Tools & materials
- Basic hand tools: ratchet, extensions, metric sockets (8–14 mm), flat & Phillips screwdrivers, Torx set (T20–T40).
- Hex/Allen set (if throttle body screws use hex).
- Multimeter (DC volts, continuity).
- Backprobe pins or fine probe set.
- Quality OBD2 diagnostic tool that can read live PIDs and clear codes (ideally Hino/Isuzu capable).
- Replacement TPS (OEM Hino 500 Series throttle position sensor or throttle body assembly if TPS is integral).
- Clean shop rags, rubber gloves, safety glasses.
- Dielectric grease.
- Torque wrench (for final fasteners).
- Optional: throttle body cleaner (use only on throttle plate/body, not directly on sensor).

Safety precautions
- Park on level ground, chock wheels, engage parking brake.
- Key out and disconnect negative battery terminal before removing electrical connectors. Wait 2–5 minutes for system to power down. If diagnostics require ignition ON, reconnect as directed in testing steps.
- Allow engine to cool before working around intake/throttle body.
- Keep hands, tools and clothing clear of moving parts if engine must be run for testing.
- Use eye protection and gloves; avoid inhaling cleaners.
- Support the vehicle properly if you must raise it — use jack stands, never rely on a jack.

Overview of the TPS on Hino 500 Series
- The TPS mounts on the throttle body and provides a variable voltage (signal) proportional to throttle plate angle. Typical 3-wire TPS: 5V reference, ground, signal (about 0.5V at closed throttle to ~4.5V at wide open).
- Some Hino/Isuzu derivatives have an electronic throttle actuator; the TPS may be part of that assembly and replaced as a unit.

Step-by-step — test (no removal) using multimeter and scan tool
1. Prepare vehicle: park, chock, key off. Reconnect battery negative if previously disconnected for power-on tests.
2. Locate throttle body on intake manifold and find TPS connector (usually 3-pin).
3. Backprobe connector: with harness connected and ignition ON (engine OFF), backprobe reference pin and ground pin. Using your multimeter set to DC volts, confirm reference ~4.5–5.0V. If reference absent — wiring/ECU issue.
4. Backprobe signal wire vs ground with ignition ON. At closed throttle you should see ~0.4–1.0V. Slowly open throttle by hand (with engine off) and watch voltage increase smoothly to ~4.0–4.5V at wide open. Voltage must change smoothly without jumps.
5. With scan tool read live TPS PID while slowly opening throttle; confirm smooth ramp and compare to expected values.
6. If voltage is erratic, jumps, stuck, or out of range, TPS is faulty or wiring connector is corroded/damaged.

Step-by-step — removal and replacement
1. Safety prep: park, chock, parking brake on, engine cool. Disconnect negative battery terminal.
2. Remove intake ducting/air hose to access throttle body and TPS. Use screwdriver/socket as needed.
3. Locate and unplug TPS electrical connector. Depress tab and pull; use small pick if stuck. Protect pins.
4. Remove TPS mounting screws (Torx/hex/phillips depending on design). Keep track of screw types.
5. Carefully withdraw TPS from throttle body. Note orientation and any O-ring/seal. Inspect shaft and bore for wear or carbon buildup.
6. Compare old TPS to new part for correct pinout and mounting orientation. Replace any O-rings or seals if provided.
7. Install new TPS: position correctly, start screws by hand, tighten to manufacturer torque (if unknown, snug then 1/4–1/2 turn — typical small sensor screws ~2–4 N·m). Do not over-torque plastic housings.
8. Reconnect electrical connector; apply a small amount of dielectric grease to pins if desired.
9. Reassemble intake ducting and ensure nothing interferes with throttle plate travel.
10. Reconnect battery negative terminal.

Post-installation testing & relearn
1. Clear stored TPS/Throttle codes with the diagnostic tool.
2. Relearn procedure (if specific factory tool instructions exist, follow them). Generic method:
- With ignition ON (engine OFF) cycle throttle a few times slowly to full open and back.
- Start engine and allow it to idle undisturbed for 2–5 minutes so ECU can re-learn idle and throttle baseline.
- Use scan tool to verify TPS PID values at idle and during throttle application.
3. Road test and confirm smooth throttle response, normal idle, and no fault codes.

How each tool is used (quick)
- Multimeter: backprobe reference & signal wires; red lead to wire, black to good chassis ground; read DC volts. Use continuity/resistance to check wiring continuity with connectors unplugged.
- Backprobe pins: insert behind connector to contact terminals without disconnecting harness.
- OBD2/diagnostic scanner: read and clear DTCs, view live TPS PID, perform throttle body adaptation if available.
- Torque wrench: tighten sensor screws to specified torque (or snug carefully if spec unknown).

Common pitfalls & how to avoid them
- Misidentifying sensor: TPS may be part of actuator — verify part number before ordering.
- Not performing relearn: ECU will keep old calibration, causing poor idle/hesitation after replacement. Use factory or capable scan tool for adaptation if available.
- Damaging connector pins: use proper backprobe and avoid forceful connector removal; inspect for corrosion.
- Overtightening screws: strip plastic housings or fracture sensor body — tighten to spec or gently snug.
- Contaminating sensor: don’t spray throttle position sensor directly with cleaner. Clean throttle plate/body carefully.
- Ignoring wiring/harness faults: sometimes problem is corroded wires, chafing or water ingress — inspect and repair wiring instead of only replacing TPS.
- Using incorrect replacement TPS: ensure correct OEM part or exact electrical specs (3-wire vs 2-wire, voltage ranges).
- Testing with engine running without care: moving parts can injure; only test live throttle conditions when safe.

Replacement parts required
- TPS sensor (OEM Hino 500 Series TPS). If TPS is integral to throttle actuator, replace throttle body assembly instead.
- Replacement O-ring/seal (if provided or damaged).
- Optional: new mounting screws if old ones are corroded.

Symptoms that indicate TPS replacement
- Erratic idle, hesitation or surging under part throttle.
- Throttle response dead zone or sudden jumps.
- Check Engine Light with TPS-related codes (e.g., P0120–P0124 family on generic systems).
- Inconsistent TPS voltage when tested.

No Yapping.
rteeqp73

Exhaust brake. #hino #hino500

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