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How to Replace Throttle Position Sensor 00-03 Chevy Suburban

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How to Replace Throttle Position Sensor 00-03 Chevy Suburban

Created on: 2014-05-09

This video will show how to remove the alternator and the throttle position sensor to help you safely replace it yourself

  1. step 1 :Removing the Air Intake Hose
    • Disconnect the negative battery cable with an 8mm wrench
    • Loosen the two intake hose clamps with a flat blade screwdriver
    • Pull the smaller hose out of the air intake hose with pliers
  2. step 2 :Removing the Alternator
    • Pull the tensioner up with a 15mm socket and ratchet
    • Pull the belt off the alternator and carefully release the tension on the ratchet
    • Disconnect the alternator harness with a flat blade screwdriver
    • Remove the boot from the 10mm nut on the alternator
    • Remove the 10mm nut from the alternator
    • Pull the wire from the 10mm bolt on the alternator free
    • Remove the two 15mm bolts from the alternator
    • Pry the alternator up an out with a pry bar on both sides
  3. step 3 :Removing the Throttle Sensor
    • Lift up the tab and disconnect the sensor harness
    • Remove the two T20 bolts from the sensor with a ratchet
    • Pull the sensor free
  4. step 4 :Installing the New Throttle Sensor
    • Feed the sensor into place
    • Replace the two T20 bolts by hand
    • Tighten the T20 bolts to the sensor with a ratchet
    • Reconnect the sensor harness
  5. step 5 :Installing the Alternator
    • Pry the alternator into place
    • Insert the 15mm bolt to the alternator halfway with a hammer and then tighten it
    • Insert and tighten the other 15mm bolt to the alternator
    • Reconnect the alternator harness
    • Place the wire back onto the 10mm bolt
    • Reconnect the 10mm nut onto the alternator
    • Replace the boot on the 10mm nut
    • Use a 15mm socket and ratchet on the tensioner
    • Replace the tension belt on the alternator
  6. step 6 :Reinstalling the Air Intake Hose
    • Push the intake hose onto the air intake box
    • Push the intake hose onto the engine
    • Tighten the intake hose clamps with a flat blade screwdriver
    • Connect the smaller hose to the intake hose
    • Reconnect the negative battery cable with an 8mm wrench

Tools needed for replacement

  • General Tools

    Hammer

  • Pliers, Cutters & misc Wrenches

    Needle nose pliers

  • Ratchets & Related

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

    Pry Bar

  • Sockets - Metric

    15mm Socket

    10mm Socket

  • Star Drivers & Sockets

    T20 Driver

  • Wrenches - Metric

    8mm Wrench

Installation Video
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Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Don from 1A Auto. I hope this how-to video helps you out, and the next time you need a part for your vehicle, think of 1AAuto.com. Thanks.

In this video, we're going to show you how to replace the throttle position sensor on this 2002 Chevy Suburban with the V8 5.3 liter engine. The items you'll need for this includes a 10mm and 15mm socket, a ratchet, a flat blade screw driver, a pair of pliers, a pry bar, a T20 Torx driver, an 8mm wrench, and a hammer.

To start off, you want to disconnect your negative battery cable. Use your 8mm wrench and just loosen that up. Then it just pulls free. Set it aside. Next, you want to loosen up this hose clamp right here. Then loosen up the hose clamp right over here. Now, you can pull this intake hose forward and pry this part free. Lift it up. Now, using your pair of pliers, just push the clip, disconnect that lower hose, and set this intake aside. Using a 15mm socket and ratchet put it on the tensioner, pull the tensioner up, and pull that belt off your alternator. Then, carefully release the tension on the ratchet.

Pry up this tab and disconnect your alternator harness. Then pull back this rubber boot and remove this 10mm nut. That wire just pulls free. Now remove these two 15mm bolts. We'll fast-forward as Don does that. Using your pry bar, just pry the alternator up and out. Once you do one side, just repeat the process on the other side of the alternator. Now, pull back on this tab and disconnect your harness, and then remove these two T20 bolts. We'll just fast-forward as Don does this. Now, the sensor will just pull free.

Take your new sensor and push it into place and replace those two T20 screws. We'll fast-forward as Don tightens those up. Then reconnect your harness. Put your alternator back down into place and then pry it until you can line up those holes. Then push your first bolt in. The first one's going to be a little more difficult than the second one will be, because you're still trying to line everything up. Just use a hammer to help knock that bolt in. Once you get it to about this point right here, you're all set. The second bolt's going to be a lot easier to put in. Now, we'll just fast-forward as Don tightens those up with the 15mm socket and ratchet.

Reconnect the harness to your alternator. Put this wire back into place, and replace that 10mm nut. Then put that boot back over it. Again, use your 15mm socket and ratchet on the tensioner, and then pull your belt back up and on to the alternator. Now, take this upper intake assembly, push it back down into place, and push it back onto the engine. Re-clip that lower hose, then reconnect this hose, and tighten up those 2 hose clamps. Now replace your negative battery cable and tighten it up with your 8mm wrench, and you're all set.
We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    General Tools

  • Hammer

  • Pliers, Cutters & misc Wrenches

  • Needle nose pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver
  • Pry Bar

  • Sockets - Metric

  • 15mm Socket
  • 10mm Socket

  • Star Drivers & Sockets

  • T20 Driver

  • Wrenches - Metric

  • 8mm Wrench

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