Guide: TPS repair guide v2 for HDi

[highwayman306]

After reading a very good thread by Dee-Turbo, many thanks to him for his guide, I thought I would do a more in depth, picture heavy thread for the same guide.

I had EML on and wanted to eliminate this problem as it was logged on ECU alongside other faults.

Tools needed:
T15 security bit
T7 bit
10mm socket
Grease (I used multi purpose)
Rags for cleaning


So here we go:

TPS is not in standard location on my car as I moved it some time back:



Unplug and remove cable from TPS, then unbolt 10mm nut holding in place, there may be two 10mm nuts on yours but mine broke when moving some years back but all was fine with mine
Feed cable out of rubber and take unit into the house.


Pick the glue out of the two T15 security screws and unscrew them:



Then remove sensor from the cable spring housing:



Now remove the three T7 screws holding the spring plate on the sensor:

Now you will be met with the insides of the sensor:

Take care with removal of the top plate here as it retains the spring holding the magnet sensor inside and pops out a bit:

Remove the magnet sensor and give it a good clean:

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Then clean the inside of the housing where the sensor seats:


Now give the cable spring housing a good clean removing all the old grease:

Now when all the old grease is cleaned off, start applying the new grease to the moving parts of the TPS:

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After the parts are greased start rebuilding the TPS:

The spring locates in a cut-out in the magnet sensor:

The top of the spring locates in the retaining plate's underside, this bit can be a bit tricky but anti-clockwise turning can keep the spring located and patience. Once it has turned the plate drops into place inside the housing locating on another cut-out:




When it is located it will drop down, hold it there and start screwing it back up:

Note that I have greased the inside of the collar where the magnet sensor pokes through

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Now the sensor unit is back together time to grease up some more


I greased up the 'O' ring just for good measure:



Place the 'O' ring back onto the unit then add a little more grease to the face of the plate, don't go overboard but make sure there is some on there:

Now place the unit back onto the cable spring housing and screw back together:


I popped a little more grease onto the screws to save the rusting plus, I like grease if you haven't already noticed




Now pop the whole unit back onto the car and connect back up. Check the plug for any corrosion, I didn't see any on mine and I doubt there will be on any other but its worth checking out just in case

There you go

Thanks to Dee-Turbo for his guide, without his I wouldn't have been able to do mine