

September 22, 2020

Page 51 of 62

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.