Throttle Body Assembly Overhaul

DISASSEMBLY PROCEDURE




1. Remove the throttle body fuel injection (TBI) unit from the engine.

IMPORTANT: Do not to remove the fuel pressure regulator valve from the TBI unit. The fuel pressure regulator valve is calibrated at the factory and is not adjustable. The fuel pressure regulator valve is not serviceable separate from the TBI upper assembly.

2. Remove the two bolts and the air cleaner bracket from the TBI unit.




3. Remove the two screws (3) and the fuel injector cover (1) (with the electrical connector attached) from the fuel injector.
4. Remove the two screws and the plate (2) covering the fuel injector wire leads.
5. Remove the fuel injector wire harness from the TBI unit.




6. Remove the fuel injector from the TBI unit.
7. Remove the two screws and the throttle position (TP) sensor from the TBI unit.




8. Remove the two screws to the upper and the lower sections of the TBI unit.
9. Separate the upper (1) and the lower (2) sections of the TBI unit.

ASSEMBLY PROCEDURE




1. Install a new gasket (1) onto the TBI lower assembly (2).

NOTE: Refer to Fastener Notice in Cautions and Notices.




2. Install the upper TBI assembly (1) to the lower TBI assembly (2) and secure with the two screws.

Tighten
Tighten the TBI unit attaching screws to 3.5 N.m (31 lb in).

3. Connect the TP sensor to the TBI unit.
4. Secure the TP sensor to the TBI unit with the two screws, but do not tighten fully.
5. Install a new lower fuel injector insulator into the fuel injector cavity of the TBI unit.

NOTE: Do not twist the fuel injector during the installation to the throttle body in order to prevent damage and misalignment of the fuel injector O-ring seals.




6. Install the fuel injector to the TBI unit.




7. Install the fuel injector wire harness into the TBI unit.
8. Install the fuel injector wire leads cover plate (2) to the TBI unit and secure with the two screws.
9. Install the fuel injector cover (1) to the fuel injector (with the electrical connector attached) and secure with the two screws (3).




10. Install the air cleaner bracket to the TBI unit and secure with the two bolts.

Tighten
Tighten the ACL bracket bolt to 10 N.m (89 lb in).

11. Install the TBI unit onto the engine.
12. Adjust the TP sensor.