Fuel Injection Manual 1978-1985 for Domestic and Imported Vehicles

• Bosch L-Jetronic, LH-Jetronic, Motronic, K-Jetronic, KE-Jetronic



• Chrysler single-point and multi-point fuel injection



• Ford central and port fuel injection



• General Motors throttle body, port, digital, and sequential fuel injection systems

TYPICAL TBI SYSTEM REMOVAL AND INSTALLATION PROCEDURES

INSTALLATION

21. Attach the fuel meter body to the throttle body as follows. Apply thread locking compound, supplied in the service kit, to the threads of the fuel meter body mounting screws. If thread locking compound is not provided, Threadlock Adhesive 262 or the equivalent may be substituted.
    
    Do not use a compound of higher strength than recommended, as it may promote screw head breakage or prevent removal of the screws when service is again required.



22. Install the fuel meter body mounting screws and lock washers.



23. Install the fuel feed and return nuts, with new gaskets, in the fuel meter body.



24. Check and clean the fuel filter on the base of the injector. To remove the filter, carefully rotate it back and forth to pull it off. The filter is installed by pushing it into the injector until it is seated.



25. Whenever the injector is removed, new O-rings should be installed. Remove the large O-ring and steel backup washer from the injector cavity, and then remove the small O-ring from the bottom of the injector.



26. Lubricate a new small O-ring with lithium-based grease and push it over the nozzle end of the injector so it is seated against the fuel filter.



27. Install the steel backup ring washer in the meter body injector cavity.



28. Lubricate the large O-ring with lithium-based grease and install it in the injector cavity, directly above the washer. When properly installed, the O-ring is flush with the fuel meter body surface.
    
    CAUTION! Do not attempt to bypass this procedure by installing the backup washer and O-ring after the injector is located in the cavity, as this would prevent proper seating of the O-ring.



29. Install a new fuel passage outlet gasket and a new fuel meter cover gasket on the fuel meter cover.



30. Use a twisting motion to install the injector into the cavity. Be sure it is fully seated and that the raised lug in the injector base is aligned with the notch in the fuel meter body.



31. Install the fuel meter cover.



32. Before installing the idle air control, measure the distance between the end of the idle air control assembly housing and the tip of the conical valve. The valve should be extended from the housing no more than 1.260 -inch (32 mm) on 1982 models or 1.125-inch (28.6 mm) on later models or damage may occur to the motor when it is installed.



33. If the distance is too large, first determine if the assembly is a Type 1, with a collar at the end of the idle air control assembly, or a Type 2, without a collar.

TYPICAL PORT INJECTION SYSTEM

REMOVAL AND INSTALLATION PROCEDURES

NOTE: While installation on various models of Ford-produced vehicles varies due to manufacturer installed component location, engine configuration (V-type or inline) and number of cylinders, the basic design of the Ford port fuel injection system will be the same in all cases, and the following typical removal and installation procedure will, with only slight modifications, outline the procedure for your vehicle.

REMOVAL

1. Drain the coolant from the radiator.



2. Disconnect the negative cable at the battery.



3. Remove the fuel cap to relieve fuel tank pressure.



4. Release the pressure from the fuel system.



5. Disconnect the electrical connector at the throttle position sensor.



6. Disconnect the injector wiring harness.



7. Disconnect the air charge temperature sensor connector.



8. Disconnect the engine coolant temperature sensor.



9. Disconnect the vacuum lines at the upper intake manifold vacuum tree. Label all hose connections with tape to aid reinstallation.



10. Disconnect the vacuum line to the EGR valve.



11. Disconnect the vacuum line to the fuel pressure regulator.



12. Remove the throttle linkage shield.