T-SB-0220-08 August 11, 2008

M.I.L. "ON" DTC B2799 "No Star t" Due to Harness WaterIntrusionServiceCategor y Vehicle Interior

Section Theft Deterrent/Keyless Entry Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2007 – 2008 Tundra

Intr oduction

Some 2007 – 2008 model year Tundra vehicles may exhibit a “no start” condition with DiagnosticTrouble Code (DTC) B2799 caused by water intrusion into the engine room wire harness. Follow theprocedures in this bulletin to inspect and replace the engine room wire harness as necessary toaddress customer concerns.

NOTE

This TSB ONLY applies to vehic les exhibiting a “no star t” condition with DTC B2799 and wateror corr osion in connector s.

Figure 1. Aff ected Areas

© 2008 Toyota Motor Sales, USA Page 1 of 8

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M.I.L. "ON" DTC B2799 "No Star t" Due to Harness Water Intrusion

Production Chang e Information

This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below.

MODEL PLANT ENGINE DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN

2WD5TBLV521*8S4788685TBRV541*8S4788685TBRV581*8S478868

3UR-FE

4WD5TBMV521*8S5100565TBBV541*8S5100565TBBV581*8S510056

1GR-FE5TFJU521*8X0038095TFLU521*8X0111625TFRU541*8X011162

2WD

5TFJT521*8X0023285TFLV521*8X0223955TFRV541*8X0223955TFRV581*8X0223955TFST541*8X0021215TFSV541*8X0021215TFEV541*8X0021215TFEV581*8X0021212UZ-FE

4WD

5TFKT521*8X0021925TFMT521*8X0126235TFBT541*8X0126235TFCT541*8X0023295TFBT581*8X0023295TFDT541*8X0023295TFDT581*8X002329

2WD

5TFJV521*8X0029145TFRT541*8X0565635TFRV541*8X0565635TFRV581*8X0565635TFST541*8X0056545TFSV541*8X0056545TFEV541*8X0056545TFEV581*8X005654

Tundra TMMTX

3UR-FE

4WD

5TFKV521*8X0029265TFMV521*8X0611415TFBV541*8X0611415TFBV581*8X0611415TFCV541*8X0072625TFDV541*8X0072625TFDV581*8X007262

© 2008 Toyota Motor Sales, USA

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M.I.L. "ON" DTC B2799 "No Star t" Due to Harness Water Intrusion

Production Chang e Information (Contin ued)

MODEL PLANT ENGINE DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN

2WD5TBLT521*8S4599845TBRT541*8S4599845TBRT581*8S459984Tundra TMMI 2UZ-FE

4WD 5TBMT521*8S4620085TBBT541*8S462008

Warranty Information

OP CODE DESCRIPTION REPAIRPROCEDURE* TIME OFP T1 T2

EL8042 Inspect & Clean Terminals A 0.5

Combo A R & R Engine Room MainWire Harness B 5.8

82111-OC### 01 17

* Follow Repair Procedure based on affected area described in Inspection Procedure.

APPLICABLE WARRANTY

• This repair is covered under the Toyota Comprehensive Warranty . This warranty is in effect for36 months or 36,000 miles, whic hever occur s fir st, from the vehic le’s in-service date .

• Warranty application is limited to correction of a problem based upon a customer’s specificcomplaint.

Parts Information

PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY

82111-OC### Same Wire Harness, Engine Room Main 1

Required Tools & Equipment

REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY

TIS techstream*

NOTE: Software version 3.01.000 or later is required.ADE TSPKG1 1

* Essential SST.

NOTE

Additional TIS techstream units may be ordered by calling Appr oved Dealer Equipment (ADE) at1-800-368-6787.

© 2008 Toyota Motor Sales, USA

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M.I.L. "ON" DTC B2799 "No Star t" Due to Harness Water Intrusion

Required Tools & Equipment (Contin ued)

REQUIRED TOOLS & MATERIAL PART NUMBER QTY

CRC Lectra-Motive Electric Parts Cleaner, or Equivalent CRC P/N 05018 As Needed

Inspection Procedure

1. Confirm that the “no start” condition and DTC B2799 are both present.

2. Inspect the passenger side (RH side) engineroom junction block for water or corrosion.

A. Disconnect the connector and inspect pinsand terminals for water or corrosion.

B. If water or corrosion is present on the engineside of the wire harness, perform RepairProcedure A, then proceed to step 3 to inspectthe RH side junction block connectors.

