Fuel Injector: Service and Repair

TBI Unit:

IMPORTANT PRECAUTIONS!
- Use care when removing injector to prevent damage to connector terminals, filter or nozzle.
- Do not immerse injectors in cleaning solvent.

SERVICE INSTRUCTIONS
- Each injector is serviced as a complete unit.


REMOVE OR DISCONNECT
- Relieve fuel pressure.
- Disconnect battery ground cable.
- Air cleaner assembly.
- Disconnect injector electrical connectors.

Fuel Meter Cover:

- Remove screws securing meter cover-to-meter body. Note locations of two shorter screws.
- Remove fuel meter cover.
- Do not remove meter cover gasket from fuel meter body. If gasket is stuck to cover, remove and place it on body.
It will protect the body during the next operation.

Fig. 89 TBI Fuel Injector Removal:

- Pry injector out of fuel meter body using a suitable screwdriver and bar stock.
- Remove and discard O-rings, washers, injector fuel and meter cover gasket.

INSPECT
- Injector filter screen for dirt or contamination. If found, check main filer, tank and lines for contamination.

IMPORTANT PRECAUTIONS!
- Always use the correct injector when replacement is required. Other injectors may look similar but have different flow rates.
- When installing an injector, install the upper O-ring before the injector to ensure proper seating of the O-ring. Reversing these steps could result in a leak and possible fire.

SERVICE INSTRUCTIONS
- Service injector packages may include an injector washer (spacer). The washer is not required on the TBI 220 application. Install injectors and o-rings according to illustrations.
- New injector service kits are supplied with new screws that are coated with a thread locking compound. If the original screws are used, be sure to lightly coat threads with Loctite 262.

INSTALL OR CONNECT
- Lubricate new upper (large) O-ring and install in fuel meter body. Be sure O-ring is seated properly and is flush with top of meter cavity.
- Lubricate replacement small O-ring with motor oil, then push O-ring onto nozzle end of injector until seated against injector fuel filter.

Fuel Injector And O-Rings:

- Install injector in injector cavity, aligning raised lug on injector with notch in fuel meter body cavity.

Fig. 91 Fuel Injector Installation:

- Push down on injector until fully seated in cavity. At this time injector electrical terminals should be approximately parallel to throttle shaft.
- New pressure regulator dust seal.
- New fuel meter outlet gasket.
- Cover gasket.
- Fuel meter cover fasteners (with thread locking compound). Torque to 3.0 Nm (27 in lb).
- Electrical connectors.
- Negative battery cable.
- Turn key ON and check for fuel leaks. Turn key OFF
- Repeat previous step 2 times.
- Air cleaner.