Reassembly (Fuel Meter Assembly) Chevrolet Astro I

1. On TBI 220, install NEW pressure regulator dust seal into recess of throttle body. Install NEW fuel meter outlet gasket on fuel meter body assembly. On all models, install NEW fuel meter body gasket on throttle body. Install TP sensor, IAC valve, rubber components, gaskets and diaphragms (if equipped).
2. On TBI 220, install ISC actuator. On TBI 295, install governor drive motor and governor throttle drive assembly, lever and bearing assembly, and fuel pressure regulator. On all models, install fuel meter body assembly onto throttle body. Apply thread locking compound (Loctite 262) to fuel meter body assembly screws and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-20112-S31308743912001010200000) .
3. Lubricate fuel inlet and outlet "O" rings with clean engine oil. Install fuel inlet and outlet "O" rings, gaskets and nuts. Install fuel injectors. On TBI 220, install fuel meter cover assembly. On TBI 295, install fuel meter body cover. On all models, apply thread locking compound (Loctite 262) to cover attaching screws. Tighten screws.

Installation

To install, reverse removal procedure. Ensure throttle body and intake manifold sealing surfaces are clean. Use NEW throttle body gasket and fuel line "O" rings. Check fuel system for leaks by turning ignition on, but DO NOT start engine.

Scheme 5

Removal

1. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELIEF (TBI) under «FUEL SYSTEM»(ref-20112-S10526903702001010200000). Disconnect fuel injector electrical connector. Remove fuel meter cover assembly (TBI 220, or fuel meter body cover (TBI 295), leaving cover gasket in place. Using screwdriver and fulcrum, pry injector out. (Scheme 6) Remove small "O" ring from nozzle end of injector.
2. Carefully rotate injector fuel filter back and forth to remove fuel filter from base of injector. Remove and discard fuel meter cover gasket. Remove large "O" ring and steel back-up washer (if equipped) from top counterbore of throttle body injector cavity.

1. Install fuel filter on nozzle end of fuel injector. Ensure large end of filter faces injector so filter covers raised rib at base of injector. Lubricate small "O" ring with Automatic Transmission Fluid (ATF), and push "O" ring on nozzle end of injector until it presses against injector filter.
2. Install steel back-up washer (if equipped) in top counterbore of throttle body injector cavity. Lubricate large "O" ring with ATF, and install "O" ring directly over back-up washer. Ensure "O" ring is seated properly in cavity, and is flush with top of throttle body casting. CAUTION: Install back-up washer and large "O" ring before installing injector. Improper seating of "O" ring will cause fuel leak.
3. Install "O" ring on injector. Install injector into cavity by aligning raised lug on injector base with cast-in notch of throttle body cavity. Push down on injector until fully seated. Install fuel meter cover.

Scheme 6