This procedure covers the replacement of the Throttle Position Sensor (TPS) on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Throttle Position Sensor × 1 — Use OEM specification
• TPS mounting screw seal washers (if equipped) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow engine to cool completely
3. Disconnect negative battery terminal and wait 90 seconds for system discharge
4. Remove engine cover by pulling upward on clips

Procedure

1. 1

   Access the throttle body assembly
   Locate the throttle body on the intake manifold near the center of the engine bay. Remove the air intake duct by loosening the hose clamp at the throttle body and disconnecting any breather hoses. Move the duct aside for access.
2. 2

   Disconnect TPS electrical connector
   Locate the TPS electrical connector on the side of the throttle body. Press the locking tab and carefully pull the connector straight off the sensor. Inspect connector terminals for corrosion or damage.
3. 3

   Remove the old TPS
   Using a Phillips screwdriver, remove the two TPS mounting screws. Note the orientation of the sensor before removal. Carefully pull the TPS straight off the throttle body shaft. Do not rotate or force the sensor during removal.
   Torque spec

   TPS Screws3 Nm (2 lb-ft)
4. 4

   Inspect throttle body shaft
   Examine the throttle body shaft for wear, scoring, or damage. Check that the shaft rotates smoothly without binding. Clean any debris from the mounting surface using a clean, lint-free cloth. Do not spray cleaners directly into the throttle body.
5. 5

   Install new TPS
   Align the new TPS with the throttle body shaft, ensuring the sensor tab engages with the shaft D-shape properly. The sensor should slide on easily without force. If equipped, install new seal washers on the mounting screws.
   ⚠Verify correct alignment before tightening screws - misalignment will cause incorrect sensor readings
6. 6

   Torque TPS mounting screws
   Install both TPS mounting screws finger-tight, then torque in a cross pattern to specification using a torque wrench. Do not overtighten as this can damage the sensor housing.
   Torque spec

   TPS Screws3 Nm (2 lb-ft)
7. 7

   Reconnect electrical connector
   Push the electrical connector onto the TPS until it clicks into place. Verify the locking tab is fully engaged by gently pulling on the connector.
8. 8

   Reinstall air intake components
   Reposition the air intake duct and tighten the hose clamp at the throttle body. Reconnect any breather hoses that were removed. Ensure all connections are secure and properly seated.
9. 9

   Reconnect battery and clear codes
   Reconnect the negative battery terminal. Turn the ignition to ON position without starting the engine. Wait 10 seconds, then turn ignition OFF. Repeat this cycle three times to allow the ECU to relearn throttle position values.

Reassembly

1. Reinstall engine cover by pressing down on clips until they snap into place
2. Verify all hose clamps and connections are tight
3. Check that no tools or parts were left in the engine bay

Verification

• Start the engine and verify it idles smoothly without surging or stalling
• Check that no warning lights are illuminated on the instrument cluster
• Test throttle response by gently pressing the accelerator pedal - response should be smooth and immediate
• Use an OBD-II scanner to verify no throttle position sensor codes are present
• Perform a test drive to confirm normal acceleration and no hesitation under load

More procedures for this vehicle