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                                                                 ACCELERATOR CONTROL, FUEL &
                                                                            EXHAUST SYSTEMS


                                                                                                     SECTION                         FE
                                                               CONTENTS
PREPARATION ...............................................................2                 REMOVAL .................................................................6
  Special Service Tool ....................................................2                 INSTALLATION..........................................................6
  Commercial Service Tools ...........................................2                Fuel Pump, Fuel Level Sensor Unit and Fuel
ACCELERATOR CONTROL SYSTEM ...........................3                                Filter .............................................................................7
  Removal and Installation .............................................3                  REMOVAL .................................................................8
  Adjusting Accelerator Wire ..........................................3                   INSTALLATION..........................................................9
FUEL SYSTEM ................................................................5        EXHAUST SYSTEM ......................................................10
  Removal and Installation .............................................5              Removal and Installation ...........................................10
  Fuel Tank .....................................................................6
                                            PREPARATION
Special Service Tool

                                            Special Service Tool                                       NFFE0001


 Tool number
                              Description
 Tool name

 KV10114400                                                        Loosening or tightening heated oxygen
 Heated oxygen sensor                                              sensors
 wrench                                                            a: 22 mm (0.87 in)




                              NT636


                                            Commercial Service Tools                                   NFFE0008


 Tool number
                              Description
 Tool name

 Oxygen sensor thread                                              Reconditioning the exhaust system
 cleaner                                                           threads before installing a new oxygen
                                                                   sensor (Use with anti-seize lubricant
                                                                   shown below.)
                                                                   a: J-43897-18 (18 mm dia. and pitch of
                                                                   1.5 mm) for zirconia oxygen sensor
                                                                   b: J-43897-12 (12 mm dia. and pitch of
                                                                   1.25 mm) for titania oxygen sensor


                              AEM488

 Anti-seize lubricant (Per-                                        Lubricating oxygen sensor thread cleaning
 matex 133AR or equiva-                                            tool when reconditioning exhaust system
 lent meeting MIL specifi-                                         threads
 cation MIL-A-907)




                              AEM489




                                                  FE-2
                           ACCELERATOR CONTROL SYSTEM
                                                                                    Removal and Installation

                                        Removal and Installation                                      NFFE0002
CAUTION:
+ When removing accelerator wire, make a mark to indicate lock nut's initial position.
+ Check that throttle valve opens fully when accelerator pedal is fully depressed. Also check that it
  returns to idle position when pedal is released.
+ Check accelerator control parts for improper contact with any adjacent parts.
+ When connecting accelerator wire, be careful not to twist or scratch wire.




                                                                                                  SFE529AA




                                        Adjusting Accelerator Wire                                    NFFE0003
                                        CAUTION:
                                        + Make sure the ASCD wire is not pulling the throttle drum.
                                        + For ASCD wire adjustment, refer to EL-240, "AUTOMATIC
                                           SPEED CONTROL DEVICE (ASCD)".
                                        1. Remove the vacuum hose connected to the throttle opener.
                                        2. Connect suitable vacuum hose to vacuum pump as shown left.
                                        3. Apply vacuum [more than -40.0 kPa (-400 mbar, -300 mmHg,
                                           -11.81 inHg)] until the throttle drum becomes free from the rod
                                           of the throttle opener.
                              SEF793W      Make sure that there is clearance between the throttle

                                                FE-3
                                 ACCELERATOR CONTROL SYSTEM
Adjusting Accelerator Wire (Cont'd)
                                                      drum and rod.
                                                      If NG, refer to EC-92, "Basic Inspection".
                                                      If OK, go to following step.




                                                 4.   Loosen lock nut.
                                                 5.   Tighten accelerator adjusting nut until throttle drum starts to
                                                      move.
                                                 6.   From that position, turn back adjusting nut 1.5 to 2 turns, and
                                                      secure lock nut.
                                                 7.   Release vacuum from the throttle opener.
                                                 8.   Remove vacuum pump and vacuum hose from the throttle
                                                      opener.
                                                 9.   Reinstall the original vacuum hose to the throttle opener
                                                      securely.
                                      SFE248AB




                                                          FE-4
                                        FUEL SYSTEM
                                                                               Removal and Installation

                                      Removal and Installation                                   NFFE0004
WARNING:
When replacing fuel line parts, be sure to observe the following:
+ Put a "CAUTION: INFLAMMABLE" sign in workshop.
+ Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
+ Be sure to disconnect battery ground cable before conducting operations.
+ Be sure to furnish workshop with a CO2 fire extinguisher.
+ Drain fuel from fuel tank and put drained fuel in an explosion-proof container and put lid on
  securely.
CAUTION:
+ Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to EC-36, "Fuel Pres-
  sure Release".
+ Do not disconnect any fuel line unless absolutely necessary.
+ Plug hose and pipe openings to prevent entry of dust or dirt.
+ Always replace O-ring and clamps with new ones.
+ Do not kink or twist hose and tube when they are installed.
+ Do not tighten hose clamps excessively to avoid damaging hoses.
+ Tighten bolts to specified torque.
+ After installation, run engine and check for fuel leaks at connections.




