Electrical Issue pt.2!!! Back w/ vengeance: Blown IGN1 no.2 fuse issues

** PROBLEM FIXED!!! **

I'm happy to share that this issues has finally been resolved. I had taken my truck to the the dealer, a private shop who contracted 2 "Toyota Master Technicians" before taking on this situation myself. I won't get into the details of what they thought the problems were, as they were very outrageous. Fortunately there was no expense for me to take it to the shops to get diagnosed.

I hope my explanation helps people in similar situations solve their fuse issues, after all, this is the beauty of technology and online resources.

To assess the issue myself, I kept track of the conditions that would cause the fuse to pop. I noticed that turning the truck on with a/c first thing in the morning would pop the fuse immediately. I would hear the compressor ramp up, and when it was almost full power, the fuse would go. Under the same circumstances later in the day with the sun out, the fuse would only pop sometimes. I had no issues with the climate controls, and noticed issues with the fuse only when the a/c button was pressed. I had the compressor changed a year prior, so I had trouble figuring how a new part could go bad so quickly.

After crawling under the truck, the last part that I had not inspected was the a/c clutch. I targeted this component as it fell in line with the issues I had been experiencing.

Upon removal of the skid plate, I found the power wire connection with corroded male and female connectors. When I unplugged the two, I noticed that moisture had made its way in.

I ended up hardwiring the connection with a soldering gun and the problem never came back. It's been 8 months without any issues.

My consensus is that morning dew would accumulate in the connector causing the fuse to pop whenever it was wet. After the moisture would dry up and the connectors would expand under warmer conditions, the a/c clutch would operate normally.

Thanks again to all who helped with this issue. I hope this post helps others.

Hi all,

Thanks to the TW community for stepping in and helping me resolve this issue when I first encountered it 2 weeks ago. For a detailed story of what happened concerning the IGN1 no.2 fuse, you can read it here:

https://www.tacomaworld.com/threads...windows-blower-fog-lights-not-working.424097/

TRUCK DESCRIPTION: 2005 Double Cab V6 Pre-Runner

CLIFFNOTES: Truck was working fine in the morning, pwr windows, speedo, fan switch do not work after being parked for 2 hours, find that the IGN1 no.2 fuse by steering wheel is blown.

UPDATE: After fuse had been replaced, truck electronics were up and running for a total of 5 days until fuse popped again. Truck was due for a new battery, so battery was replaced to factory specifications. After turning truck on, IGN1 no.2 blew again. Tried narrowing problem down, and found that IGN1 no.2 fuse would blow after turning fan switch on, or activating the A/C. I have now replaced the fuse 3 times, each time after touching said fan switch or A/C button.

ISSUE: I am not sure (or electronically savvy enough) to pinpoint that the problem is occurring from my A/C compressor. It was replaced only 5 months ago after the old compressor seized, so it is still relatively new.

BIG QUESTION: If anyone has endured this issue, is there a common resistor, relay, harness, or fuse that would relate the blown IGN1 NO.2 fuse to the fan switch or A/C?

A big thank you to anyone who can help steer me in the right direction.

 

I would first be looking at the Blower motor and the Resistor Pack and the associated Wire Connectors at the blower as those are known problem areas. The IGN1 No2 fuse supplies that circuit for the blower.

See the thread below with pictures:
https://www.tacomaworld.com/threads/replacement-of-hvac-blower-motor-resistor.8310/

The 10 Ampere IGN1 No2 Fuse supplies these circuits:

ABS (w/ VSC), TRAC, VSC, Auto LSD, Downhill Assist Control and
Hill–Start Assist Control
ABS (w/o VSC)
Accessory Meter
Air Conditioning
Automatic Glare–Resistant EC Mirror
Charging
Cruise Control (1GR–FE)
Cruise Control (2TR–FE)
Door Lock Control
Electronically Controlled Transmission and A/T Indicator (1GR–FE)
Electronically Controlled Transmission and A/T Indicator (2TR–FE)
Engine Control (1GR–FE)
Engine Control (2TR–FE)
Headlight
Illumination
Interior Light
Light Auto Turn Off System
Multi Mode 4WD and Rear Differential Lock
Power Outlet (115V)
Power Window
Rear Differential Lock (2WD)
Shift Lock
Starting
Stop Light
Tire Pressure Warning System
Trailer Towing
Wireless Door Lock Control

 

If you need the resistor and connector here is what you need from the dealer:

Here is a link to information:
https://www.tacomaworld.com/threads/blower-motor-issue.412012/#post-11657897

Connector Part #

$32 82141-04M40

82141-04M40 Resistor Part # 87138-0452

Note: this is an updated resistor pack and will look different that what you have installed unless it has been replaced before.

 

I quoted you so you would get an alert... Look above.

 

Replace your blower motor. I had this exact issue for almost two years. Finally wnet away after I replaced my blower motor.

 

Thank you Jimmy and 08TRD for the response regarding my situation.

I just replaced the blower resistor and connector with parts from Toyota. Unfortunately, I am still experiencing the same results.

I find that the fan switch can operate on its own without the IGN1 No.2 fuse blowing.

When I proceed to press the A/C button, the fuse will blow 1-2 seconds after.

Any recommendations as to what u should troubleshoot next?

Thank you again for your help, I appreciate it.

 

The fan blows fine as long as the AC is off and then the fuse blows shortly after pressing the AC Button?

I would then check the AC Clutch Coil on the compressor or its associated wiring.

 

Could be the magnetic clutch on the ac compressor...I suspected this on mine for a while too...and if my issue resurfaces this summer, with more frequent use of the ac, this is the next thing I will trouble shoot.

Not sure if it is serviceable independently of the compressor though.

EDIT: Seems like JimmyH and I are thinking the same thing.

 

I just ran a couple scenarios to see if I can hone in on anything.

For whatever reason, I was able plug a fuse in IGN1 No.2 with the A/C button pressed on and got the compressor to cycle on and off without popping. The air would change temps so I'm thinking it might be ok.

However, when I pressed the circulation button to on, the fuse popped.

I beginning to think that there is something funny going on around the switch panel with the fan switch and buttons. I'm going to take that apart and I have a look before diving into the more heavy duty systems.

Again, a big thanks for helping me assess this issue Jimmy and 08TRD

 

Here is the thread I had about my issue on TN.

http://www.toyotanation.com/forum/6...-code-continiously-blowing-ig1-no-2-fuse.html

Pay particular attention to RTFM's posts as they contain a wealth of knowledge and quite a bit of trouble shooting procedure. Towards the end he mentions trouble shooting procedure on the fan setting switch.

Just out of curiosity, have you pulled the AC controls and looked at the larger connector, particular the pin with the largest white wire? If so, is there scorching on the plug?

 

Like this...

 

Bump for a problem that is solved.

 

What did you come up with for a solution?

EDIT: NM, saw the update to your original post. I will have to pull my skid and inspect my connections at the A/C clutch. I have suspected it had something to do with the A/C Clutch for quite some time., just haven't done anything about it.

When I would tow, I just reach down and turn off the ac button before downshifting, and I haven't blown a fuse since starting this practice.

 

If it's still the IGN No.2 fuse, it's definitely something being triggered by low amps. My AC system has been completely fine to this day. Have you replaced the towing harness yet since this happens when you're in tow? From my experience, I'd check exterior connection points and low voltage ground connections.

 

Harness was replaced about a year ago due to a rear end accident.