Nope. You only have to find the break and make the repair there. Running back to the splice would usually be extremely difficult and time-consuming. That would not be in the best interest of our customers. You CAN do it that way, but there's more important things to consider. The biggest issue is when there's a wire shorted to ground someplace and a fuse is blowing. A lot of people will cut the offending wire at both ends, then tie in an entirely new piece of wire, thus eliminating the short. That was never an acceptable repair for my students. It will get that circuit working again, but the question is, why did a short occur on that wire? I required my people to follow that wire until they found exactly where the short had occurred, because wires always run in a bundle, or harness, and how long will it be before another wire in that harness develops the same short? This is common when a harness has fallen down onto hot exhaust parts, is draped across the sharp edge of a metal bracket, or in the case of some GM models, the harness runs under the carpet under the driver's feet, and has been sliding back and forth for years. By finding the location of the short, you are forced to inspect all the other wires in that area, and remedy the cause before it occurs on the next wire. That next wire could disable the electric fuel pump, ... On a late Saturday night, ... When the wife is all alone, ... In the country, ... In freezing weather. You can be sure we're going to hear about that from her angry husband, especially when finding the first problem would have given us a chance to prevent the next one.
That said, you're jumping ahead and you're assuming there is going to be a broken wire buried in a harness. While that is a possibility, lets concentrate on the more common causes first. Those are a break, or an intermittent break inside the sensor itself, and a weak connection between a pair of mating terminals in the three-wire TPS connector. The three voltage readings will tell us if we have to look in a different direction.
You got us going down the right path with the signal wire voltage, but you need to list specific voltages. The acceptable range for sensors of this type is from 0.5 to 4.5 volts, corresponding to idle and wide-open-throttle. Those values are for training purposes. In actual practice you may find 0.42 and 4.27 volts, for example. The point is you'll never see close to 0.0 volts or 5.0 volts. When you do, there's a defect and that is what sets the fault code.
Assuming you are indeed finding very close to 5.0 volts on the signal wire, that is going to set the code, and there's no mystery, (or frustration), involved in figuring this out. There's two ways this defect can occur. First let me approach this from a different angle and imagine we lost the 5.0 volt supply to the sensor. Then it becomes rather easy to see with no voltage, there will be no voltage anywhere related to that sensor. The entire circuit is dead and there's 0 volts on every terminal / wire. What's not so easy to visualize is when there's a missing ground circuit. Without going into all kinds of electrical theory, you'll have 5.0 volts all over, including on the ground wire all the way up to the break. You'll have 5.0 volts at every point along the sensor, regardless of actual throttle position. That's the 5.0 volts that's outside the acceptable range and what triggers the fault code. There isn't a lot of ground wire to check. The break has to be before or up to the splice. Remember, four or five other sensors use that same ground wire, and they aren't setting fault codes, so the part they have in common has to be okay.
The second way this can happen is a little trickier to understand, even for experienced electrical experts. That's when there's a break in the signal wire. The best clue here is when you take the voltage readings at the sensor, you'll find the nice smooth sweep from 0.5 to 4.5 volts as you work the throttle from idle to wide-open-throttle, (and you'll bang your head against the wall because the voltage sweep looks perfect, yet you keep getting that stupid fault code, but if you look at live data on a scanner, you'll see what the computer is seeing, and that is 5.0 volts. With the break in the signal wire, what you see at the sensor is not the same as what the computer is seeing. I'll give you the explanation, but you won't be tested on this later. Inside the computer, that signal wire is interconnected with all kinds of other circuitry. Because of that, when there's a break in that wire, the voltage that shows up and is seen by the computer can "float" to some random value. If, by chance, that random voltage was to remain between 0.5 and 4.5 volts, the computer would accept it and try to run on it. There would be no fault code to direct you to the circuit that needs further diagnosis, and symptoms would be from mild to miserable with a very elusive solution. To prevent that, all computer sensor circuits use a "pull-up resistor" or a "pull-down resistor". Many import models use pull-down resistors. Most domestic models use pull-up resistors. That is a resistor of such high value, it has absolutely no effect on a properly working circuit. You'd never know it's there. That is, until you get that break in the signal wire. That is when that pull-up resistor, which is tied to the regulated 5.0-volt supply, places 5.0 volts on the signal wire's circuit inside the computer. That forces a defective condition to be detected, the computer sets the fault code, and you know exactly which circuit needs to be diagnosed.
When a pull-down resistor is used by the manufacturer, when a break occurs in the signal wire, that resistor is tied to ground. Again, if the circuit is working properly, no one even knows that resistor is in there. When the break occurs, 0.0 volts is placed on the signal wire, which is the other defective condition. On newer models, the fault codes get a real lot more specific. It will state whether the signal voltage is too high or too low. Yours has to be determined with the voltage reading you took.
Now what I want you to do is see exactly what all three voltages are. Do it that way because then there's no confusion over wire colors or whether you measured on the right one. Once I know those, this can again become a little confusing because it's an issue of it's rather easy to do, but difficult to explain. Instead of confusing you with a list of possible tests, we'll stick with just what applies to your car.
Remember, these readings are only valid when you leave the TPS plug connected and you back-probe through the weather seals alongside the wires. If you unplug the connector, you WILL have an open circuit, (break in the circuit), You run the risk of introducing a different, second problem.
If you have access to a scanner, let me know. Also, some of the very inexpensive code readers are sophisticated enough to give sensor data. I have a few and found they update their readings painfully slowly, but with this problem, they can be just what is needed to see what the computer is seeing, then we can compare that to what you find at the sensor.
Sunday, November 27th, 2022 AT 1:58 AM