Replace the throttle position sensor (TPS) on the electronic throttle body of the 6.7L Cummins diesel engine to restore accurate throttle angle monitoring and proper engine performance.

Warnings

Tools required

Parts

• Throttle Position Sensor × 1 — Mopar 5149062AA or equivalent
• TPS mounting screws × 2 — Included with sensor or reuse OEM

Preparation

1. Ensure the engine is cool to the touch
2. Disconnect the negative battery cable and wait 2 minutes
3. Remove the engine cover by pulling upward on the cover to release the mounting grommets
4. Clean the area around the throttle body to prevent debris from entering the intake system

Procedure

1. 1

   Access the throttle body
   Locate the throttle body on the driver side of the engine, mounted to the intake manifold. The TPS is integrated into the throttle body assembly on the side facing the engine block. You may need to move wiring harnesses aside for better access.
2. 2

   Disconnect the TPS electrical connector
   Press the red locking tab on the TPS electrical connector and pull the connector straight off the sensor. Use a small flathead screwdriver or pick tool to release the secondary lock if present. Set the connector aside where it won't contact engine components.
3. 3

   Remove the old TPS mounting screws
   Using the Torx T20 bit, carefully remove the two TPS mounting screws. These screws are small and have low torque specifications, so avoid stripping them. Keep track of the screws if they will be reused.
4. 4

   Remove the old TPS
   Gently pull the TPS straight off the throttle body shaft. The sensor slides off the D-shaped throttle shaft. If the sensor is stuck due to heat cycling or corrosion, gently wiggle it while pulling - do not pry against the throttle body housing.
5. 5

   Clean the mounting surface
   Inspect the throttle shaft D-profile for any debris or corrosion. Wipe the TPS mounting surface on the throttle body with a shop towel. If needed, use electrical contact cleaner to remove any oil or contamination. Ensure no cleaner enters the throttle bore.
6. 6

   Install the new TPS
   Align the new TPS with the D-shaped throttle shaft, ensuring the flat side of the shaft matches the flat side inside the sensor. The sensor should slide on easily with only light pressure. If it doesn't fit easily, rotate it slightly to align the D-profile - never force it.
7. 7

   Install and torque the TPS mounting screws
   Install the two TPS mounting screws and hand-tighten them to ensure proper seating. Using an inch-pound torque wrench, torque the screws in a crossing pattern to specification. These fasteners are critical for proper sensor alignment and electrical contact.
   Torque spec

   TPS Screws3 Nm (2 lb-ft)
8. 8

   Reconnect the electrical connector
   Push the electrical connector firmly onto the TPS until you hear or feel it click into place. Ensure the red locking tab is fully engaged. Gently tug on the connector to verify it is locked and won't pull off.
9. 9

   Complete final checks
   Verify all wiring is properly routed and secured away from hot exhaust components and moving parts. Reinstall the engine cover by aligning the mounting grommets and pressing down firmly until seated. Reconnect the negative battery cable.

Reassembly

1. No additional calibration or adaptation procedures are required for the TPS on this vehicle
2. The engine control module will automatically recognize the new sensor upon startup

Verification

• Turn the ignition to the ON position without starting the engine and verify no check engine light or throttle-related fault codes are present
• Start the engine and verify smooth idle with no surging or hunting
• With the engine idling, gently press the accelerator pedal and verify immediate engine response without hesitation or rough running
• Road test the vehicle to confirm normal throttle response and smooth acceleration throughout the pedal travel range
• Use a scan tool to monitor TPS voltage readings: should show approximately 0.5-0.9V at idle and increase smoothly to 4.5V at wide open throttle

More procedures for this vehicle