Canada - Electrical/Starting - Hard Start/Extended Crank Time
Bulletin
TSB2116
Issue Date
October 12, 2004
Market
Canada
Title
INTERMITTENT EXTENDED OR "HARD" CRANKING
Component
ENGINE ELECTRICAL
Models
'03 - '04 Tacoma (V6)
Some 2003 -- 2004 model year Tacoma (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 Tacoma vehicles equipped with 5VZ-FE (V6) engines.
PARTS INFORMATION:
WARRANTY INFORMATION:
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.
HINT:
Push upward on the clamp to remove it.
C. Remove the nut, and disconnect the 2 wires from the positive (+) terminal.
D. Disconnect the connector from the relay block No. 2.
E. Disconnect the alternator connector and clamp.
F. Remove the nut, and disconnect the alternator wire.
G. Disconnect the 2 wire clamps.
H. Raise the vehicle on a lift.
3. Remove Left Front Tire.
4. Remove Front Fender Apron Seal.
A. Remove the 12 clips and the front fender apron 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.
HINT:
Unlock the clamp and remove it 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.
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 2 wire clamps.
F. Connect the alternator connector and clamp.
G. Connect the alternator wire with a nut.
Torque: 7 - 13 N-m (70 - 130 kgf-cm, 61 - 112 in.-lbf)
H. 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)
HINT:Install the clamp by pushing it down.
I. Connect the connector to the relay block No. 2.
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 - 502 kgf-cm, 261 - 435 in.-lbf)
NOTE:
Tighten the ground strap at an angle of 30° or less as shown in the illustration so that the oil cooler does not interfere with the wire.
L. Fasten the No. 2 wire harness at positions (A) and (B) as shown in the illustration using the 2 wire ties.
NOTE:
The engine No. 2 wire harness (82122--35A60) includes 4 wire ties (90464--00551). Use two of them and keep 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 from the aligned position.
NOTE:
To prevent heat damage or damage to the wire cover, please observe the following:
- Fasten the engine No. 2 wire 30 mm or more apart from the exhaust manifold.
- Fasten the engine No. 2 wire 17 mm or more apart from the front suspension tower.
- Fasten the engine No. 2 wire at an angle of 30_ or less behind the engine wire.
HINT:
At position "B," align the edge of the clamp with the edge of the yellow tape, and fasten the wires with the wire tie within 5 mm 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 Undercover.
9. Install Front Fender Apron Seal.
10. Install Left Front Tire.
11. Connect Negative Battery Terminal.
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.