Testing TPS
The connector to the TPS needs to be connected so the ECU and send the supply voltage to the TPS and we can read the signal/return voltage to determine if the sensor is working proper. Mercury sells a 3-way test connector, but I have used an easier way. Get a couple inch long piece of multi-strand wire. Remove sheath on wire and separate 3 individual, thin, wires. Unplug TPS connector and insert a thin wire into each female connector... then plug connector back together (don't let thin exposed wires touch). Now you can test voltages across all three wires.
- Unplug starboard(passenger) side cylinder head temp sensor
- Turn ignition key to ON (but do not start... ensure good battery)
- Find wire with supply voltage to TPS.
- Find wire with sensor return voltage Low-to-Hi (other wire will be Hi-to-Low)
- With throttle at zero/idle... read return voltage... should be 0.20 - 0.30 volts
- Slowly advance throttle to full/wot... observe voltages while doing... smooth voltage transition expected
- if voltages jump all over the place while moving throttle... likely bad TPS.
- Put throttle to full/wot... read return voltage... should be ~ 7.46 volts
- loosen TPS fasteners and adjust/rotate TPS (small changes)... adjust until correct volts low/hi read.
- tighten TPS fasteners, recheck, remove thin wires in connector, replug connector, done.