Throttle Position Sensor

This procedure covers removal and installation of the Throttle Position Sensor (TPS) on the 8.0L V10 engine, including electrical connector disconnection and sensor adjustment verification.

Warnings

Tools required

Parts

• Throttle Position Sensor × 1 — Use OEM specification
• TPS mounting screw O-rings (if equipped) × 2 — Verify with parts diagram

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition to OFF position and remove key
3. Disconnect negative battery cable and wait 2 minutes for capacitor discharge
4. Allow engine to cool to ambient temperature if recently operated

Procedure

1. 1

   Access throttle body area
   Locate the throttle body assembly on the driver side of the intake plenum. The TPS is mounted on the driver side of the throttle body, opposite the throttle cable linkage. Remove any air intake tubing or ducting that restricts access to the throttle body and TPS mounting area.
2. 2

   Disconnect TPS electrical connector
   Locate the TPS electrical connector on the sensor body. Press the locking tab on the connector and pull straight away from the sensor to disconnect. Do not pull on the wiring harness itself. Inspect the connector terminals for corrosion or damage.
3. 3

   Remove TPS mounting screws
   Remove the 2 TPS mounting screws securing the sensor to the throttle body using a socket or driver. Note the orientation of the sensor relative to the throttle shaft before removal. The sensor should pull straight away from the throttle body once the screws are removed.
4. 4

   Remove TPS from throttle body
   Carefully pull the TPS straight away from the throttle body. The sensor shaft is keyed to the throttle shaft with a D-shaped or flat-sided engagement. Do not rotate or twist during removal as this can damage the throttle shaft or sensor internals. Inspect the sensor O-ring or seal (if equipped) for damage.
5. 5

   Inspect throttle shaft and mounting surface
   Inspect the throttle shaft for wear, damage, or debris. The shaft should be clean and free of carbon buildup at the TPS mounting location. Check the throttle body mounting surface for cracks or damage. Clean the mounting surface with a shop towel if necessary. Do not spray carburetor cleaner or solvents into the TPS mounting bore.
6. 6

   Prepare new TPS for installation
   Inspect the new TPS for shipping damage and verify the correct part application. Check that the sensor shaft engagement matches the throttle shaft configuration. If the sensor includes replaceable O-rings or seals, ensure they are properly seated in their grooves. Do not lubricate the sensor shaft or mounting surface.
7. 7

   Install TPS onto throttle shaft
   Align the TPS shaft with the throttle shaft, ensuring the keyed engagement is correctly oriented. The sensor should slide onto the shaft with light finger pressure only. If resistance is felt, remove the sensor and verify alignment. Do not force the sensor as this will damage the throttle shaft splines or sensor internals. The sensor mounting holes should align with the throttle body mounting holes when correctly positioned.
8. 8

   Install and torque TPS mounting screws
   Install the 2 TPS mounting screws by hand, threading them carefully to avoid cross-threading. Tighten the screws in an alternating pattern to ensure even seating. Torque the mounting screws to specification using a torque wrench.
   Torque spec

   TPS Screws3 Nm (2 lb-ft)
9. 9

   Reconnect TPS electrical connector
   Reconnect the electrical connector to the TPS by aligning the connector and pressing firmly until the locking tab clicks into place. Verify the connection is secure by gently pulling on the connector body (not the wiring).
10. 10

    Reinstall air intake components
    Reinstall any air intake tubing or ducting that was removed for access. Ensure all clamps are properly tightened and all connections are secure.
11. 11

    Reconnect battery and clear codes
    Reconnect the negative battery cable. Reconnect the negative battery cable. Note that the 1992 Viper predates OBD-II and does not use a generic scan tool; if diagnostic codes need to be cleared, use the key-cycle (key-on/off) method or disconnect the battery per Chrysler SBEC procedure. Verify no obvious fault indications after reconnecting power.

Reassembly

1. Ensure TPS mounting screws are torqued to 3.0 Nm (2.0 lb-ft) in an alternating pattern
2. Verify electrical connector is fully seated with locking tab engaged
3. Confirm all air intake components removed for access are properly reinstalled

Verification

• Start the engine and verify smooth idle with no surging or hunting
• With engine at idle, verify no check engine light or TPS-related diagnostic trouble codes are present
• Perform a road test and verify smooth throttle response with no hesitation or dead spots during acceleration
• If a scan tool is available, monitor TPS voltage at idle (should be approximately 0.5-1.0 volts) and at wide open throttle (should be approximately 4.0-4.5 volts)
• Verify throttle blade returns to closed position smoothly when throttle is released

Related trouble codes on this vehicle

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