BEFORE YOU BEGIN:
• Always wear proper safety equipment when performing repairs.
• Ensure this part fits your exact vehicle year, make, model and configuration. You can verify at your point of purchase using the part number on the box,
or using the part number above at DormanProducts.com.
• Reference the appropriate service manual for your vehicle. If you do not have a service manual, and do not have the training or experience to perform
the necessary procedures correctly, seek the services of a qualified technician.
This Tech Note contains instructions for installing the integrated sensor on pedals with a separate idle validation switch or replacing
an existing integrated sensor.
Important! Before replacing an existing sensor, check engine manufacturer's latest instruction bulletin to insure that your diagnosis
of a sensor fault is correct. Replacing the sensor will reset the system and any other fault with be temporarily cleared. Uncorrected
problems will reoccur!
1.
Remove pedal from vehicle if necessary. Depending on pedal installation, it may not be possible to replace integrated sensor
without removing pedal from vehicle. NOTE: Carefully observe the routing of the wiring harness. Marking the wire routing is
suggested. Correct harness routing is critical to performance of product.
2.
Remove cover screws (item 6) and sensor cover (item 17). Pry up clip on connector of wiring harness to disconnect it from
sensor. Retain sensor cover. Discard screws and sensor (item 29). Clean surface where sensor mounts to pedal with Stoddard
solvent. Inspect bearing and bearing housing for wear. If there is damage to sensor shaft or bearing, replace entire upper
pedal assembly.
3.
Inspect connector for any damage to green rubber seal. If damage is evident, replace wiring harness. To replace wiring harness,
remove screws (item 7) and cable clamps (item 31), again carefully observing the routing of the wiring harness. Discard wiring
harness (item 13), clamps and screws.
4.
If separate idle validation switch is in place beneath pedal, remove screws securing switch and wiring harness. Discard screws,
switch, clamps, and wiring harness.
5.
Position new sensor on pedal, lining up holes in sensor with holes in casting. Replace sensor cover. Secure with screw provided
in kit. Torque to 15–25 in.·lbs. Over tightening screws may damage screw holes in casting. Connect wiring harness provided in kit
to sensor.
6.
Secure wiring harness to base plate with cable clamps and screws provided in kit. Leave a large loop in the harness assembly to
eliminate excessive bending of the wires. Torque to 20–35 in.·lbs.
7.
Reinstall pedal in vehicle if removal was necessary. Secure wiring harness as originally routed. Attach connector(s)
to vehicle wiring harness.
Disclaimer: Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a
qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so
may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to your motor vehicle (such as Federal Motor Vehicle Safety Standards by
the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.
Dorman Products, Inc. | Corporate Office and Customer Service: 1-800-523-2492 | Tech Line: 1-866-933-2911
©2021 No reproduction in whole or in part without prior written approval.
904-7692 ACCELERATOR PEDAL SENSOR
TECH NOTE: INSTALLATION
1
904-7692_Tech-Note