Tools & supplies
- Metric socket set (1/4" & 3/8" drives), extensions, swivel
- Torque wrench (0–50 Nm range)
- Ratchet, 10/12/14/17 mm sockets commonly used
- Flat & Phillips screwdrivers, picks
- Hose-clip pliers or pliers for spring clamps
- Soft-bristle brush, clean lint-free rags
- Throttle-body cleaner (non-chlorinated, sensor-safe)
- Disposable nitrile gloves, safety glasses
- Multimeter and OBD2 scanner or Toyota Techstream (for diagnostics & relearn)
- New throttle-body gasket (OEM), replacement throttle-body assembly or rebuild kit if required
- Replacement wiring harness connectors if cracked, dielectric grease
- Container to catch any drips

Safety precautions
- Work on a cold engine; hot intake parts/coolant can burn you.
- Disconnect negative battery terminal before disconnecting TB wiring (prevent shorting, ECU errors). Wait 2–5 minutes for capacitors to discharge.
- Keep dirt, rags and tools out of the open intake opening.
- Wear gloves and eye protection when using cleaners.
- Do not spray cleaner onto electrical connectors, sensors, or inside turbo inlet without control.
- If the TB has coolant passages (confirm on your unit), have a catch pan and be ready to top up coolant; avoid spilling.

Overview / what you’re about to do
- Remove intake ducting, disconnect sensors and hoses, unbolt throttle body, inspect/clean or replace, reinstall with new gasket, torque to spec, reconnect and perform ECU relearn/scan-tool adaptation if required.

Step-by-step procedure
1) Preparation
- Park on level ground, set parking brake, chock wheels.
- Remove engine cover or any obstructing trim.
- Disconnect negative battery terminal.

2) Access & note
- Label or photograph vacuum lines, electrical connectors and hose routing for reassembly.
- Remove intake ducting/snorkel and airbox components to expose throttle body and intake flange.

3) Remove connectors & hoses
- Unplug throttle-position/ETC actuator electrical connector(s) gently — depress locking tab, pull straight out.
- Remove any vacuum lines, breather hoses, and heater/coolant lines if present. If coolant lines are clamped, be prepared to catch small amounts; plug lines to prevent contamination.
- Remove sensor mounting screws if sensor needs to be removed from TB for cleaning (only if necessary).

4) Unbolt & remove throttle body
- Using appropriate sockets, remove bolts securing throttle body to intake manifold. Keep bolts in order.
- Carefully lower throttle body away from manifold, avoiding contact with the throttle shaft. If it grips, check for any remaining hoses or bolts.

5) Inspect parts
- Inspect gasket surface and intake flange for damage or carbon buildup.
- Inspect throttle shaft for play/wear and check for signs of oil contamination or scoring. Excess shaft play or heavy corrosion means replace TB.

6) Clean throttle body (if reuse)
- Use throttle-body cleaner and a soft brush to remove carbon and grime from the throttle plate, bore and edges. Spray cleaner onto rag or brush — do not soak electrical components.
- Hold throttle plate closed with one hand (or a small tool) while cleaning edges. Avoid aggressive prying on the plate or shaft.
- Wipe clean with lint-free rags until no residue remains. Let solvent evaporate fully.

How to use the cleaner/tool
- Hold spray can 6–8" from surfaces; short bursts. Use brush to loosen carbon, catch runoff on rag. Do not aim directly at sensors or wiring. Use a vacuum or rag to prevent debris from falling into intake.

7) Replace gasket & reassembly
- Fit a new throttle-body gasket (always replace gasket). Align and hand-start bolts.
- Tighten bolts in a criss-cross pattern to seat the gasket, then torque to factory spec. If you do not have exact spec available, torque bolts to roughly 8–12 Nm (6–9 ft-lb) — but verify with the Toyota service manual for exact values.
- Reconnect any sensor(s), vacuum lines, coolant hoses and the air intake ducting.

8) Reconnect battery & relearn
- Reconnect negative battery terminal.
- If you have Techstream or a capable aftermarket scanner, perform throttle valve closed position (TVCP) initialization / idle relearn per Toyota procedure.
- If no scan tool: many Toyota diesels will settle into normal idle after a prescribed key-on/key-off cycle and a drive cycle. Common basic sequence (verify with manual): turn ignition ON (do not start) for 2–3 seconds, OFF for 2–3 seconds, repeat 3 times, then start engine and allow to idle until normal. If engine runs poorly or check-engine lamp remains, use scanner to clear codes and run relearn.

9) Test
- Inspect for vacuum leaks and coolant leaks (if lines were removed). Start engine and observe idle, listen for hissing.
- Drive gently and check for check-engine light. Re-scan for trouble codes.

Replacement parts commonly required
- Throttle-body-to-intake gasket (replace always)
- Throttle-body assembly (replace if heavy shaft wear, sticking, electrical fault)
- Wiring connector or harness repair kit if brittle/damaged
- O-rings or hose clamps if any were damaged during removal

Common pitfalls & how to avoid them
- Reusing old gasket: causes vacuum leaks — always replace.
- Forcing plate or prying on shaft: can bend shaft or damage actuator — support plate gently while cleaning.
- Letting debris fall into intake: plug intake with clean rag or foam while TB is off.
- Over-torquing bolts: can crack throttle body or intake flange — use torque wrench.
- Not performing TB/ECU relearn: can cause high/low idle and limp behavior — use scanner or proper procedure.
- Spraying cleaner on sensors or wiring: can damage TPS/actuator electronics — shield connectors and spray onto brush/rag.
- Not checking for coolant passages: if you separate a coolant line, be ready to capture and top up coolant; do not run with air in system.
- Damaging wiring clips: disconnect gently using the proper release tab — avoid twisting connectors.
- Retaining carbon in recesses: clean thoroughly around the bore and plate edges; partial cleaning can leave rough idle.

Electrical diagnosis / testing (brief)
- If suspect TPS/ETC issues: check connector voltage reference (usually +5 V), ground and signal using a multimeter against service manual pinouts. Replace TB assembly if actuator or TPS readings are out of range.

Final notes
- If cleaning doesn’t cure sticking, rough idle or codes (P0121/P2135 equivalents for throttle/POS), replace the throttle-body assembly with OEM part and perform ECM adaptation with Techstream.
- Keep all removed bolts and clamps organized; reuse only undamaged fasteners.

End.
rteeqp73

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