Welp, this sucks…. 2016 dash wiring harness melted! (1 Viewer)

[VER1TAS]

Ran into an issue where the AC would not work in my wife’s 2016 LC. It will turn on but just kick out basic air. In addition to this, the seat heater would come on full blast and not turn off into the dealership. To try and get the seat to not fry my butt, I pulled the fuse (which didn't work). Dealership thought the AC amplifier was potentially burned out so they ordered a brand new one and got it in, tested the system again, and found that there is something more electrical in nature.

Low and behold, the EK1 or EK2 junction box showed corrosion and several wires that were fused together! The Tech is going to try and repair the cables if he can, but I don't think it's even possible. Does anyone know what the part number is for this harness for a 2016 LC? Is this even repairable?

 

[doru]

It is repairable if you can get new pins/connectors depending on how damaged they are. For wires is just replacing the damage with new and solder and crimping.
But you should also find the cause of the corrosion and fix that. Do you have a leak?

 

[VER1TAS]

It is repairable if you can get new pins/connectors depending on how damaged they are. For wires is just replacing the damage with new and solder and crimping.
But you should also find the cause of the corrosion and fix that. Do you have a leak?

This is the first issue we've had with this LC, so I don't know. There is no evidence in the footwell that there was anything wrong.

 

[VER1TAS]

Just got word that the whole harness has to be replaced, FML....

 

[doru]

Dealer will not fix it. They just replace at a very high cost. Ask for the cost before you approve. Post it here for future education.

For connectors look for a very small print 5 digit number. Put that after "90980-" and you have the part number for your connector to look it up (thanks to @bloc). You either DIY it or find an electrical shop/audio that will do it for you at a fraction of what the dealer will ask for the harness.

Use Google to search Mud for threads on water damage, water intrusion and water leaks. Just fixing the harness will not prevent this happening again.

There are three main culprits for water ingress in this situation:
Blocked/clogged sunroof drain tube
Poor and leaking windshield installation
Problem with the cowl allowing water to drain in the air intake for the interior fan unit.

 

[CanadianRockyCruiser]

Dealer will not fix it. They just replace at a very high cost. Ask for the cost before you approve. Post it here for future education.

For connectors look for a very small print 5 digit number. Put that after "90980-" and you have the part number for your connector to look it up (thanks to @bloc). You either DYI it or find an electrical shop/audio that will do it for you at a fraction of what the dealer will ask for the harness.

Use Google to search Mud for threads on water damage, water intrusion and water leaks. Just fixing the harness will not prevent this happening again.

There are three main culprits for water ingress in this situation:
Blocked/clogged sunroof drain tube
Poor and leaking windshield installation
Problem with the cowl allowing water to drain in the air intake for the interior fan unit.

sage advice!

 

[bloc]

That harness and job may end up being over 10k. Don’t approve it before you hear the cost and shop around.. it is repairable, but that too will be a lot of work.

 

[VER1TAS]

That harness and job may end up being over 10k. Don’t approve it before you hear the cost and shop around.. it is repairable, but that too will be a lot of work.

I hope that's not the case! We don't really have the ability to shop around for a better deal unfortunately.

 

[DallasTide]

I'd be more worried about what caused that. Wouldn't want to fix it more than once.

 

[bloc]

It probably needs a dash harness and MSRP on that is almost $4k. I can't look up the floor harness on either side, the diagrams say to check the number on the existing harness. But it could be more or less. Then, nearly the whole interior has to come out, including the dash.

It's a huge job.

And, what @DallasTide said.

 

[VER1TAS]

It probably needs a dash harness and MSRP on that is almost $4k. I can't look up the floor harness on either side, the diagrams say to check the number on the existing harness. But it could be more or less. Then, nearly the whole interior has to come out, including the dash.

It's a huge job.

And, what @DallasTide said.

I am literally sitting at the dealership right now, they have the truck apart. Was just told that Toyota doesn't make the part anymore.

 

[doru]

So, if no part are they going to roll their sleeves and actually fix the harness? Or are they sending you away to figure it out elsewhere?

How about investigating the cause?

 

[VER1TAS]

So, if no part are they going to roll their sleeves and actually fix the harness? Or are they sending you away to figure it out elsewhere?

They said they're going to try and fix it, but we'll see. If they can't I have no idea what I am going to do.

 

[Fisher23]

Myself .. I would be looking for a wrecked LC and have them cut out that part.

 

[doru]

If they not, ask them to give you the connectors part # (or the code on them) while the truck is apart, order the connectors, and go to a car audio shop to fix it.

And while waiting for parts minimize the use of the truck to prevent further electrical damage.

 

[roadstr6]

I believe @Malleus had a similar issue with his LX570. Dealership replaced his harness under warranty or at least partially under warranty.

 

[bigredmachine]

that looks like a very easy job to just cut out the crusty wires and solder in a repair, at least thats what i would have done. but i will say that if the can bus wires are damaged they are not supposed to be repaired as per toyota and that would be the only reason that i would recommend a harness. we always had spare harnesses laying around the shop for making repairs or just ordering the pig tails and connector if possible

 

[777Gage]

So sorry you are having this headache!!!

Like @doru and @bloc mentioned above - this is fixable, but the dealership is going to gouge you plenty for doing it. It's outside their "normal" book work. Do you have anyone, a friend or someone at a audio store you've dealt with before that you can call? Get a new plug/pins and have them repair the wires, but hunt down the issue 1000%.
I've helped my neighbor repair his Prius harness when some rat went to town and he was DOA like you. Also had similar experience on a previous owned FJ40 and our old RV - rats as well, chewed up the ignition and fuel injection wiring.

I've got a 2016 200 like yours and had the passenger footwell leak mentioned above - was afraid of a wiring meltdown being a possibility.

You will get through this!

 

[doru]

but i will say that if the can bus wires are damaged they are not supposed to be repaired as per toyota

By cutting *all* wires (except for the 2 big ones in the picture) and replacing all that issue is mitigated. The resistance will match across the harness (same length and wire). But I don't think that is the actual reason. It is more like Toyota wanting to ensure quality of repair in case of bad soldering and the like.

 

[VER1TAS]

So sorry you are having this headache!!!

Like @doru and @bloc mentioned above - this is fixable, but the dealership is going to gouge you plenty for doing it. It's outside their "normal" book work. Do you have anyone, a friend or someone at a audio store you've dealt with before that you can call? Get a new plug/pins and have them repair the wires, but hunt down the issue 1000%.
I've helped my neighbor repair his Prius harness when some rat went to town and he was DOA like you. Also had similar experience on a previous owned FJ40 and our old RV - rats as well, chewed up the ignition and fuel injection wiring.

I've got a 2016 200 like yours and had the passenger footwell leak mentioned above - was afraid of a wiring meltdown being a possibility.

I don’t have anyone I know locally who can help. I’m sitting watching the tech and service guy talk through the windows and am not feeling confident.