(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.
S
2003 2004 model year Tacoma vehicles equipped with 5VZFE (V6) engines.
PREVIOUS PART NUMBER
CURRENT PART NUMBER
PART NAME
QTY
8212204052
8212235A60
Wire, Engine, No. 2
1
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EG4016
R & R Wiring Harness, Relocate Ground
1.0
8212204052
07 99
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 vehicles
in-service date.
* Warranty application is limited to correction of a problem based upon a customers specific complaint.
ENGINE
Introduction
Applicable
Vehicles
Parts
Information
Warranty
Information INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 2 of 10
Engine No. 2 Wire Harness
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.
Location
Repair
Procedure
Clamp
Push INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 3 of 10
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.
Repair
Procedure
(Continued)
Alternator Wire
Alternator Connector
Clamp INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 4 of 10
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
(Access from Underside of Vehicle).
A. Remove the bolt, and disconnect
the ground strap.
Repair
Procedure
(Continued)
Oil Filter INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 5 of 10
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 harness.
Starter Wire
Starter Connector
Repair
Procedure
(Continued)
Engine Oil Pan
NOT ACCEPTABLE
To Ground
Engine No. 2 Wire INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 6 of 10
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
S
m
(80 120 kgf
S
cm, 70 104 in.
S
lbf)
1
2
3
Repair
Procedure
(Continued)
Engine Oil Pan
Starter Wire
Starter Connector INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 7 of 10
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
S
m
(70 130 kgf
S
cm, 61 112 in.
S
lbf)
H. Connect the wire to the relay
block No. 2 with a nut.
Torque: 5 15 N
S
m
(51 153 kgf
S
cm, 44 133 in.
S
lbf)
HINT:
Install the clamp by pushing it down.
I.
Connect the connector to the
relay block No. 2.
Repair
Procedure
(Continued)
Alternator Wire
Alternator Connector
Clamp
Clamp
Push INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 8 of 10
J. Connect the 2 wires to the
positive (+) terminal with a nut.
Torque: 10 16 N
S
m
(100 160 kgf
S
cm, 87 139 in.
S
lbf)
NOTE:
Be sure to put the positive (+) terminal
cover on.
K. Install the ground strap to the new
position indicated by the arrow.
Torque: 30 50 N
S
m
(300 502 kgf
S
cm, 261 435 in.
S
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
(8212235A60) includes 4 wire ties
(9046400551). Use two of them and
keep other wire ties as spares.
Repair
Procedure
(Continued)
Oil Cooler
30
_
Side View
Exhaust Manifold
Engine Ground
Wire No. 2
A
B
Front INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 9 of 10
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.
NOTE:
To prevent heat damage or damage to
the wire cover, please observe the
following:
S
Fasten the engine No. 2 wire 30 mm
(1.2 in.) or more apart from the
exhaust manifold.
S
Fasten the engine No. 2 wire 17 mm
(0.67 in.) or more apart from the
front suspension tower.
S
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 (0.2 in.) from the
aligned position.
Repair
Procedure
(Continued)
A SIDE VIEW
Engine Wire
White Tie
Within 5 mm
(0.2 in.)
Engine Ground
Wire No. 2
Lower Edge
of Clamp
Upper Edge of
White Tape
Front
Within 5 mm
(0.2 in.)
Front
Engine Ground
Wire No. 2
Engine Wire
Within 30
_
30 mm (1.2 in.)
or More
17 mm (0.67 in.)
or More
Exhaust Manifold
Front Suspension Tower
A TOP VIEW
Engine Ground
Wire No. 2
Engine Wire
B TOP VIEW
Wire Tie
Edge of
Clamp
Within 5 mm
(0.2 in.)
Edge of
Yellow Tape INTERMITTENT EXTENDED OR HARD CRANKING EG042-04
September 20, 2004
Page 10 of 10
M. Connect the ground strap with
a bolt.
Torque: 7 10 N
S
m
(70 100 kgf
S
cm, 61 87 in.
S
lbf)
8. Install Engine Under Cover.
9. Install Front Fender Apron Seal.
10. Install Left Front Tire.
11. Connect Negative Battery Terminal.
Repair
Procedure
(Continued)