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Old 01-15-2010, 08:54 PM   #1 (permalink)
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Lightbulb A piece of tape fixed my intermittent stall (TPS wiring harness)

I joined this forum to get some help diagnosing a problem I had. I think others may have the same issue that I found an easy effective fix for. Sorry if this got a bit long.

I bought an automatic, 2 door 1992 Geo Tracker (Canadian, I think) and soon found that it had an odd intermittent stalling problem. It would stall at stops or slow speed. Sometimes it wouldn't die completely. It would start right back up no problem.

Long story short, the white 6-wire wiring harness going to the Throttle Position Sensor was the issue. A tech at the local dealer found it during their $90 diagnosis. If the harness got shaken from the road or just the right idle vibration — the car would stall. I was even able to wiggle the wires by hand and make the car shut right down.

The dealer wanted $450 to rewire it cuz they said the (Genuine GM) part is no longer made. I thought about buying a whole new TPS/harness but first I tried a few inches of clear packing tape and taped the 6 wires together and to the plastic harness they plug into. It's been a couple months now, lots of bumps and hard winter starts but so far NO STALLING! Yay!

See pic in reply below. Good luck!

Last edited by SunChaser; 01-17-2010 at 04:19 PM. Reason: Image wasn't showing so I attached it instead.
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Old 01-16-2010, 08:02 AM   #2 (permalink)
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Hey, whatever works. Obviously there is a short in either harness or TPS, aggravated when the wires moved around with bumps or vibration of the car. By holding the wires still, the short does not occur. Good move!
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Old 01-16-2010, 11:58 AM   #3 (permalink)
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NOTICE not one mention of the CEL lamp.
i bet he ignored it or did no check to see if it is even working.???
but a bad TPS idle switch , my not DTC . (unless you are driving fast and it illegally closes)

but bad idle TPS is covered in my bad idle and stall page is #2 after egr sticking open.

92 has no scan tool (OTC) , and this device is so easy to monitor.

other readers, next time,,,,, look at all sensors / actuators on the motor when it runs bad, look for simple damage. a shaking motor can break a wire after 15 years.
sensor wiring must look good. if they look ratty ,they are. fix them.


THANK YOU ! and thanks for sharing !!!

that for the GM tip on NO LONGER MADE ,GM lie..
the truth , NO LONGER STOCKED BY GM ,truth !,

my hard to find parts page shows fine after market connectors.
fine quality connectors (water proof and all)
and dirt cheap.

cheers.

best repair. (long term solution)
is get on flee bay and buy a used injector or whole throttle body ,
and nice connector comes with.
or cut one off at a Pick-a-part or U-pick wreckers.
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Old 01-17-2010, 04:17 PM   #4 (permalink)
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Default Cheap tape fix for GEO Tracker TPS wiring harness photo

I tried to edit my original post to add the photo but it didn't seem to take. Maybe this will work.
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A piece of tape fixed my intermittent stall (TPS wiring harness)-01172010895.jpg  
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Old 01-17-2010, 11:12 PM   #5 (permalink)
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If possible
1: use solder to do correct the breaks.
and with marine heat shrink.(done first)
2 heat the shrink then wrap with electrician tape , tight.
id see about using a high qual connector here.

here is how to do it from scratch, with a nice new connector.

Waterproof Cable to Cable Electrical Connectors
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Old 01-18-2010, 12:33 AM   #6 (permalink)
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Yes you should dig in further, like Kick-Fix says.
Leave the tape jobs to experts in the field, like Red Green
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Old 01-18-2010, 11:24 AM   #7 (permalink)
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and if either end runs , your good to go.
Hybrid has a whole new meaning.

just dont run into self,,,,, the best of the best thanks mr. bacon


yes, packing tape just hates, 200degree + motor bays.

but know knows, maybe is just a MR. Green day ,not too long term?
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Old 01-18-2010, 11:47 AM   #8 (permalink)
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You know, I only heard of Red Green for the first time about one month ago. I posted what I thought was the most hysterical thing on this website. Not too many people looked at it (maybe bad heading), so I posting it again. This guy is a genius. However, for the repair in question (Sunchaser) I might have used electrical tape. However, just shows you that sometimes an expensive 'repair' can be fixed with creative thinking.

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Old 01-18-2010, 12:37 PM   #9 (permalink)
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for sure,
one can just hard splice in the whole thing with marine shrink
for next to nothing.

or :
go to wrecker and get this end of the harness. cut out
or post a WTB on craigs. for Engine bay harness. $50?

or get a pro style automotive style connector like i linked. $20

id go the harness find rought , for me i want next buyer to see no hacks.
cuz then you will really lose.

pay now or pay later.
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Old 01-18-2010, 02:47 PM   #10 (permalink)
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My "fix" is hilarious indeed. But it worked and just in time for season. I'll be sure to post if the tape ultimately fails or bursts into flames.

What's key though isn't my cheapo fix but that the same problem (the loose TPS harness) is possibly quite common and I'll bet lots of time, money and energy has been spent trying to diagnose the really odd intermittent stall it created. I had a few mechanics take a quick look but since it showed no codes, they pretty much lost interest. Usually, I'd assume a "bad part" but I wouldn't have thought about something with no moving parts and as trivial as a wiring harness.

I've seen several posts from people with similar issues, so jiggle those wires before you replace the whole sensor. (Be careful not to catch your clothing on anything or electrocute yourself when you lean in to mess with it.)
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