Figure 2. Engine Room Junction Bloc k

1

1

1

1 Junction Bloc k Connector

© 2008 Toyota Motor Sales, USA

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M.I.L. "ON" DTC B2799 "No Star t" Due to Harness Water Intrusion

Inspection Procedure (Contin ued)

3. Inspect the RH side junction block connectors for water intrusion.

A. Remove the RH side scuff plate by detachingthe 6 claws and 3 clips.

Figure 3. Front Door Scuff Plate RH

:

:

1

2

1 Clip

2 Claw

B. Remove the cowl side trim board RH.

(1) Remove the clip.

(2) Detach the 2 clips and remove the cowlside trim board.

Figure 4. Cowl Side Trim Boar d RH

: 1

1 Clip

© 2008 Toyota Motor Sales, USA

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M.I.L. "ON" DTC B2799 "No Star t" Due to Harness Water Intrusion

Inspection Procedure (Contin ued)

C. Disconnect connector AJ5.

HINT

AJ5 is a white 22 pin connector located onthe RH side kic k panel.

Figure 5. Location of Connector AJ5

Figure 6. Connector AJ5

1 2

1 Engine Side

2 Vehic le Side

D. If water or corrosion is present on the cab side of the wire harness, perform RepairProcedure B.

© 2008 Toyota Motor Sales, USA

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M.I.L. "ON" DTC B2799 "No Star t" Due to Harness Water Intrusion

Repair Procedure A

1. Clean off the contaminated pins, using an electric parts cleaner (CRC Lectra-Motive, P/N 05018,or equivalent).

2. Return to the Inspection Procedure, step 3.

Repair Procedure B

1. Disconnect the negative (–) battery terminal.

2. Replace the engine room main wire harness and clean the remaining AJ5 terminals using anelectric parts cleaner (CRC Lectra-Motive, P/N 05018, or equivalent).

Refer to the Technical Information System (TIS), 2007 or 2008 model year Tundra RepairManual to remove/detach the following:

A. Driver’s Side Kick Panel

2007 Tundra:Vehicle Interior – Interior Panels/Trim – “Instrument Panel: Instrument Panel SafetyPad (for Column Shift Type) / (for Floor Shift Type): Removal”

2008 Tundra:Vehicle Interior – Interior Panels/Trim – “Instrument Panel: Instrument Panel SafetyPad (for Column Shift Type) / (for Floor Shift Type): Removal”

B. Body ECU (for easier access)

C. Air Cleaner Case

2007 Tundra:Engine/Hybrid System – Intake/Exhaust – “3UR-FE / 2UZ-FE / 1GR-FE Intake: AirCleaner: Removal”

2008 Tundra:Engine/Hybrid System – Intake/Exhaust – “3UR-FE / 2UZ-FE / 1GR-FE Intake: IntakeManifold: Removal”

D. Hood to Cowl Seal (for access to wiper motor connector)

2007 or 2008 Tundra:Vehicle Exterior – Wiper/Washer – “Wiper and Washer: Front Wiper Motor: Removal”

E. Headlight Assemblies

2007 or 2008 Tundra:Vehicle Exterior – Lighting (ext) – “Lighting: Headlight Assembly: Removal”

© 2008 Toyota Motor Sales, USA

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M.I.L. "ON" DTC B2799 "No Star t" Due to Harness Water Intrusion

Repair Procedure B (Contin ued)

F. Windshield Washer Jar Assembly

2007 or 2008 Tundra:Vehicle Exterior – Wiper/Washer – “Wiper and Washer: Washer Motor: Removal”

G. Hood Latch Assembly

2007 or 2008 Tundra:Vehicle Exterior – Door/Hatch – “Engine Hood / Door: Hood Lock Control CableAssembly: Removal”

H. Detach Radiator

2007 Tundra:Engine/Hybrid System – Cooling – “3UR-FE / 2UZ-FE / 1GR-FE Cooling: Radiator: Removal”

2008 Tundra:Engine/Hybrid System – Cooling – “3UR-FE / 2UZ-FE / 1GR-FE Cooling: Radiator: Removal”

I. Detach ABS Actuator

2007 or 2008 Tundra:Brake – Brake Control/Dynamic Control System – “Brake Control: Brake Actuator: Removal”

3. Replace the engine room main wire harness.

4. Reassemble in reverse order of disassembly.

5. Reconnect the negative (–) battery terminal.

6. Clear DTCs, and check that the “no start” condition and DTC B2799 are no longer present.

© 2008 Toyota Motor Sales, USA