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This TBI exploded view is from the factory service manual for a 1987 Mitsubishi Starion. This style of Mikuni TBI was also used on the Mitsubishi (Dodge) Colt, and Tredia.
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Disconnect the negative battery post. Remove intake. Drain radiator if TBI uses coolant as a pre-heater.
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Clearly label electrical connections and vacuum lines before removing TBI. No, you won't remember what goes where later.
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Always have a fire extinguisher nearby when working with gasoline. Relieve fuel pressure. Remove fuel supply and return lines. Remove bolts that hold the TBI to the intake manifold.
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Remove the TBI. Note discoloration at base caused by fuel leakage from worn gasket and o-rings.
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Failure to completely remove the old gasket from the intake manifold mounting surface will result in improper sealing. Use a rag to prevent debris from entering the intake manifold.
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Place the TBI on a solvent-proof catch tray. Use carburetor or fuel injection cleaner to remove gum and varnish from all passages and ports. Do not use wire or sharp objects. If a chemical dip is used, do not submerge rubber and plastic parts or fuel injectors.
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Small picks will help remove old o-rings. Replace with same size o-rings from the rebuild kit. Old o-rings may appear to be slightly larger than replacements due to wear.
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Loosen the mounting screws and remove the injector holder and fuel pressure regulator (FPR) from the mixing body.
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Replace all o-rings in FPR. Use cleaner to clean any debris from injector holder catch screens. Do not attempt to remove screens. Lubricate o-rings with gasoline or brake fluid for proper seating. Reassemble the FPR.
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Gently rock the injector back and forth to remove it from the mixing body. Take note of the position of the connector pins and the color of the injector.
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Replace the fuel injector o-rings and collars. Check the injector body for cracks. Replace any cracked or leaking injectors.
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This lemon shaped o-ring was shot, so it allowed fuel to leak from the throttle body.
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Replace all fuel injector seal rings. Gently push in fuel injector. Note that the square side of the seal ring faces up.
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Do not disturb or remove the Throttle Position Sensor (TPS). If the TPS position is changed, it must be recalibrated.
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The Idle Speed Control motor, or ISC, helps maintains cold start idle, and compensates for A/C compressor drag. It also cuts fuel between shifts, and on deceleration.
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With fresh gaskets, o-rings, and gummed-up fuel and varnish removed, the TBI is ready to be installed.
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