T-SB-0220-08 Rev1 August 11, 2008 M.I.L. "ON" DTC B2799 "No Start" Due to Harness Water Intrusion Service Category Vehicle Interior Section Theft Deterrent/Keyless Entry Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2007 2008 Tundra TSB REVISION NOTICE November 12, 2008 Rev1: The Production Change Information section has been updated with new VIN information. Any previous printed versions of this service bulletin should be discarded. Introduction Some 2007 2008 model year Tundra vehicles may exhibit a no start condition with Diagnostic Trouble Code (DTC) B2799 caused by water intrusion into the engine room wire harness. Follow the procedures in this bulletin to inspect and replace the engine room wire harness as necessary to address customer concerns. NOTE This TSB ONLY applies to vehicles exhibiting a no start condition with DTC B2799 and water or corrosion in connectors. Page 1 of 9
T-SB-0220-08 Rev1 August 11, 2008 Page 2 of 9 Introduction (Continued) Figure 1. Affected Areas Warranty Information OP CODE DESCRIPTION REPAIR PROCEDURE* EL8042 Inspect & Clean Terminals A 0.5 Combo A R & R Engine Room Main Wire Harness B 5.8 * Follow Repair Procedure based on affected area described in Inspection Procedure. TIME OFP T1 T2 82111-OC### 01 17 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.
T-SB-0220-08 Rev1 August 11, 2008 Page 3 of 9 Production Change Information This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below. MODEL PLANT ENGINE DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN Tundra TMMTX TMMI 1GR-FE 2UZ-FE 3UR-FE 2UZ-FE 2WD 4WD 2WD 4WD 2WD 4WD 5TFJU521*8X003809 5TFLU521*8X011162 5TFRU541*8X011162 5TFJT521*8X002328 5TFLT521*8X022395 5TFRT541*8X022395 5TFET541*8X022395 5TFET581*8X022395 5TFRT581*8X022395 5TFST541*8X002121 5TFKT521*8X002192 5TFMT521*8X012623 5TFBT581*8X012623 5TFDT541*8X012623 5TFDT581*8X012623 5TFBT541*8X012623 5TFCT541*8X002329 5TFJV521*8X002914 5TFRV541*8X056563 5TFEV541*8X056563 5TFEV581*8X056563 5TFLV521*8X056563 5TFRV581*8X056563 5TFSV541*8X005654 5TFKV521*8X002926 5TFMV521*8X061141 5TFBV541*8X061141 5TFDV541*8X061141 5TFDV581*8X061141 5TFBV581*8X061141 5TFCV541*8X007262 5TBLT521*8S459984 5TBRT541*8S459984 5TBRT581*8S459984 5TBMT521*8S462008 5TBBT541*8S462008
T-SB-0220-08 Rev1 August 11, 2008 Page 4 of 9 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 Approved Dealer Equipment (ADE) at 1-800-368-6787. REQUIRED TOOLS & MATERIAL PART NUMBER QTY CRC Lectra-Motive Electric Parts Cleaner, or Equivalent CRC P/N 05018 As Needed
T-SB-0220-08 Rev1 August 11, 2008 Page 5 of 9 Inspection Procedure 1. Confirm that the no start condition and DTC B2799 are both present. 2. Inspect the passenger side (RH side) engine room junction block for water or corrosion. A. Disconnect the connector and inspect pins and terminals for water or corrosion. B. If water or corrosion is present on the engine side of the wire harness, perform Repair Procedure A, then proceed to step 3 to inspect the RH side junction block connectors. Figure 2. Engine Room Junction Block 1 1 1 1 Junction Block Connector
T-SB-0220-08 Rev1 August 11, 2008 Page 6 of 9 Inspection Procedure (Continued) 3. Inspect the RH side junction block connectors for water intrusion. A. Remove the RH side scuff plate by detaching the 6 claws and 3 clips. Figure 3. Front Door Scuff Plate RH 1 Clip 2 Claw B. Remove the cowl side trim board RH. Figure 4. Cowl Side Trim Board RH (1) Remove the clip. (2) Detach the 2 clips and remove the cowl side trim board. 1 Clip
T-SB-0220-08 Rev1 August 11, 2008 Page 7 of 9 Inspection Procedure (Continued) C. Disconnect connector AJ5. Figure 5. Location of Connector AJ5 HINT AJ5 is a white 22 pin connector located on the RH side kick panel. Figure 6. Connector AJ5 1 Engine Side 2 Vehicle Side D. If water or corrosion is present on the cab side of the wire harness, perform Repair Procedure B.
T-SB-0220-08 Rev1 August 11, 2008 Page 8 of 9 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 an electric parts cleaner (CRC Lectra-Motive, P/N 05018, or equivalent). Refer to the Technical Information System (TIS), 2007 or 2008 model year Tundra Repair Manual to remove/detach the following: A. Driver s Side Kick Panel 2007 Tundra: Vehicle Interior Interior Panels/Trim Instrument Panel: Instrument Panel Safety Pad (for Column Shift Type) / (for Floor Shift Type): Removal 2008 Tundra: Vehicle Interior Interior Panels/Trim Instrument Panel: Instrument Panel Safety Pad (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: Air Cleaner: Removal 2008 Tundra: Engine/Hybrid System Intake/Exhaust 3UR-FE / 2UZ-FE / 1GR-FE Intake: Intake Manifold: Removal D. Hood to Cowl Seal (for access to wiper motor connector) Vehicle Exterior Wiper/Washer Wiper and Washer: Front Wiper Motor: Removal E. Headlight Assemblies Vehicle Exterior Lighting (ext) Lighting: Headlight Assembly: Removal
T-SB-0220-08 Rev1 August 11, 2008 Page 9 of 9 Repair Procedure B (Continued) F. Windshield Washer Jar Assembly Vehicle Exterior Wiper/Washer Wiper and Washer: Washer Motor: Removal G. Hood Latch Assembly Vehicle Exterior Door/Hatch Engine Hood / Door: Hood Lock Control Cable Assembly: 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 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.