Important: Refer to the Fuel Pressure Relief before disconnecting the fuel lines.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery terminal.
2. Loosen the filler cap in order to relieve the fuel tank pressure.
3. Remove the air cleaner assembly, the extension, and the gasket. Refer to Air Cleaner and Extension Replacement .
4. Disconnect the electrical connectors to the IAC valve, the TP sensor, and the fuel injectors.
5. Disconnect the injector wiring harness.
6. Disconnect the governor motor locking tab insert.
7. Disconnect the throttle cable
8. Remove the governor motor wiring harness connector.



9. Disconnect the vacuum hoses (3). Observe the position of the hoses.
10. Disconnect the fuel feed (2) and return (1) lines.

Use a backup wrench on the TBI fittings in order to prevent them from turning.

11. Remove the fuel line O-rings.

Discard the O-rings.

12. Remove the TBI attaching bolts (1).




Important: Stuff the manifold (4) opening with a shop towel in order to prevent dirt and other contaminants from entering engine.

13. Remove the TBI unit (2).

Remove and discard the gasket (3).

Notice: Use care when cleaning the old gasket from the aluminum surfaces in order to prevent damage to the sealing surfaces.

14. Clean the gasket sealing surfaces.
15. Inspect the manifold bore for loose parts and foreign material.
16. Inspect the intake manifold sealing surface for cleanliness.

1. Install the new TBI gasket (3).
2. Install the TBI unit (2).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the TBI attaching bolts (1).

Tighten
Tighten the TBI attaching bolts to 22.0 N·m (16 lb ft).

4. Install the new O-rings on the fuel lines.



5. Install the fuel feed (2) and return lines (1).

Tighten
Tighten the fuel line nuts to 27.0 N·m (20 lb ft) using a backup wrench on the TBI fittings in order to prevent them from turning.

6. Connect the vacuum hoses and bracket.

Important: Make sure the throttle cable does not hold the throttle open.

7. Connect the throttle cable
8. Connect the injector wiring harness.
9. Connect the electrical connectors making sure the connectors are fully seated and latched.
10. Connect the governor motor wiring harness connecting.
11. Install the governor motor connector locking tab insert.
12. Connect the negative battery terminal.
13. With the engine OFF and the ignition ON, check for fuel leaks.
14. Inspect the gasket, the extension (spacer), and the air cleaner assembly. Refer to Air Cleaner and Extension Replacement .
15. Reset IAC valve pintle position using the following steps:

15.1.

Depress the accelerator pedal slightly.

15.2.

Start and run the engine for 3 seconds.

15.3.

Turn the ignition OFF for 10 seconds.

15.4.

Restart the engine. Check for the proper idle operation.