A) Resistor mod or CEL fix for code P0546. Package of five 2.2k ohm, ½-watt resistors costs 99 cents (at the time of this writing) at your local Radio Shack. You want to use part number 271-1121. You only need one for the CEL fix. Save the others for spares in case you ruin one of them.

The following CEL fix requires no splicing of wires or soldering. It allows for installation of a new EGT sensor if the reason for the CEL was a sensor gone bad.

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"…axles of evil…" - george w. bush

 

B) Passenger side engine compartment solenoid cover. Remove the cover with ¼-turn twist of the two fasteners. Be careful not to lose the fasteners - they are not positively retained in the cover and can fall out if you tip the cover.

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"…axles of evil…" - george w. bush

 

C) Solenoid cover removed, exposing wiring harness connectors clipped to cadmium-plated bracket.

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"…axles of evil…" - george w. bush

 

D) Looking over right-side fender, the EGT sensor connector is the third one down or the bottommost connector on the bracket.

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"…axles of evil…" - george w. bush

 

E) The EGT sensor connector still installed on the bracket. Carefully remove the connector from the bracket so that the connector may be opened. Squeeze tab while pulling two halves apart.

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"…axles of evil…" - george w. bush

 

F) EGT sensor connector split apart.

G) Another view of the male and female ends of the EGT sensor connector.

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"…axles of evil…" - george w. bush

 

H) Connector wire tab lock is easily removed with needle-nose pliers from male connector.

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"…axles of evil…" - george w. bush

 

I) View of male connector with tab lock removed, exposing wire terminals and locking tabs. Removal of wires from connector housing requires two jewelers screwdrivers with tiny blades to spread a black plastic locking tab on each side of the wire terminal. It's tricky removing the wires and helps to have someone else hold the connector housing while you maneuver the screwdrivers, but it can be done without damaging the locking tabs or the wires.

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"…axles of evil…" - george w. bush

 

J) Here's what the wires look like when removed from the connector. Notice the silicone rubber inserts that seal out contaminants from the connector.

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"…axles of evil…" - george w. bush

 

K) Bend the wire ends of the resistor so they may be inserted into the female end of the connector where the wires were once plugged. Some of the resistor wire end will have to be snipped off so that the resistor sits flush against the connector as shown.

When the resistor is installed in this position, the male end of the connector may be re-connected once the wire terminals have been removed.

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"…axles of evil…" - george w. bush

 

L) EGT sensor harness connector re-installed in mounting bracket, with male connector wires wrapped and secured using a nylon tie. Male connector is also protected using aluminum foil secured with a nylon tie to seal the holes left after removing the wire terminals.

Reset ECU by disconnecting negative battery terminal then stepping on brake pedal several times to clear CEL on dash display. Re-connect battery terminal. You may lose your radio presets as well as your resettable trip odometer readings.

An alternative to this resistor mod installation would be to simply cut the wires between the male connector and the EGT sensor and solder in the resistor. Tape everything securely and use heat shrink tubing to provide for a clean, insulated connection.

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"…axles of evil…" - george w. bush

 

A friend of mine tried this recently- for some reason, the resistor and wires wouldn't solder together. Better to just insert it into the plug exactly as you showed above. Great post Alan, thanks.