Electrical - Intermittent Hard Start/Long Crank Time
ENGINEEG046-04
Title:
INTERMITTENT EXTENDED OR "HARD" CRANKING
Models
'03 - '04 Tundra (V6)
October 15, 2004
Introduction
Some 2003 - 2004 model year Tundra (V6) vehicles may experience an intermittent extended or ~hard" engine cranking at startup. A revised engine wire harness and ground point relocation is required to correct this condition.
Applicable Vehicles
^ 2003 - 2004 model year Tundra vehicles equipped with 5VZ-FE (V6) engines.
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Location
Repair Procedure
1. Disconnect Negative Battery Terminal.
2. Disconnect Engine No. 2 Wire Harness (Under Hood).
A. Remove the bolt, and disconnect the ground strap.
B. Remove the nut, and disconnect the wire from the relay block No. 2.
C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal.
D. Disconnect the alternator connector and clamp.
E. Remove the nut, and disconnect the alternator wire.
F. Disconnect the connector from the relay block No.2.
G. Disconnect the wire clamp.
H. Raise the vehicle on a lift.
3. Remove Left Front Tire.
4. Remove Front Fender Apron Seal.
A. Remove the 4 clips and the front fender apron rear LH seal.
5. Remove Engine Under Cover.
6. Remove Engine No. 2 Wire Harness (Access from Underside of Vehicle).
A. Remove the bolt, and disconnect the ground strap.
B. Disconnect the starter connector.
C. Remove the nut, and disconnect the starter wire.
D. Disconnect the wire clamp.
E. Disconnect the 2 wire clamps and remove the engine No. 2 wire harness.
HINT:
Unlock the clamp with a long flathead screwdriver.
NOTE:
Be careful not to install the new engine No.2 wire harness as shown in the illustration. The ground should not wrap around engine No.2 wire harness.
7. Install New Engine No. 2 Wire Harness (Under Vehicle).
NOTE:
Reuse the following parts.
(1) Positive (+) terminal cover
(2) Alternator wire cover
(3) Starter wire cover
A. Install the new engine No. 2 wire harness and connect the 2 wire clamps.
B. Connect the wire clamp.
C. Connect the starter connector.
D. Connect the starter wire with a nut.
Torque: 8 - 12 N.m
(80 - 120 kgf.cm, 70 - 104 in.lbf)
E. Connect the wire clamp.
F. Connect the connector to the relay block No. 2.
G. Connect the alternator connector and clamp.
H. Connect the alternator wire with a nut.
Torque: 7 - 13 N.m
(70 - 130 kgf.cm, 61 - 112 in.lbf)
I. Connect the wire to the relay block No. 2 with a nut.
Torque: 5 - 15 N.m
(51 - 153 kgf.cm, 44 - 133 in.lbf)
J. Connect the 2 wires to the positive (+) terminal with a nut.
Torque: 10 - 16 N.m
(100 - 160 kgf.cm, 87 - 139 in.lbf)
NOTE:
Be sure to put the positive (+) terminal cover on.
K. Install the ground strap to the new bolt position indicated by the arrow.
Torque: 30 - 50 N.m
(300 - 520 kgf.cm, 261 - 435 in.lbf)
HINT:
Tighten the bolt in the area where the front fender apron seal has been removed.
NOTE:
Tighten the ground strap at an angle of 300 or less as shown in the illustration so that the oil cooler does not interfere with the wire.
NOTE:
Route the engine No. 2 wire harness as shown in the illustration to prevent heat damage from the exhaust manifold.
L. Fasten the engine No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties.
NOTE:
Place the engine No. 2 wire harness directly on top of the engine wire as shown.
NOTE:
The engine No. 2 wire harness (P/N 82122-0C120) includes 4 wire ties (P/N 90464-00551). Use two of them and keep the other wire ties as spares.
HINT:
Align the lower edge of the clamp with the upper edge of the white tape, and fasten the wires with the wire tie within 5 mm (0.2 in.) from the aligned position.
M. Connect the ground strap with a bolt.
Torque: 7 - 10 N.m
(70 - 100 kgf.cm, 61 - 87 in.lbf)
8. Install Engine Under Cover.
9. Install Front Fender Apron Seal.
10. Install Left Front Tire.
11. Connect Negative Battery Terminal.