Throttle Position Sensor Replacement Write-Up -
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Unread 05-21-2012, 01:32 PM   #1
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1999 TJ Wrangler 
Join Date: Mar 2008
Location: Boston, MA
Posts: 3,506
Throttle Position Sensor Replacement Write-Up

Couldn't find a write up on here, so I thought that I would post one just in case anyone else needs the information on how to do this! My TPS was failing, which is exhibited by loss of power during acceleration and an unsteady idle. My TJ started throwing a CEL last September but never had any other signs of failure. A few weeks ago though I lost power accelerating up a hill on the way to a trail run, and it became worse after that.

I purchased the part from RockAuto for $24 and had it a few days later (usually their shipping is quick, but this came from Cali to Mass so it took a little longer).

  • Throttle Position Sensor - RockAuto part #TH189T
  • 1/4" Drive Ratchet
  • 1/4" Drive Ratchet Extension
  • T20 Torx Bit

So first, lets locate the Throttle Position Sensor. It's right on the side of the Throttle Body, and has a harness connecting it to the engine computer. After removing the computer harness and securing it out of the way, we can begin backing out the long torx bolts that hold it into place.

There are two of the torx screws. They were sent from the factory with Loc-Tite on the end, so be prepared to fight a little. This can be a pain in the *** since there isnt a lot of room due to the wires and parts so closely near by that get in the way. The drivers side of the two screws might require use of the aforementioned socket extension just to get out of the way a little.

After both screws are out, you will be able to remove the TPS from the Throttle Body. It may take a little force, but it's a plastic piece so it should not be too difficult. Be sure to not lose the screws. At this point you can put it next to the new one and marvel at what little damage 13 years does to a piece of plastic, compared to a 13 year old part of steel or aluminum on the same Jeep.

The next step is to secure the gasket around the front of the TPS. Mine was blue. From there, you re-align the TPS with the TB, and screw it back in place. Be sure to note that it may take some slight off-camber positioning in order to get it onto the throttle body. Be gentle but move it around a bit to get it on there. Also make sure that the screws are nice and tight, and that there are no gaps between the TPS and the throttle body. After that, reconnect the harness and put away your tools...... The Jeep is back in service!

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Unread 05-21-2012, 01:37 PM   #2
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2004 TJ Wrangler 
Join Date: Sep 2011
Location: Tulsa, OK
Posts: 5,239
nice write-up and pics

Obviously, it is much easier to get at if you happen to have the throttle body off for cleaning already anyway
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Unread 05-21-2012, 04:00 PM   #3
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2003 TJ Wrangler 
Join Date: Oct 2005
Location: Baton Rouge, La
Posts: 629
Originally Posted by djflyy View Post

There are two of the torx screws. They were sent from the factory with Loc-Tite on the end, so be prepared to fight a little.
No kiddin'!

I twisted the splines on both of my T20 bits trying to get those screws out, so I ran out and bought a new set of "heavy-duty" Torx bits. Twisted the T20 in that set, then gave up and took it to a shop who had to drill the Torx screws out. I was out of time and patience.
'03 red Rubi
rouxbicon is offline   Reply With Quote Quick reply to this message

bad idle , loss of power , throttle , throttle position sensor , tps

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