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Disassembly & Reassembly

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2002 Toyota Tacoma, 2002 Toyota RAV4, 2002 Toyota Prius, 2002 Toyota MR2, and 2002 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. If necessary to remove TP sensor, remove TP sensor retaining screws and TP sensor from throttle body. See Figure. Use care not to drop or damage TP sensor.
  2. To install TP sensor, ensure throttle valve opening on throttle body is about 3.5 degrees. Install TP sensor on throttle body so it is at position No. 1 (15 degrees) and loosely install TP sensor retaining screws. See Figure. Rotate TP sensor counterclockwise to position No. 2 until it contacts throttle valve and slightly tighten TP sensor retaining screws. See Figure.
    3. NOTE: Ensure electrical connector is not installed on throttle control motor when checking TP sensor adjustment.
  3. To check TP sensor adjustment after installation on throttle body, install electrical connector on TP sensor. Ensure electrical connector is NOT installed on throttle control motor. Connect Toyota hand-held tester to data link connector No. 3. See Figure. Turn ignition on. DO NOT depress accelerator pedal after turning ignition on when adjusting TP sensor.
  4. Using hand-held tester, read the throttle valve opening which is displayed as a percentage. Throttle valve opening may be read by accessing THROTTLE POS under CURRENT DATA on hand-held tester.
  5. While reading throttle valve opening, rotate TP sensor counterclockwise until throttle valve opening is 14.8 percent, as this is the center of the standard throttle valve opening of 14.0-15.6 percent. Tighten TP sensor retaining screws to specification. See TORQUE SPECIFICATIONS . When TP sensor retaining screws are tightened, this may cause the throttle valve opening to change. Ensure throttle valve opening remains at 14.8 percent after TP sensor retaining screws are tightened. Readjust TP sensor if necessary.
  6. Ensure throttle valve on throttle body is fully closed. Using hand-held tester, read the throttle valve opening again. With throttle valve fully closed, throttle valve opening should be 10-14 percent.
  7. If throttle valve opening is not within specification with throttle valve fully closed, repeat steps  5 and  6 until correct throttle valve opening is obtained. Turn ignition off. Remove hand-held tester. Disconnect electrical connector at TP sensor.
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