Toyota 89452-30140
Throttle Position Sensor

The throttle position sensor replacement process begins with disconnecting the lead wire connector before removing its 2 set screws and removing the sensor. The new throttle position sensor installation demands the throttle valve to maintain a 5.5-inch opening angle and a 15-degree location to the right of the specified positioning position before securing the sensor. Roll the sensor downward until it touches the throttle valve shaft followed by a temporary screw tightness of the 2 set screws. Link the throttle position sensor connector without connecting the accelerator pedal position sensor connector. Attach a TOYOTA hand-held tester or an OBDII scan tool to DLC3 then turn ON the ignition switch without pressing the pedal and adjust the throttle position sensor for 14.4 - 16% standard throttle valve opening by securing it with 2.0 Nm of torque (20 kg.cm, 18 in.lb). Follow the adjustment process again for the throttle valve opening percentage when it fails to reach the designated parameters. Thoroughly check the throttling valve to ensure its position matches between 10% to 14%. Make another adjustment if needed before painting the set screws and turning OFF the ignition and unplugging the sensor and connector. The replacement process for the throttle control motor begins with sensor removal followed by connector disconnection of the motor and subsequent screw removal of the throttle control motor cover and motor assembly with its attached washer. Place the wave washer inside the new throttle control motor cover before positioning the pins through the holes and placing the grommet and installing 3 screws with torque reaching 3.4 Nm (35 kg.cm, 30 in.lb). Installation requires applying thin grease to the gear teeth followed by washer placement before positioning the throttle control motor cover with its pin to the throttle body and screwing it tightly with 6 screws torqued at 3.4 Nm (35 kg.cm, 30 in.lb). Finally, reconnect the throttle control motor connector. Replace the accelerator pedal position sensor by removing its three set screws and the sensor before installing a new sensor which must be oriented 20 degrees to the left from the specified installation position when the throttle valve has an opener opening angle of approximately 4 degrees. Turn the sensor clockwise until it reaches the throttle valve shaft then apply 5.4 Nm of torque to the set screws with 55 kg.cm force or 48 in.lb torque specification. Perform an inspection of the accelerator pedal position sensor by connecting its connector to the TOYOTA hand-held tester or OBDII scan tool at DLC3 then check the ACCEL POS #1 (VPA) voltage between 0.35 - 0.85 V with the ignition switch turned ON without pressing the pedal. Check the system operation after installing the throttle body.

The first step for throttle position sensor replacement includes disconnecting the lead wire connector and removing the 2 set screws and throttle position sensor from the vehicle. Place the new throttle position sensor into the assembly with a valve position of 5.5 degrees. Place the sensor 15° right of the stated position before turning it clockwise until it reaches the shaft then tighten the set screws briefly. Attach the throttle position sensor connector while keeping the accelerator pedal position sensor connector disconnected. Connect the TOYOTA hand-held tester or OBD II scan tool to DLC3 followed by turning the ignition switch ON with no accelerator pedal application and tighten the screws to reach 14.4 - 16 % throttle valve opening percentage at 2.0 Nm (20 kg.cm, 18 in.lb). Perform another measurement of the throttle valve opening at the specifications points until it falls inside the allowed range. If not achieved, execute the adjustment process again. A full throttle valve percentage check should confirm it is maintained at 10 - 14 %. Perform the adjustment steps again if the percentage range is not met during the inspection. First paint the two set screws then turn off the ignition switch before disconnecting the tester and properly disconnecting the throttle position sensor connector. To replace the throttle control motor begin by taking out the throttle position sensor along with disconnecting the throttle control motor connector before unplugging six screws to remove the throttle control motor cover and its motor assembly and washer. Extract the three screws together with the throttle control motor unit while taking out its accompanying wave washer from the throttle control motor cover. Necessary for new throttle control motor installation is to position the wave washer into the cover then make pin hole alignment with positioning pins followed by grommet attachment before screwing the device with 3 screws that reach 3.4 Nm (35 kg.cm, 30 in.lb) torque. First, add a thin layer of specified grease to the gear teeth then add the washer before you place the throttle control motor cover at the positioning pin of the throttle body and fix it with 6 screws at 3.4 Nm (35 kg.cm, 30 in.lb) torque. Rejoin the throttle motor cable then put back the throttle sensor with subsequent adjustments to its position. The sensor replacement for the accelerator pedal position requires removal of its 3 set screws and sensor followed by new sensor installation with the throttle valve in an opener opening angle of about 4 degrees. Screw the sensor into position 20 degrees left from stated specifications through progressive clockwise movements until it reaches the throttle valve shaft then tighten its 3 screws to 5.4 Nm (55 kg.cm, 48 in.lb) torque. To inspect the accelerator pedal position sensor plug its connector into place then link the TOYOTA hand-held tester or OBD II scan tool to DLC3 and turn the ignition switch ON while avoiding pedal pressure to verify the ACCEL POS #1 (VPA) voltage falls within 0.35 - 0.85 V. Check the system operation after installing the throttle body.

Proceed with replacing the throttle position sensor by disconnecting the lead wire connector followed by taking out the two set screws and sensor. The new throttle position sensor needs installation in a position 15° to the right of its specified position with the throttle valve at 5.5° opener opening angle. Twist the sensor counter-clockwise while it moves toward the throttle valve shaft and fasten the set screws temporarily. Connect the throttle position sensor connector but keep the accelerator pedal position sensor connector disconnected from the circuit. Activating the TOYOTA hand-held tester or OBD II scan tool through DLC3 connections allows users to adjust the throttle position sensor while operating the ignition switch without pressing the accelerator pedal between 14.4 - 16 %. Tighten the screws with 2.0 N.m (20 kgf.cm, 18 in.lbf) torque. Regularly verify the throttle valve opening percentage while maintaining it between 10 and 14 percent following a throttle check where the valve is fully closed. First paint the set screws then turn off the ignition and remove the connector as well as the testing probe. To replace the throttle control motor start by removing the throttle position sensor followed by disconnecting the throttle control motor connector and removing its 6 screws and cover and motor assembly along with washer. The installation process requires use of a new throttle control motor with a wave washer inserted into the throttle control motor cover while matching pin holes to positioning pins and attaching the grommet before securing the motor with 3 screws at 3.4 N.m (35 kgf.cm, 30 in.lbf). A small layer of grease should cover the gear teeth before placing the washer and securing it by aligning the throttle control motor cover to the throttle body positioning pin then installing six screws with matching torque. Reinstall the throttle position sensor then adjust its position following the connection of the throttle control motor connector. The process to install a new accelerator pedal position sensor begins with removing 3 set screws then placing the sensor correctly at an angle of 4° while positioning it 20° to the left from the designed location. Screw the sensor against the throttle valve shaft while keeping it in a clockwise position until installation is complete and set the 3 screws with 5.4 N.m torque amount (55 kgf.cm, 48 in.lbf). To inspect the accelerator pedal position sensor the technician must connect its connector using a TOYOTA hand-held tester or OBD II scan tool at the DLC3 while turning the ignition switch ON while keeping the accelerator pedal free of key pressure then verify that the ACCEL POS #1 (VPA) voltage falls between 0.35 - 0.85 V. Totally check the system functionality after installing the throttle body.