NHTSA ID Number: 10187260
Manufacturer Communication Number: T-SB-0093-20 Rev
TSB/Document Date: 2021-02-16
Summary
TSB: Some 2016 ? 2021 model year Tacoma vehicles may exhibit a condition where the air conditioning system shuts down and stops blowing cool air during periods of extended engine idle with ambient temperatures greater than 100°F. Follow the Repair Procedure in the bulletin to address this condition.
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 127.
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
© 2021 Toyota
Motor Sales, USA
T-SB-0093-20
Rev1
September 22, 2020
Page 52 of 62
Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
Figure 128.
NOTE
For the f ollowing steps when the wire
crimp tool is required, use a crimp tool that
includes insulated terminal crimp
f eatures 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 129.
K. Crimp both ends of the joint terminal
with the crimp tool at the INS position.
Figure 130.
Draft - Confidential
© 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)
L. Using silicone tape, measure a 150 mm
length piece of tape and cut it
with scissors.
Figure 131.
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 132.
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.
Draft - Confidential
Figure 133.
© 2021 Toyota Motor Sales, USA
Page 53 of 62
T-SB-0093-20
Rev1
September 22, 2020
Page 54 of 62
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 134.
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 135.
1
1
Remaining Pin 8 Wire to Harness to Fold Back
Figure 136.
1
1
Draft - Confidential
© 2021 Toyota Motor Sales, USA
Remaining Electrical Tape (Pin 8 Wire
to Harness)
T-SB-0093-20
Rev1
September 22, 2020
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 137.
Figure 138.
Figure 139.
R. Go to step 72.
71. 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).
Draft - Confidential
Figure 140.
© 2021 Toyota Motor Sales, USA
Page 55 of 62
T-SB-0093-20
Rev1
September 22, 2020
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 141.
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 142.
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).
Draft - Confidential
© 2021 Toyota Motor Sales, USA
Page 56 of 62
T-SB-0093-20
Rev1
September 22, 2020
Page 57 of 62
Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
72. 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 143.
1
1
73. 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 144.
1
2
3
Draft - Confidential
4
1
Upper Left-Hand Body Plug
2
Lower Left-Hand Body Plug
3
Right-Hand Body Plug
4
Skid Plate Seal
© 2021 Toyota Motor Sales, USA
T-SB-0093-20
Rev1
September 22, 2020
Page 58 of 62
Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
A. Install the two NEW left-hand body
plugs in the indicated locations on the
left side of the radiator core support.
Some vehicles may require modification
to the upper left-hand body plug to allow
clearance for the metal tab.
Figure 145.
Figure 146.
1
2
1
Metal Tab
2
Metal Tab Clearance Modification
Figure 147.
1
2
Draft - Confidential
1
Upper Left-Hand Body Plug
2
Lower Left-Hand Body Plug
© 2021 Toyota Motor Sales, USA
T-SB-0093-20
Rev1
September 22, 2020
Page 59 of 62
Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
B. Install the NEW right-hand body plug in
the indicated locations on the right side
of the radiator core support.
Figure 148.
Figure 149.
1
1
C. Remove the No. 1 engine under cover
sub-assembly by removing the
four bolts.
Draft - Confidential
Right-Hand Body Plug
Figure 150.
© 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)
D. Install the NEW skid plate seal in the
position as shown.
Figure 151.
E. Reinstall the No. 1 engine under cover sub-assembly with the four bolts.
Torque: 30 N*m (306 kgf*cm, 22 ft*lbf)
74. Reinstall the passenger side foot air duct
removed in step 19.
Figure 152.
75. Reinstall the instrument lower panel
assembly removed in step 18.
Figure 153.
Draft - Confidential
© 2021 Toyota Motor Sales, USA
Page 60 of 62
T-SB-0093-20
Rev1
September 22, 2020
Page 61 of 62
Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
76. Reinstall the lower No. 2 instrument panel
airbag assembly.
Figure 154.
A. Connect the airbag connector.
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)
77. Reconnect the negative (–) battery terminal.
Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf)
78. Start the vehicle, turn the air conditioner ON, and set the blower speed and temperature to the
lowest setting.
79. 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.
Draft - Confidential
© 2021 Toyota Motor Sales, USA
T-SB-0093-20
Rev1
September 22, 2020
Page 62 of 62
Lack of A/C Performance at Idle in High Ambient Temperature
Repair Procedure (continued)
80. Reinstall ALL previously removed interior trim panels, air deflectors, frame seal, and grille.
81. 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 155.
1
1
Silicone Sealer Application
82. Verify installation and air conditioning operation.
83. Perform the millimeter wave radar sensor adjustment.
NOTE
For vehicles equipped with Toyota Safety System.
Refer to TIS, applicable model and model year Repair Manual:
• 2018 – 2021 Tacoma:
Engine/Hybrid System – Cruise Control – “Cruise Control: Millimeter Wave Radar
Sensor: Adjustment”
Draft - Confidential
© 2021 Toyota Motor Sales, USA
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TSB/Document ID: T-SB-0093-20 Rev
Replacement Service Bulletin Number:
MFR Communication Date: 2021-01-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION:PRESSURE/TEMPERATURE SENSOR
MFR Component System:
MFR Component Subsystem:
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