                                                                                              SFE593A




                                              FE-5
                       FUEL SYSTEM
Fuel Tank
                      Fuel Tank                                                    NFFE0006
                      REMOVAL                                                    NFFE0006S01
                      1. Release fuel pressure from fuel line.
                         Refer to EC-36, "Fuel Pressure Release".
                      2. Disconnect battery ground cable.
                      3. Drain fuel from fuel tank.
                      4. Disconnect electrical connector.
                      5. Remove the quick connector as follows.
                      a. Put mating marks on tubes and connectors for correct instal-
            SFE558A
                         lation.
                      b. Hold the sides of the connector, push in tabs, and pull out the
                         tube inserted in the retainer.
                      CAUTION:
                      + The tube can be removed when the push in tabs are com-
                         pletely depressed. Do not twist it more than necessary.
                      + Do not use any tools to remove the quick connector.
                      + Keep the connecting portion of the tube and the quick
                         connector clean.



            SFE562A

                      6.   Disconnect filler hose, vent hose and evaporation hose at fuel
                           tank side.
                      7.   Remove fuel tank mounting band bolts while supporting fuel
                           tank.
                      8.   Remove fuel tank.




            SFE594A

                      INSTALLATION                                               NFFE0006S02
                      To install, reverse the removal procedure. Connect the quick con-
                      nector as follows:
                      + Align mating marks on tubes and connectors for correct instal-
                           lation.
                      + Align push in tabs with retainer openings.
                      + Be sure that the connecting portion of the tube and the quick
                           connector is clean and smooth.
                      + Insert tube into the center of the connector until you hear a
                           click.
            SFE560A

                      After connecting quick connector, make sure the connection is
                      firmly made using the following method.
                      + Pull on the fuel tube and connector to make sure they are firmly
                           connected.
                      + Start the engine, increase engine speed and verify that there
                           are no leaks.




            SFE561A


                               FE-6
                                     FUEL SYSTEM
                                                         Fuel Pump, Fuel Level Sensor Unit and Fuel Filter

                                   Fuel Pump, Fuel Level Sensor Unit and Fuel
                                   Filter                                                           NFFE0007




                                                                                                 SFE619A


1.   Fuel level sensor unit   3.   Fuel pump                         5.   Fuel pump bracket
2.   Fuel filter              4.   Pump support rubber




                                             FE-7
                                                  FUEL SYSTEM
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter (Cont'd)
                                                REMOVAL                                                     NFFE0007S01
                                                1.   Release fuel pressure from fuel line.
                                                     Refer to EC-36, "Fuel Pressure Release".
                                                2.   Remove rear seat bottom. Refer to BT-41, "Removal and
                                                     Installation".
                                                3.   Remove inspection hole cover located under the rear seat.
                                                4.   Disconnect electrical connector.
                                                5.   Remove the quick connectors.
                                                +    For removal of quick connectors, refer to step 5. of "Fuel Tank
                                                     Removal".
                                     SFE563A
                                                6.   Remove the six screws.




                                     SFE558A

                                                7.   Pull out the fuel level sensor unit and fuel pump.
                                                +    Do not damage the arm of the fuel level sensor and fuel
                                                     tank temperature sensor.




                                     SFE564A

                                                8.   Remove flange of fuel level sensor unit and fuel pump bracket.
                                                +    Using a screwdriver, remove the snap fit portion in the order
                                                     of (1), (2), (3) and (4) as shown in the figure at left.




                                     SFE620A

                                                9. Pull out the fuel level sensor unit from the fuel pump bracket.
                                                10. Disconnect fuel pump connector.




                                     SFE621A


                                                             FE-8
           FUEL SYSTEM
                         Fuel Pump, Fuel Level Sensor Unit and Fuel Filter (Cont'd)
          11. Remove fuel pump, then push down the fuel pump as shown
              in the figure at left.




SFE622A

          12. Separate the fuel pump from the fuel pump bracket, and pump
              support rubber.
          INSTALLATION                                                    NFFE0007S02
          Installation is in the reverse order of removal.




SFE623A




                  FE-9
                                     EXHAUST SYSTEM
Removal and Installation

                                     Removal and Installation                               NFFE0005
                                     CAUTION:
                                     + Always replace exhaust gaskets with new ones when
                                        reassembling. If gasket remains on flange surface, scrape
                                        off completely as shown at left.
                                     + With engine running, check all tube connections for
                                        exhaust gas leaks, and entire system for unusual noises.
                                     + Check to ensure that mounting brackets and mounting
                                        insulators are installed properly and free from undue
                                        stress. Improper installation could result in excessive
                           SEF180A      noise or vibration.
                                     + Discard any heated oxygen sensor (HO2S) which has
                                        been dropped from a height of more than 0.5 m (19.7 in)
                                        onto a hard surface such as a concrete floor; use a new
                                        one.
                                     + Before installing a new oxygen sensor, clean exhaust sys-
                                        tem threads using oxygen sensor thread cleaner tool,
                                        J-43897-18 or J-43897-12, and apply anti-seize lubricant.




                                                                                          SFE637A




                                            FE-10



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