Accelerator Pedal Position Sensor: Service and Repair
ACCELERATOR PEDAL POSITION SENSORREMOVAL
Early Diesel Engines
Fig.1 Cable/Lever/Throttle Linkage Cover:
The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated to its mounting bracket. The APPS assembly is located at left-front of engine below plastic cable/lever/linkage cover.
Fig.3 Apps Assembly:
CAUTION: Do not attempt to remove sensor from its mounting bracket as electronic calibration will be destroyed (sensor-to-bracket mounting screws are permanently attached). Two accelerator lever set screws are used to position lever. Do not attempt to alter positions of these set screws as electronic calibration will be destroyed.
1. Disconnect both negative battery cables at both batteries.
2. Remove cable cover. Cable cover is attached with 2 Phillips screws, 2 plastic retention clips and 2 push tabs. Remove 2 Phillips screws and carefully pry out 2 retention clips. After clip removal, push rearward on front tab, and upward on lower tab for cover removal.
Fig.2 Servo Cable At Throttle Lever:
3. Using finger pressure only, disconnect end of speed control servo cable from throttle lever pin by pulling forward on connector while holding lever rearward. DO NOT try to pull connector off perpendicular to lever pin. Connector will be broken.
4. Using two small screwdrivers, pry throttle cable connector socket from throttle lever ball. Be very careful not to bend throttle lever arm.
5. Disconnect transmission control cable at lever arm (if equipped).
6. Squeeze pinch tabs on speed control cable and pull cable rearward to remove from cable mounting bracket.
7. Squeeze pinch tabs on throttle cable and pull cable rearward to remove from cable mounting bracket.
8. If equipped with an automatic transmission refer to Transmission for transmission control cable removal procedures.
9. Disconnect wiring harness clip at bottom of bracket.
Fig.4 Apps Connector:
10. Remove 6 mounting bolts and partially remove APPS assembly from engine. After assembly is partially removed, disconnect electrical connector from bottom of sensor by pushing on connector tab.
11. Remove APPS assembly from engine.
Late Diesel Engines
Fig.5 Apps Location (Late):
The APPS is serviced (replaced) as one assembly including the sensor, plastic housing and cable. The APPS assembly is located under the left vehicle battery tray. Access to APPS is gained from over top of left / front tire.
1. Disconnect negative battery cable at battery.
2. Disconnect APPS cable at accelerator pedal. Refer to Accelerator Pedal Removal/Installation.
3. Remove wheel house liner at left I front wheel. Refer to Body
Fig.6 Apps Remove/Install (Late):
4. Gain access to APPS electrical connector by opening swing-down door. Disconnect electrical connector.
5. Remove 3 mounting bolts.
6. Remove APPS assembly from battery tray.
Fig.7 APPS Cable (Late):
7. If cable is to be separated at APPS, unsnap cable clip from ball socket. Release cable from plastic housing by pressing on small cable release tab.
INSTALLATION
Early Diesel Engines
The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated to its mounting bracket.
1. Snap electrical connector into bottom of sensor.
2. Position APPS assembly to engine and install 6 bolts. Tighten bolts to 24 Nm (18 ft.lbs.) torque.
3. Connect wiring harness clip at bottom of bracket.
4. If equipped with an automatic transmission, refer to Transmission for transmission control cable installation procedures.
5. Install speed control cable into mounting bracket. Be sure pinch tabs have secured cable.
6. Install throttle cable into mounting bracket. Be sure pinch tabs have secured cable.
7. Connect throttle cable at lever (snaps on).
8. Connect speed control cable to lever by pushing cable connector rearward onto lever pin while holding lever forward.
9. Install cable cover.
10. Connect both negative battery cables to both batteries.
11. ECM Calibration: Turn key to ON position. Without starting engine, slowly press throttle pedal to floor and then slowly release. This step must be done (one time) to ensure accelerator pedal position sensor calibration has been learned by ECM. If not done, possible DTC's may be set.
12. Use DRB III scan tool to erase any DTC's from ECM.
Late Diesel Engines
1. Install Accelerator Pedal Position Sensor (APPS) cable to accelerator pedal. Refer to Accelerator Pedal Removal/Installation.
2. Connect electrical connector to APPS.
3. If necessary, connect cable to APPS lever ball socket (snaps on).
4. Snap APPS cable cover closed.
5. Position APPS assembly to bottom of battery tray and install 3 bolts. Refer to Torque Specifications.
6. Install wheelhouse liner. Refer to Body.
7. Perform the following procedure:
a. Connect negative battery cables to both batteries.
b. Turn key switch ON, but do not crank engine.
c. Leave key switch ON for a minimum of 10 seconds This will allow ECM to learn electrical parameters
8. If necessary, use DRB III Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM.