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FE


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                                                    ACCELERATOR CONTROL, FUEL &                                                                                     GI
                                                               EXHAUST SYSTEMS
                                                                                                                                                                    MA


                                                                                             SECTION                                  FE                            EM

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                                                          CONTENTS                                                                                                  FE

PREPARATION................................................................2   FUEL SYSTEM ................................................................4
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  Special Service Tool ....................................................2     Fuel Tank .....................................................................4
ACCELERATOR CONTROL SYSTEM ...........................3                          Fuel Pump and Gauge ................................................7
  Adjusting Accelerator Wire ..........................................3       EXHAUST SYSTEM ........................................................8             MT

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                                                      PREPARATION

                                                     Special Service Tool
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)               Description
Tool name
KV10114400                                                                             Loosening or tightening front and rear heated
(J-38365)                                                                              oxygen sensors
Heated oxygen sensor
wrench


                               NT636                                                   a = 22 mm (0.87 in)


Tool name
                               Description
(Kent-Moore No.)
Oxygen sensor                                                                          Reconditioning the exhaust system threads
thread cleaner                                                                         before installing a new oxygen sensor. Use
(J-43897-18)                                                                           with anti-seize lubricant shown below.
(J-43897-12)                                                                           A: J-43897-18 18 mm Diameter, for Zirconia
                                                                                          oxygen sensor
                                                                                       B: J-43897-12 12 mm Diameter, Titania oxy-
                                                                                          gen sensor.


                               AEM488

Anti-seize Lubricant                                                                   Lubricating oxygen sensor thread, cleaning
PermatexTM 133AR                                                                       tool when reconditioning exhaust system
or equivalent meeting                                                                  threads.
MIL Specification
MIL-A-907




                               AEM489




                                                               FE-2
                           ACCELERATOR CONTROL SYSTEM

CAUTION:                                                                                               GI
q When removing accelerator wire, mark initial position of lock nut.
q Check that throttle valve opens fully when accelerator pedal is fully depressed. Check that throttle
  valve returns to idle position when accelerator pedal is released.                                   MA
q Check accelerator control parts for improper contact with any adjacent parts.
q When connecting accelerator wire, do not twist or scratch the inner wire.
q For adjustment of A/T throttle wire, refer to AT section (``Throttle Wire Adjustment'', ``ON-VEHICLE EM
  SERVICE'').
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                                                                                                 AFE107

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                                        Adjusting Accelerator Wire
                                        CAUTION:
                                        q  Make sure the ASCD wire is not pulling the throttle drum. HA
                                        q  For ASCD wire adjustment, refer to EL section [``AUTO-
                                           MATIC SPEED CONTROL DEVICE (ASCD)''].
                                                                                                          EL
                                        1. Loosen lock nut, and tighten adjusting nut until throttle drum
                                           starts to move.
                                        2. Loosen adjusting nut 1.5 to 2 turns and tighten lock nut.      IDX
                             SFE248AB


                                                FE-3
                                          FUEL SYSTEM

                                        Fuel Tank
WARNING:
When replacing fuel line parts, be sure to observe the following:
q  Put a ``CAUTION: FLAMMABLE'' sign in workshop.
q  Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
q  Furnish workshop with a CO2 fire extinguisher.
CAUTION:
q  Before removing fuel line parts, carry out the following procedures:
a. Put drained fuel in an explosion-proof container and put the lid on securely.
b. Release fuel pressure from fuel line. Refer to EC section (``Fuel Pressure Release'', ``BASIC SER-
   VICE PROCEDURE'').
c. Disconnect battery ground cable.
q  When installing fuel check valve, install it in the correct direction. Refer to EC section (``EVAPO-
   RATIVE EMISSION SYSTEM'').
q  Always replace O-ring with a new one.
q  Do not kink or twist tubes and hoses during installation.
q  To avoid damaging hoses, do not tighten hose clamps excessively.
q  After installing tubes, run engine and check for fuel leaks at connections.
q  Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL
   may turn on.




                                                                                                 AFE078




                                                FE-4
          FUEL SYSTEM
         Fuel Tank (Cont'd)
         REMOVAL                                                           GI
         CAUTION:
         q  Do not disconnect any fuel line unless absolutely neces-
            sary.                                                    MA
         q  Plug hose and pipe openings to prevent entry of dust and
            dirt.
                                                                           EM

                                                                           LC


         1.   Release fuel pressure. Refer to EC section (``Fuel Pressure EC
              Release'', ``BASIC SERVICE PROCEDURE'').
         2.   Disconnect battery ground cable.
         3.   Drain fuel from fuel tank.                                    FE
         4.   Disconnect electrical connector.
         5.   Remove filler protector.
         6.   Disconnect filler tubes, EVAP hose, fuel supply tube and fuel CL
              return tube.

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AFE076

         7.   Remove fuel tank protector.                                  AT

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AFE081

         8.   Remove four fuel tank mounting bolts while supporting fuel
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              tank.
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AFE082


                  FE-5
          FUEL SYSTEM
         Fuel Tank (Cont'd)
         9.   Remove fuel tank.




AFE054

         INSTALLATION
         To install, reverse the removal procedure.
         CAUTION:
         q    Do not kink or twist hoses and tubes during installation.
         q    To avoid damaging hoses, do not tighten hose clamps
              excessively.
         q    Tighten bolts to specified torque.
         q    After installation, run engine and check for leaks at con-
              nections.




                 FE-6
          FUEL SYSTEM

         Fuel Pump and Gauge                                              GI
         REMOVAL
         1.   Remove fuel tank. Refer to FE-5.                             MA
         2.   Disconnect fuel supply tube, fuel return tube and electrical
              connector.
         3.   Remove the six screws.                                       EM

                                                                          LC
AFE076

         4.   Remove fuel pump and gauge.                                 EC

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AFE077

         INSTALLATION                                                     RA
         To install, reverse the removal procedure.
         CAUTION:                                                          BR
         q    Tighten bolts to specified torque.
                     : 2.0 - 2.5 N m (0.20 - 0.26 kg-m, 17.4 - 22.6 in-lb)
         q    Always replace O-ring with a new one.                        ST
         q    After installation, run engine and check for leaks at con-
              nections.
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                 FE-7
          EXHAUST SYSTEM

          CAUTION:
          q  Replace exhaust gaskets with new ones when reassem-
             bling.
             If gasket remains on flange surface, scrape off completely
             as shown at left.
          q  With engine running, check all tube connections for
             exhaust gas leaks, and entire system for unusual noises.
          q  Check to ensure that mounting brackets and mounting
             insulators are installed properly and are free from undue
             stress. Improper installation could result in excessive
SFE180A
             noise or vibration.
          q  Discard any heated oxygen sensor 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.
          q  Before installing new oxygen sensor, clean exhaust sys-
             tem threads using oxygen sensor thread cleaner Tool
             J-43897-18 or J-43897-12 and approved anti-seize lubri-
             cant.




                 FE-8
EXHAUST SYSTEM

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                 AFE080


     FE-9
EXHAUST SYSTEM




                 AFE079


    FE-10



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