ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS GI
SECTION FE MA
EM
LC
EC
CONTENTS
PREPARATION ...............................................................2 REMOVAL .................................................................6
CL
Special Service Tool ....................................................2 INSTALLATION..........................................................6
Commercial Service Tools ...........................................2 Fuel Pump, Fuel Level Sensor Unit and Fuel MT
ACCELERATOR CONTROL SYSTEM ...........................3 Filter .............................................................................7
Removal and Installation .............................................3 REMOVAL .................................................................8
Adjusting Accelerator Wire ..........................................3 INSTALLATION..........................................................9 AT
FUEL SYSTEM ................................................................5 EXHAUST SYSTEM ......................................................10
Removal and Installation .............................................5 Removal and Installation ...........................................10
Fuel Tank .....................................................................6
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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 (0.71 in) dia. and
pitch of 1.5 mm (0.059 in)] for zirconia
oxygen sensor
b: J-43897-12 [12 mm (0.47 in) dia. and
pitch of 1.25 mm (0.0492 in)] 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:
I When removing accelerator wire, make a mark to indicate lock nut’s initial position. GI
I Check that throttle valve opens fully when accelerator pedal is fully depressed. Also check that it
returns to idle position when pedal is released.
MA
I Check accelerator control parts for improper contact with any adjacent parts.
I When connecting accelerator wire, be careful not to twist or scratch wire.
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Adjusting Accelerator Wire NFFE0003
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CAUTION:
I Make sure the ASCD wire is not pulling the throttle drum.
I For ASCD wire adjustment, refer to EL-276, “AUTOMATIC
EL
SPEED CONTROL DEVICE (ASCD)”.
1. Remove the vacuum hose connected to the throttle opener. IDX
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-65, “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: GI
I Put a “CAUTION: INFLAMMABLE” sign in workshop.
I Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. MA
I Be sure to disconnect battery ground cable before conducting operations.
I Be sure to furnish workshop with a CO2 fire extinguisher.
I Drain fuel from fuel tank and put drained fuel in an explosion-proof container and put lid on EM
securely.
CAUTION: LC
I Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to EC-34, “Fuel Pres-
sure Release”.
I Do not disconnect any fuel line unless absolutely necessary. EC
I Plug hose and pipe openings to prevent entry of dust or dirt.
I Always replace O-ring and clamps with new ones.
I Do not kink or twist hose and tube when they are installed.
I Do not tighten hose clamps excessively to avoid damaging hoses.
I Tighten bolts to specified torque. CL
I After installation, run engine and check for fuel leaks at connections.
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SFE593A
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FE-5
FUEL SYSTEM
Fuel Tank
Fuel Tank NFFE0006
REMOVAL NFFE0006S01
1. Release fuel pressure from fuel line.
Refer to EC-34, “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:
I The tube can be removed when the push in tabs are com-
pletely depressed. Do not twist it more than necessary.
I Do not use any tools to remove the quick connector.
I 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:
I Align mating marks on tubes and connectors for correct instal-
lation.
I Align push in tabs with retainer openings.
I Be sure that the connecting portion of the tube and the quick
connector is clean and smooth.
I 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.
I Pull on the fuel tube and connector to make sure they are firmly
connected.
I 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
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SFE619A BR
1. Fuel level sensor unit 3. Fuel pump 5. Fuel pump bracket
2. Fuel filter 4. Pump support rubber ST
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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-34, “Fuel Pressure Release”.
2. Remove rear seat bottom. Refer to BT-41, “Removal and Instal-
lation”.
3. Remove inspection hole cover located under the rear seat.
4. Disconnect electrical connector.
5. Remove the quick connectors.
I 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.
I 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.
I 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.
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SFE622A LC
12. Separate the fuel pump from the fuel pump bracket, and pump
support rubber.
EC
INSTALLATION NFFE0007S02
Installation is in the reverse order of removal.
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FE-9
EXHAUST SYSTEM
Removal and Installation
Removal and Installation NFFE0005
CAUTION:
I Always replace exhaust gaskets with new ones when
reassembling. If gasket remains on flange surface, scrape
off completely as shown at left.
I With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
I 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.
I 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.
I 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.
SFE595A
FE-10
EXHAUST SYSTEM
Removal and Installation (Cont’d)
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FE-11
NOTES
