Throttle Position Sensor: Service and Repair

Throttle Position (TP) Sensor - 5.4L

Removal

1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

2. Disconnect the crankcase vent tube quick connect coupling from the ACL outlet pipe-to-Throttle Body (TB) adapter. For additional information, refer to Fuel Delivery and Air Induction.





3. Disconnect the vacuum hose and wire harness retainer from the ACL outlet pipe-to-TB adapter and position aside.





4. Remove the 4 bolts and the ACL outlet pipe-to-TB adapter.





5. Remove the TB O-ring seal.





6. Disconnect the Throttle Position (TP) sensor electrical connector.





7. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F).

NOTE: Do not use power tools.

Remove the TP sensor.

1. Using a heat gun, apply heat to the top of the ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 25.4 mm (1 in) away from the ETB.

2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a digital temperature laser or infrared thermometer, while heating the ETB.

3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard.

4. Using hand tools, remove the remaining bolt and discard.

5. Remove and discard the TP sensor.





Installation

1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB.

NOTE: Do not use power tools.

Install the new TP sensor.
- Using hand tools, install the 2 new bolts.
- Tighten to 3 Nm (27 lb-in).





2. Connect the TP sensor electrical connector.





3. Install the TB O-ring seal.





4. Install the ACL outlet pipe-to-TB adapter and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





5. Connect the wire harness retainer and vacuum hose to the ACL outlet pipe-to-TB adapter.





6. Connect the crankcase vent tube quick connect coupling to the ACL outlet pipe-to-TB adapter. For additional information, refer to Fuel Delivery and Air Induction.





7. Install the ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.