Page 2305 of 2898

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION
FE
CONTENTS
QG
PREPARATION...............................................................2
Special Service Tools ..................................................2
Commercial Service Tools ...........................................2
ACCELERATOR CONTROL SYSTEM...........................3
Removal and Installation .............................................3
Adjusting Accelerator Wire ..........................................3
MODELS WITH THROTTLE OPENER.........................3
MODELS WITHOUT THROTTLE OPENER..................4
FUEL SYSTEM................................................................5
Checking Fuel Lines ....................................................5
Removal and Installation .............................................5
Fuel Tank .....................................................................6
REMOVAL.................................................................7
INSTALLATION........................................................ 11
Fuel Pump, Fuel Level Sensor Unit and Fuel
Filter ...........................................................................12
REMOVAL...............................................................12
INSTALLATION........................................................14
EXHAUST SYSTEM......................................................15
Checking Exhaust System.........................................15
Removal and Installation ...........................................15
YD
PREPARATION.............................................................18
Special Service Tool ..................................................18Commercial Service Tool ...........................................18
ACCELERATOR CONTROL SYSTEM.........................19
Removal and Installation ...........................................19
Inspection...................................................................19
FUEL SYSTEM..............................................................20
Checking Fuel Lines ..................................................20
Water Draining from Fuel Filter .................................20
DRAINING WATER..................................................20
FUEL FILTER CHECK..............................................20
Changing Fuel Filter ..................................................20
REMOVAL...............................................................20
INSTALLATION........................................................21
Bleeding Fuel Filter....................................................21
Checking Priming Pump ............................................21
Checking Water in Fuel Filter Sensor (where
fitted) ..........................................................................22
Removal and Installation ...........................................22
Fuel Tank ...................................................................23
REMOVAL...............................................................25
INSTALLATION........................................................28
Fuel Level Sensor Unit ..............................................29
REMOVAL...............................................................30
INSTALLATION........................................................31
EXHAUST SYSTEM......................................................32
Checking Exhaust System.........................................32
Removal and Installation ...........................................32
Page 2306 of 2898
Special Service ToolsNJFE0029
Tool number
Tool nameDescription
KV10114400
Heated oxygen sensor
wrench
NT636
Loosening or tightening front and rear
heated oxygen sensors
a: 22 mm (0.87 in)
KV999G0010
Fuel tank lock ring
socket
NT057
Removing and installing fuel tank lock
ring
Commercial Service ToolsNJFE0030
Tool number
Tool nameDescription
Oxygen sensor thread
cleaner
AEM488
Reconditioning the exhaust system threads
before installing a new oxygen sensor (Use
with anti-seize lubricant shown below.)
a: 18 mm dia. with pitch 1.5 mm for zir-
conia oxygen sensor
b: 12 mm dia. with pitch 1.25 mm for
titania oxygen sensor
Anti-seize lubricant
(Permatex 133AR or
equivalent meeting MIL
specification MIL-A-
907)
AEM489
Lubricating oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads
PREPARATIONQG
Special Service Tools
FE-2
Page 2307 of 2898

Removal and InstallationNJFE0002CAUTION:
+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.
YFE006
SEF793WB
Adjusting Accelerator WireNJFE0003MODELS WITH THROTTLE OPENERNJFE0003S011. 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 þ40.0 kPa (þ400 mbar, þ300 mmHg,
þ11.81 inHg)] until the throttle drum becomes free from the rod
of the throttle opener.
Make sure that there is clearance between the throttle
drum and rod.
If NG, refer to EC-202, ªBasic Inspectionº.
If OK, go to following step.
ACCELERATOR CONTROL SYSTEMQG
Removal and Installation
FE-3
Page 2308 of 2898
SFE248AB
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.
NFE020
MODELS WITHOUT THROTTLE OPENERNJFE0003S021. Loosen lock nut, and tighten adjusting nut until throttle drum
starts to move.
2. From that position turn back adjusting nut 1.5 to 2 turns, and
secure lock nut.
ACCELERATOR CONTROL SYSTEMQG
Adjusting Accelerator Wire (Cont'd)
FE-4
Page 2309 of 2898

SMA803A
Checking Fuel LinesNJFE0009Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.
MMA104A
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
Removal and InstallationNJFE0004WARNING:
When replacing fuel line parts, be sure to observe the following.
+Put a ªCAUTION: FLAMMABLEº sign in workshop.
+Be sure to furnish workshop with a CO
2fire extinguisher.
+Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
CAUTION:
+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-40, ªFuel Pressure Releaseº.
c) Disconnect battery ground cable.
+Always replace O-ring and clamps with new ones.
+Do not kink or twist tubes when they are being installed.
+Do not tighten hose clamps excessively to avoid damaging hoses.
+After installing tubes, run engine and check for fuel leaks at connections.
FUEL SYSTEMQG
Checking Fuel Lines
FE-5
Page 2310 of 2898
Fuel TankNJFE0006
JFE607A
FUEL SYSTEMQG
Fuel Tank
FE-6
Page 2311 of 2898
SFE649A
JFE613A
REMOVALNJFE0006S01For SedanNJFE0006S01011. Release fuel pressure from fuel line.
Refer to EC-40, ªFuel Pressure Releaseº.
2. Disconnect battery ground cable.
3. Open fuel filler lid and filler cap.
4. Drain fuel from fuel tank.
5. Remove rear seat cushion. Refer to BT-60, ªRemoval and
Installationº.
6. Remove inspection hole cover under the rear seat.
FUEL SYSTEMQG
Fuel Tank (Cont'd)
FE-7
Page 2312 of 2898

JFE608A
7. Disconnect electrical connector.
8. Disconnect the quick connector as follows.
a. Put mating marks on tubes and connectors for correct
installation.
SFE562A
JFE628A
b. Hold the connector while pushing in tabs, and pull out the tube.
CAUTION:
+The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
+Do not use any tools to remove the quick connector.
+Keep the resin tube away from heat. Be especially careful
when welding near the tube.
+Prevent acid liquid such as battery electrolyte etc. from
getting on the resin tube.
+Do not bend or twist the tube during installation and
removal.
+Only when the tube is replaced, remove the remaining
retainer.
+When the tube is replaced, also replace the retainer with
a new one.
Retainer color:
Orange (Feed hose side)
White (Return hose side)
JFE609A
9. Remove exhaust center tube.
10. From rear left area of fuel tank, remove filler hose, vent hose
and EVAP hose.
CAUTION:
To prevent fuel from flowing out, install a blind cap immedi-
ately after the fuel hose is disconnected.
JFE610A
11. Set a suitable transmission jack under fuel tank.
12. Remove fuel tank mounting band bolts while supporting fuel
tank.
FUEL SYSTEMQG
Fuel Tank (Cont'd)
FE-8