Engine Controls - Throttle Position Sensor Replacement

Condition

Throttle Position (TP) Sensor -G69-, Installing New-Style Switch





24 07 01 Jan. 10, 2007, 2004112, supersedes Technical Bulletin Group 24 number 03-02, Feb. 3, 2003 due to inclusion in ElsaWeb.

Technical Background
The "old style" Throttle Position (TP) sensor -G69- has separate connector housings to the Transmission Control Module (TCM) -J217- harness.
In the "new style" TP sensor, see Required Parts and Tools, the Engine Control Module (ECM) -J220- harness is replaced by an ECM connector housing only.

Production Solution
N/A

Service





If the TP sensor is replaced with a new sensor, see Required Parts and Tools (arrow), it requires a wiring harness modification, which:
- splices signal wire (terminal 2) of wire harness from TCM connector at TP sensor into signal wire (terminal 2) of wire harness from ECM connector at TP sensor, and
- terminates unused wiring from TCM connector (terminal 1 - power) and terminal 3 - ground.

- Install new TP sensor -G69- using two M4 x 12 Phillips-head screws, see Required Parts and Tools.See also Repair Group 24 Throttle Position (TP) Sensor, replacing.
- Remove terminal from Position 2 in (three-wire) TP sensor connector on throttle body.
- Locate repair wire (with replacement terminal that matches terminal from TP sensor connector) in the Wiring Harness Repair Kit.See Required Parts and Tools.
- Install repair wire into Position 2 of the (three-wire) TP sensor connector and install appropriate seal (over wire) into connector housing.
- Cut repair wire approximately 75 mm from connector.
- Strip insulation and install (crimp) a red splice connector, see Required Parts and Tools, to the repair wire, using an appropriate crimping tool from the Wiring Harness Repair Kit.
- Remove tape as necessary from ECM and TCM wire harnesses leading to TP sensor.
- Remove terminal and strip insulation from ECM signal wire (Position 2 of 3-wire connector housing).
- Remove terminal and strip insulation from TCM signal wire (Position 2 of 4-wire connector housing).





- Place these two stripped wires (together) into other end of red splice connector (white arrow) and crimp using an appropriate crimping tool from the Wiring Harness Repair Kit.
- Heat wire splice to seal splice as necessary (see instruction manual for Wiring Harness Repair Kit).
- Cut and properly terminate wiring from TCM connector (black arrow), terminal 1 - power and terminal 3 - ground, and tape back to harness.
- Discard TCM connector housing.
- Tape harness as necessary for a neat appearance. - Reinstall ECM connector to the new TP sensor.
- Clear any stored DTCs using VAS 5051 or VAS 5052.

Warranty
Information only

Required Parts and Tools








Tip: Part number(s) are for reference only.Always see ETKA for the latest part(s) information.