Note. Due to the relative ease of replacing parts, the throttle body does not need to be disconnected from the intake manifold or disassembled. However, for clarity, the work performed is shown on the example of the TBI assembly removed from the vehicle.
1. Relieve the fuel pressure in the system (see section 2).
2. Disconnect the wire from the negative battery terminal.
3. Remove the air filter, adapter and gaskets.
Note. The fuel pressure regulator is located in the cover of the fuel supply meter. Whenever the meter cover or the regulator itself is replaced, the entire assembly must be replaced. The regulator must not be removed from the cover.
4. Disconnect electric sockets of atomizers.
5. Loosen the long and short screws of the fuel gauge cover (see illustration) and remove the cover.
12.5. Model 220 TBI Block Details: 1 - a long screw for fastening the cover of the fuel supply meter; 2 - a short screw for fastening the cover of the fuel supply meter; 3 - fuel supply meter cover; 4 - gasket cover of the fuel supply meter; 5 - gasket for the outlet of the fuel supply meter; 6 - pressure regulator seal; 7 - pressure regulator; 8 - fuel injector; 9 - fuel injector inlet filter; 10 - lower sealing ring; 11 - top sealing ring; 12 - gasket ring; 13 - screw connecting the body of the fuel supply meter and the throttle body; 14 - housing of the fuel supply meter; 15 - gasket; 16 - air filter gasket; 17 - sealing ring of the drain fuel line; 18 - fuel pipe nut; 19 - sealing ring of the inlet pipe; 20 - inlet pipe nut; 21 - gasket for the exhaust pipe nut; 22 - gasket for the inlet pipe nut; 23 - throttle position sensor lever screw (TPS); 24 - throttle position sensor lever (TPS); 25 - throttle position sensor screw (TPS); 26 - throttle position sensor screw retainer (TPS); 27 - throttle position sensor (TPS); 28 - plug of the idle lock screw; 29 - locking screw idle; 30 - idle stop screw spring; 31 - throttle body; 32 - flange gasket; 33 - spool for additional air at idle (IAC); 34 - IAC spool gasket
6. Remove the fuel gauge outlet gasket, cover gasket, and pressure regulator seal. Carefully remove any remnants of old gaskets with a blade (see illustration).
12.6. Carefully remove the fuel gauge outlet gasket and cover gasket with a blade
Attention! Do not attempt to reuse any of these pads.
7. Inspect the cover for dirt, foreign bodies, and casting distortion. If there is dirt, clean the cap with a clean cloth soaked in solvent. Do not immerse the fuel gauge cap in cleaning solvent; this can damage the pressure regulator diaphragm and gasket.
Attention! Do not loosen the four screws (see illustration), pressing the pressure regulator to the cover of the fuel supply meter. The regulator has a large, compressed spring that could cause injury if accidentally released. Disassembly of this assembly may also result in fuel leakage between the diaphragm and regulator housing. The new fuel gauge cover assembly has a new pressure regulator.
12.7. Never loosen the four screws on the pressure regulator (marked with arrows) from the cover of the fuel supply meter
8. Install a new pressure regulator seal, fuel gauge outlet gasket, and cover gasket.
9. Install the meter cover using Loctite 262 (or similar) for screws.
Note. The short screws are tightened after the injectors have been installed.
10. Connect the electrical connectors to both nozzles.
11. Connect the wires to the battery.
12. Turn off the engine and turn on the ignition, check for leaks on the gaskets and connections of the fuel line.
13. Install the air filter and gaskets.