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Written by a Jeep newbie, for Jeep newbies. Owned my 2002 TJ SE for about 4 weeks, and had to replace the throttle position sensor last night. Troubleshooting is not documented here, because TPS failure modes seem to be common and are listed in about every other post here. Regardless, here it goes:

Throttle Position Sensor replacement ( pictures shown for 2.5L motor, though I did a '96 XJ Cherokee 4.0 and I believe the actual TPS is the same).

Time needed: ~20 minutes (do it while you're draining oil for a oil change)
Parts needed:
1) TPS - take the advice on the forum, use an OEM Mopar part (# 4874371AC from Morris 4x4)

consumables (as necessary)
- 3-inch hose clamp x 3
- thread-lock of your choice
- throttle body/ mass air flow cleaner (or some other quick-evaporating aerosol cleaner)
- electrical contact cleaner (aerosol)
- dielectric grease

Tools:
- 1/4" ratchet drive (short handle)
- 1/4" Torx bits, T20 size
- flat-blade screwdriver
- 8mm wrench or socket

Reference Point List (see photos for references):

(A) Battery
(B) Intake Air Cleaner
(C) Intake Air Duct/Resonator Box
(D) Throttle body
(E) Throttle Cable
(F) Throttle Position Sensor (TPS)
(G) TPS wiring harness


Steps:

disconnect the negative battery cable from the terminal
- go ahead and hit the terminal with a wire brush to get the crud off.
7-battery.jpg

loosen the hose clamps on the air hose from the intake air cleaner box and the throttle body.
8mm wrench or screwdriver, whichever is easier.

remove the two screws holding the intake air resonator to the engine valve cover.
Use 8mm wrench.
6-intake air ductwork.jpg

pull the intake air ducting away from the throttle body.
Go ahead and clean the throttle cable pivot point (external to the throttle body), and clean around the throttle plate (interior of the throttle body).
4-throttlebody duct2.jpg

locate the throttle position sensor connector and remove from the throttle position sensor.
This connector uses a small locking slider on the top of the sensor. slide it out and wiggle the connector off.
2-throttle body closeup.jpg

clean the contactors on the sensor connector.
give it a spray with electrical contact cleaner.

locate the throttle position sensor and remove.
there are two screws (only one shown, difficult location to photograph) that must be removed with a T20 bit. Use a ratchet/bit, or if you've got one, a snubby T20 screwdriver. it's crammed right up there next to the firewall so have a flashlight and patience.
1-TPS closeup.JPG

install new throttle positon sensor.
you'll have to give it a little wiggle to line it up with the throttle plate pivot shaft, but it will slide right on. put some thread-locker on the two screws, and tighten down. careful not to crack the plastic sensor housing.
reconnect the wiring. slide the connector back on and click into place

reinstall the air duct. push back down onto throttle body, re-install screws holding resonator to valve cover, and reattach hose end to intake air filter box. tighten hose clamps.

you're done! finish your oil change.

finish your beer (cause you did it so fast).


congratulate yourself for having done this while teaching your toddler what all the parts of the throttle body are called.

have another beer.:thumb:
 

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I hunted all over the place for the size of the two screws that hold in the TPS. After pulling the throttle body to get the screws out and still losing three T20 torx bits to the effort, I made a run to ACE hardware.

The screws are 5mm x 0.8 and ACE hardware has them in many lengths, stainless steel with regular allen heads that fit great. When you pick up the TPS, grab a packet of dielectric grease and maybe some anti seize as well. If you have a 5mm tap, it wouldn't hurt to chase the threads in the holes to clean them up

Because if you're like me, you really don't want to ever have to break a handful of T20 tips or pull off the throttle body to change this thing next time.

Oh, and O'Reilly has a lifetime guarantee on their TPS sensors. I'll never have to buy one of these darn things again.
 

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throttle position sensor

Has anyone ran across a different plug on the sensor on a 1997 jeep wrangler 2.5L motor? I have picked up a replacement part from Oreily's and everything that I have researched, the part is correct but the plug on the wire harness does not match up. The problem is flat prongs verses round prongs. Help please!
 

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Has anyone ran across a different plug on the sensor on a 1997 jeep wrangler 2.5L motor? I have picked up a replacement part from Oreily's and everything that I have researched, the part is correct but the plug on the wire harness does not match up. The problem is flat prongs verses round prongs. Help please!
After 7/1997 the wiring harness was upgraded to OBDII, that's what I have heard. If you call the dealership they offer you 2 options for a TPS for the 2.5L 1997 wrangler. Open the driver door to see when your wrangler was made or give the dealer your vin and get the part number from them. If it was made before 7/1997 (mine 4/1997) you might need a different TPS than wranglers made after 7/1997.
 

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I hunted all over the place for the size of the two screws that hold in the TPS. After pulling the throttle body to get the screws out and still losing three T20 torx bits to the effort, I made a run to ACE hardware.

The screws are 5mm x 0.8 and ACE hardware has them in many lengths, stainless steel with regular allen heads that fit great. When you pick up the TPS, grab a packet of dielectric grease and maybe some anti seize as well. If you have a 5mm tap, it wouldn't hurt to chase the threads in the holes to clean them up

Because if you're like me, you really don't want to ever have to break a handful of T20 tips or pull off the throttle body to change this thing next time.

Oh, and O'Reilly has a lifetime guarantee on their TPS sensors. I'll never have to buy one of these darn things again.
No, but you'll be back at it again swapping out when it prematurely fails. MOPAR n done for our finicky TJs I say. Others chime in.
 
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