Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2004EXPRESS 2500 2WD V8-6.0L VIN UREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSTHROTTLE POSITION SENSORSERVICE AND REPAIR
2004 Chevrolet Express 2500 2WD V8-6.0L VIN U
Throttle Position Sensor: Service and Repair
2004 Chevrolet Express 2500 2WD V8-6.0L VIN USECTION Service and Repair
THROTTLE POSITION (TP) SENSOR REPLACEMENT
REMOVAL PROCEDURE
CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.
NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result.
1. Disconnect the negative battery cable.
2. Remove the generator.
3. Disconnect the throttle position (TP) sensor electrical connector.
4. Remove the TP sensor attaching screws (5).
5. Remove the TP sensor (6).
6. Remove the TP sensor O-ring seal (7).
INSTALLATION PROCEDURE
1. Install the TP sensor O-ring seal (7) on the TP sensor (6).
2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Make sure the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the TP sensor attaching screws (5).
Tighten
Tighten the screws to 2 N.m (18 lb in).
4. Connect the TP sensor electrical connector.
5. Install the generator.
6. Connect the negative battery cable.
REMOVAL PROCEDURE
CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.
NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result.
1. Disconnect the negative battery cable.
2. Remove the generator.
3. Disconnect the throttle position (TP) sensor electrical connector.
4. Remove the TP sensor attaching screws (5).
5. Remove the TP sensor (6).
6. Remove the TP sensor O-ring seal (7).
INSTALLATION PROCEDURE
1. Install the TP sensor O-ring seal (7) on the TP sensor (6).
2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Make sure the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the TP sensor attaching screws (5).
Tighten
Tighten the screws to 2 N.m (18 lb in).
4. Connect the TP sensor electrical connector.
5. Install the generator.
6. Connect the negative battery cable.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.