Watch a teardown or throttle body removal video first to get comfortable with the process, then use these notes at the bench.

  1. Remove the rubber intake hose connecting the airbox to the throttle body.
  2. Unplug the throttle body connector.
  3. Undo the four 5mm Allen key screws incrementally in a cross pattern.
  4. Move the throttle body to a comfortable work surface.
  5. Cut through the silicone holding the aluminium cap to the bottom of the throttle body.
  6. Carefully pry up the aluminium plate, working around the perimeter.
  7. Dig out the green potting compound around the three TPS wires and pins.
  8. Split the TPS pins from the throttle body pins. They are spot-welded and will not desolder cleanly.
  9. Remove the four screws holding the TPS to the throttle body.
  10. Gently pry the TPS out, watching that the pins are actually disconnected.
  11. Remove potting around the second pin from the bottom on the stepper motor side.
  12. Separate the pins so they cannot contact each other again.
  13. Loosen the nut on the throttle shaft, then snug it back up lightly.
  14. Remove the exposed non-threaded portion of the throttle shaft with a grinder or rotary tool.
  15. Test-fit the new TPS and check that it clears through the full throttle blade range.
  16. Remove the pre-loosened nut on the throttle shaft.
  17. Fit the new TPS magnet and test rotational alignment.
  18. Gently bend the pins on the new TPS so the pins touch for testing before soldering.
  19. Run the extra wire from the new sensor to the exposed stepper motor pin.
  20. Attach the new TPS, checking that the pins touch and the wire is not pinched.
  21. Solder the wire to the exposed throttle housing pin.
  22. Reassemble the throttle housing onto the car without over-tightening the screws.
  23. Plug in the throttle housing and scan for codes with ignition on.
  24. If the car starts, idles, and has no codes, continue. If not, adjust the magnet alignment and test again.
  25. Once the car starts and idles cleanly, remove the throttle housing.
  26. Optionally add thread-lock to the nut/thread, then reattach the TPS.
  27. Solder the three TPS pins, taking care not to melt the added wire.
  28. Optionally repot the pins.
  29. Flatten the aluminium cap and reattach it with RTV, clamping while it sets.
  30. Reattach the throttle housing, plug it in, reassemble the intake hoses, and test.