Electrical - EPC/MIL ON/DTC's P0121/P0221 Set
01 07 67Oct. 26, 2007
2016089
Vehicle Information
Condition
EPC Warning Light On and/or Throttle Body DTC P0121 / P0221 Stored in ECM Fault Memory Electronic Power Control (EPC) and/or Malfunction Indicator Lamp (MIL) warning lamp(s) illuminated with DTCs set.
Technical Background
Routing of engine electrical harness too loose, producing intermittent connection at Throttle Position (TP) Sensor -G79-/Accelerator Pedal Position Sensor 2 -G185- connector.
Typical DTCs set:
^ 00289 / P0121, Throttle/Pedal Position Sensor/Switch "A" Circuit Range/Performance
^ 00545 / P0221, Throttle/Pedal Position Sensor/Switch "B" Circuit Range/Performance
Production Solution
Revised engine wiring harness routing around the throttle valve control module and improved throttle valve beginning with VIN:
^ 3C_7E115305
^ 3C_7P087974
Service
In case of a malfunction, check wiring harness routing around throttle valve control module. If necessary, replace all pins in 6-pin connector on throttle valve control module as follows:
Remove air filter to expose wiring harness around throttle body control module. Verify that the harness requires modification. Harness routing around throttle body control module as shown in illustration A -below- will require modification.
Tip:
Wires with yellow insulation internal to conduit are an indication that harness has already been modified.
Modification Procedure
Remove and discard the following components:
^ Corrugated tube T-connector -1-.
^ Corrugated tube -2-.
^ Electrical tape -3-.
^ Disconnect connector and remove all terminals with terminal removal tool VAS1978/7.
Assemble and install six jumper wires.
^ Install six wires using Part No: 000979019A.
^ Seal terminals with yellow terminal seal Part No: 3B0972742B.
^ Tape the six wires and remaining harness wires together - 1- using 5 cm (2 in.). of electrical tape Part No: 000979950.
^ Shorten wires by approximately 4 cm (1.5 in.) and arrange them/mark them so that one wire leads to each pin.
^ Shortest wire should lead to pin 1 and longest wire should lead to pin 6.
^ Connect individual wires using splice connectors Part No: 111971941A.
Tip:
Use crimping tool VAS1978/1-1.
^ Secure wires -1- using electrical tape Part No: 000979950.
^ Reconnect original corrugated tube -2-.
^ Install a new corrugated tube -3- Part No: N90773501.
Tip:
Ensure that the corrugated tube overlaps both ends of exposed harness.
^ Install protective cap -4- Part No: 021971921.
^ Install new T-connector Part No: N90669501 on corrugated tube.
Tip:
Make sure that ends of corrugated tubes overlap in T-connector and are locked tight.
^ Install clip Part No: 4A0820199 at locations -1- and -2- above
Warranty
Required Parts and Tools
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information.