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.
2003 Kia Optima V6-2.7LFACTORY OEM SERVICE PROCEDURE
Throttle Position Sensor: Adjustments
THROTTLE POSITION SENSOR (TP SENSOR) ADJUSTMENT
NOTE: Before adjusting the TP Sensor, complete the basic idle speed adjustment.
1. Disconnect the throttle position sensor connector.
2. Using jumper wires, connect a voltmeter between terminal 1 and terminal 2 of the throttle position sensor connector.
3. Insert a 0.65 mm (0.0256 in.) thick feeler gauge between the fixed SAS and throttle lever.
4. Loosen the throttle position sensor mounting bolts and turn the TP Sensor body fully counterclockwise.
5. In this condition, check that there is continuity between terminals 1 and 2.
6. Slowly turn the throttle position sensor clockwise until you find a point at which there is no continuity between terminal 1 and 2. Then, tighten the throttle position sensor mounting bolt securely.
7. Connect the throttle position sensor connector.
8. Connect the scan tool to the data link connector in the fuse box.
9. If the scan tool is not used, connect a voltmeter between throttle position sensor connector terminals 2 (sensor ground) and 3 (sensor output) using pin.
NOTE
- Do not disconnect the TP Sensor connector.
- Use a digital type voltmeter to obtain an accurate value.
10. Turn the ignition switch "ON."
NOTE: Do not start the engine.
11. Check the throttle position sensor output voltage.
Throttle position sensor output voltage : 250 - 800 mV
12. If the voltage is out of specification, check the throttle position sensor and associated harnesses.
13. Remove the feeler gauge.
14. Turn the ignition switch OFF.
NOTE: Before adjusting the TP Sensor, complete the basic idle speed adjustment.
1. Disconnect the throttle position sensor connector.
2. Using jumper wires, connect a voltmeter between terminal 1 and terminal 2 of the throttle position sensor connector.
3. Insert a 0.65 mm (0.0256 in.) thick feeler gauge between the fixed SAS and throttle lever.
4. Loosen the throttle position sensor mounting bolts and turn the TP Sensor body fully counterclockwise.
5. In this condition, check that there is continuity between terminals 1 and 2.
6. Slowly turn the throttle position sensor clockwise until you find a point at which there is no continuity between terminal 1 and 2. Then, tighten the throttle position sensor mounting bolt securely.
7. Connect the throttle position sensor connector.
8. Connect the scan tool to the data link connector in the fuse box.
9. If the scan tool is not used, connect a voltmeter between throttle position sensor connector terminals 2 (sensor ground) and 3 (sensor output) using pin.
NOTE
- Do not disconnect the TP Sensor connector.
- Use a digital type voltmeter to obtain an accurate value.
10. Turn the ignition switch "ON."
NOTE: Do not start the engine.
11. Check the throttle position sensor output voltage.
Throttle position sensor output voltage : 250 - 800 mV
12. If the voltage is out of specification, check the throttle position sensor and associated harnesses.
13. Remove the feeler gauge.
14. Turn the ignition switch OFF.
Factory Service Tools
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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.
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