Electrical Connector

[Rick]

Hey y’all,

So I have a short between my throttle position sensor signal wire and pcm (it’s open ground). The wire is bundled with about 20 others behind the engine block and will be nearly impossible to find and repair (the short is not near or around the connectors). My solution is to run a new signal wire from the tps to pcm. I would like to replace the wire in the connectors at the tps and pcm instead of snipping off the ends, soldering, and heat shrinking. I’ve never done this and haven’t really found too many great videos online. I watched this one by Eric…

https://ericthecarguy.com/videos/7-videos/4-electrical-videos?start=15&videoid=L61LJcz7H6g

Which shows him disconnecting the wire from the connector, but I will need to solder (I assume) a new prong onto my wire at both ends to fit into the connector. I could definitely use some advice and/or links and videos on

a) removing the wire from the connector
b) soldering that metal prong (don’t know the technical term) to the wire
c) installing back into the connector

Please and thank you.

Topic

[Jonathan Stiver]

Hey, just read your first thread on MAP problems, sounds like you have a very similar issue as my Jeep right now. How did you come to the conclusion that was the wire with the short? Like you I’m having TPS codes, drivability problems that improve with the TPS disconnected, and I’m showing like 1.3v on the 5v reference and sensor ground circuits with the PCM unplugged. I swapped the TPS sensor with a working one and the car was great for a little while but problems returned quickly so I concluded a short is damaging or manipulating the TPS signal….

[college man]

I would cut the wire at the connector leaving a 6”
pig tail and solder and heat shrink the new wire.

[Rick]

I did end up swapping my TPS for a new one and still throws a TPS code, so I knew that wasn’t the issue. I went back to the service manual and found a section I overlooked. I disconnected the TPS connector and the PCM connector that holds the TPS signal wire. You then check the signal wire at the disconnected TPS connector with ground. If there is no continuity, which there wasn’t, there is a short in the wire between the TPS connector and the PCM.

[Rick]

You’re probably right college man, that will most likely be easier. Just kind of wanted to see how difficult it would be and if it’s worth it.

[Krys Kozlowski]

Well, if you are not as experienced at soldering, you may want to use a clamped prong instead, like for audio cables.

http://www.foerch.de/documents/thumbs/2110728976_20112212155048_800x800_Fit_0_0.png

Run a long wire set from ECU to TPS with all the lines you need and attach them with the appropriate endings. That might last longer than weak soldering links, just saying 😉

[Krys Kozlowski]

Not sure if by heat shrinking you mean those wire connectors:

http://www.foerch.at/documents/thumbs/-396954096_20110512163048_800x800_Fit_0_0.png

I personally love those. Just add heat from a lighter for a moment and bob’s your uncle 😉

[Jonathan Stiver]

I just did mine with a TPS connector from a donor car and ran a new wire from the TPS signal to as far back as I could get the wire from the PCM connector without taking the harness apart, maybe 3″. I guess you could do all 3 if you think there might be a problem with the TPS’s splice from the sensor ground and/or 5v circuit in the harness. Installed a brand new TPS after doing that and so far so good. I like to use crimp connectors most the time but since I seemed to have suspect enough wiring as it is and this is for sensitive engine mgmt I went ahead and soldered these.

[Author]

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