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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 Tank .....................................................................5
                                                                                                                                                                     CL
  Special Service Tools ..................................................2         Removal ..................................................................5
ACCELERATOR CONTROL SYSTEM ...........................3                             Installation ...............................................................6
  Accelerator Control System.........................................3            Fuel Pump and Gauge ................................................7              MT
  Adjusting Accelerator Wire ..........................................3            Removal And Installation ........................................7
FUEL SYSTEM ................................................................4   EXHAUST SYSTEM ........................................................8
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                                                      PREPARATION

                                                     Special Service Tools
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
KV10117100                                                                             Loosening or tightening rear heated oxygen
(J3647-A)                                                                              sensor (For left bank)
Heated oxygen sensor
wrench




                              NT379                                                    For 22 mm (0.87 in) hexagon nut
KV10114400                                                                             Loosening or tightening rear heated oxygen
(J38365)                                                                               sensor (For right bank)
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.
PermatexTM 133AR                                                                       Cleaning tool when reconditioning exhaust sys-
or equivalent meeting                                                                  tem threads.
MIL - Specification
MIL-A-907




                               AEM489




                                                               FE-2
                          ACCELERATOR CONTROL SYSTEM

                                        Accelerator Control System                                          GI
CAUTION:
q When removing accelerator wire, make a mark to indicate lock nut's initial position.                MA
q Check that throttle valve opens fully when accelerator pedal is fully depressed. Also check that it
  returns to idle position when pedal is released.
q Check accelerator control parts for improper contact with any adjacent parts.                       EM
q When connecting accelerator wire, be careful not to twist or scratch its inner wire.
q Refer to EL section (``AUTOMATIC SPEED CONTROL DEVICE'') for ASCD wire adjustment.
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                                                                                                   AFE090
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                                                                                                            RA
                                        Adjusting Accelerator Wire
                                        1.   Loosen lock nut, and tighten adjusting nut until throttle drum
                                             starts to move.                                                 BR
                                        2.   From that position, turn back adjusting nut 1.5 to 2 turns, and
                                             secure lock nut.
                                                                                                            ST

                                                                                                            RS
                             SFE249AE
                                                                                                            BT

                                                                                                            HA

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                                                 FE-3
                                      FUEL SYSTEM

WARNING:
When replacing fuel line parts, be sure to observe the following:
q  Put a ``CAUTION: INFLAMMABLE'' sign in workshop.
q  Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
q  Be sure to furnish the 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 lid on securely.
b. Release fuel pressure from fuel line. Refer to MA section (``Changing Fuel Filter'').
c. Disconnect battery ground cable.
q  Always replace O-rings with new ones.
q  Do not kink or twist hose and tube when they are installed.
q  Do not tighten hose clamps excessively to avoid damaging hoses.
q  After installation, run engine and check for fuel leaks at connections.




                                                                                         AFE097




                                            FE-4
           FUEL SYSTEM

          Fuel Tank                                                          GI
          REMOVAL
          1.   Release fuel pressure from fuel line.                         MA
               Refer to MA section (``Changing Fuel Filter'').
          2.   Disconnect battery ground cable.
          3.   Drain fuel from fuel tank.                                    EM
          4.   Disconnect electrical connector.
          5.   Remove filler protector.
                                                                             LC


          6. Remove the quick connector as follows.                          EC
          a. Put mating marks on tubes and connectors for correct instal-
             lation.
          b. Hold the sides of the connector, push in tabs, and pull out the FE
             tube inserted in the retainer.
          CAUTION:
          q  The tube can be removed when the push in tabs are com- CL
             pletely depressed. Do not twist it more than necessary.
          q  Do not use any tools to remove the quick connector.
                                                                             MT
 AFE108

          7.   Disconnect filler hose, vent hose and evaporation hose at fuel AT
               tank side.
                                                                             TF

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SFE421A

          8.   Remove fuel tank protector.                                   RA

                                                                             BR

                                                                             ST

                                                                             RS
 AFE096

          9. Remove fuel tank mounting bolts while supporting fuel tank.
                                                                             BT
          10. Remove fuel tank.
                                                                             HA

                                                                             EL

                                                                             IDX
SFE423A


                   FE-5
          FUEL SYSTEM
         Fuel Tank (Cont'd)
         INSTALLATION
         To install, reverse the removal procedure. Connect the quick con-
         nector as follows:
         q    Align push in tabs with retainer openings.
         q    Insert the tube into the center of the connector until you hear
              a click.




AFE110

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




AFE109




                 FE-6
              FUEL SYSTEM

          Fuel Pump and Gauge                                                   GI

                                                                                MA

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                                                                       AFE091

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                                                                                FA


          REMOVAL AND INSTALLATION                                              RA
          1.   Remove fuel tank. Refer to ``Fuel Tank'' ``REMOVAL,'' FE-5.
          q    For removal of quick connectors, refer to step 6 of ``Fuel Tank'' BR
               ``Removal,'' FE-5.
          2.   Remove the six screws.
          3.   Remove fuel gauge retainer and fuel gauge.                        ST
          4.   Remove fuel pump with bracket while lifting the pawl of the fuel
               pump bracket upward.
                                                                                RS
SFE425A

          5. Installation procedure is the reverse order of removal.
                                                                                BT
          q  Install fuel gauge as shown.
          CAUTION:                                                         HA
          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.                         EL
          q  After installation, run engine and check for leaks at connec-
             tions.
                                                                                IDX
 AFE095


                   FE-7
                                    EXHAUST SYSTEM

CAUTION:
q Always replace exhaust gaskets with new ones when reassembling.
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 free
  from undue stress. Improper installation could result in excessive noise or vibration.
q Discard any heated oxygen sensor 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.
q Before installing new oxygen sensor, clean exhaust system threads using oxygen sensor thread
  cleaner Tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.
q Do not overtorque the oxygen sensor. Doing so may cause damage to the oxygen sensor, result-
  ing in the MIL coming on.




                                             FE-8
                                    EXHAUST SYSTEM

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                                                                             AFE098   RS

1   Gasket                      4   Gasket            7   Mounting bracket
2   Front tube                  5   Mounting rubber   8   Center muffler
                                                                                      BT
3   Rear heated oxygen sensor   6   Clamp             9   Rear muffler

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                                                                                      EL

                                                                                      IDX


                                             FE-9
                                    EXHAUST SYSTEM




                                                                             AFE118


1   Gasket                      4   Gasket            7   Mounting bracket
2   Front tube                  5   Mounting rubber   8   Center muffler
3   Rear heated oxygen sensor   6   Clamp             9   Rear muffler




                                            FE-10



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