ACCELERATOR CONTROL, FUEL &

EXHAUST SYSTEMS

SECTION FE
CONTENTS
QG/SR Commercial Service Tool...........................................13
ACCELERATOR CONTROL SYSTEM .........................14
PREPARATION ...............................................................2
Removal and Installation ...........................................14
Special Service Tools ..................................................2
Inspection...................................................................14
Commercial Service Tools ...........................................2
FUEL SYSTEM ..............................................................15
ACCELERATOR CONTROL SYSTEM ...........................3
Checking Fuel Lines ..................................................15
Removal and Installation .............................................3
Water Draining from Fuel Filter .................................15
Adjusting Accelerator Wire ..........................................3
DRAINING WATER ..................................................15
MODELS WITH THROTTLE OPENER .........................3
FUEL FILTER CHECK ..............................................15
MODELS WITHOUT THROTTLE OPENER ..................4
Changing Fuel Filter ..................................................15
FUEL SYSTEM ................................................................5
REMOVAL ...............................................................15
Checking Fuel Lines ....................................................5 INSTALLATION........................................................16
Removal and Installation .............................................5 Bleeding Fuel Filter....................................................16
Fuel Tank .....................................................................6 Checking Priming Pump ............................................16
REMOVAL .................................................................6
Checking Water in Fuel Filter Sensor (where
INSTALLATION..........................................................8
fitted) ..........................................................................17
Fuel Pump, Fuel Level Sensor Unit and Fuel
Removal and Installation ...........................................17
Filter .............................................................................9
Fuel Tank ...................................................................18
REMOVAL .................................................................9
REMOVAL ...............................................................19
INSTALLATION........................................................10
INSTALLATION........................................................20
EXHAUST SYSTEM ......................................................11
Fuel Level Sensor Unit ..............................................21
Checking Exhaust System.........................................11
REMOVAL ...............................................................21
Removal and Installation ...........................................11 INSTALLATION........................................................22
EXHAUST SYSTEM ......................................................23
YD Checking Exhaust System.........................................23
PREPARATION .............................................................13 Removal and Installation ...........................................23
Special Service Tool ..................................................13
 PREPARATION QG/SR
Special Service Tools

Special Service Tools NLFE0029

Tool number
Description
Tool name

KV10114400 Loosening or tightening front and rear

Heated oxygen sensor heated oxygen sensors
wrench a: 22 mm (0.87 in)

NT636

KV999G0010 Removing and installing fuel tank lock

Fuel tank lock ring ring
socket

NT057

Commercial Service Tools NLFE0030

Tool number
Description
Tool name

Oxygen sensor thread Reconditioning the exhaust system threads

cleaner 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

AEM488

Anti-seize lubricant Lubricating oxygen sensor thread cleaning

(Permatex 133AR or tool when reconditioning exhaust system
equivalent meeting MIL threads
specification MIL-A-
907)

AEM489

FE-2
 ACCELERATOR CONTROL SYSTEM QG/SR
Removal and Installation

Removal and Installation NLFE0002

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.

YFE002

Adjusting Accelerator Wire NLFE0003

MODELS WITH THROTTLE OPENER NLFE0003S01
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 (−40.0 bar, −300 mmHg,
−11.81 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-99 (QG), EC-623 (SR) “Basic Inspection”.
SEF793WB If OK, go to following step.

FE-3
 ACCELERATOR CONTROL SYSTEM QG/SR
Adjusting Accelerator Wire (Cont’d)
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 OPENER NLFE0003S02

1. 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.

NFE020

FE-4
 FUEL SYSTEM QG/SR
Checking Fuel Lines

Checking Fuel Lines NLFE0009

Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.

SMA803A

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.

MMA104A

Removal and Installation NLFE0004

WARNING:
When replacing fuel line parts, be sure to observe the following.
+ Put a “CAUTION: FLAMMABLE” sign in workshop.
+ Be sure to furnish workshop with a CO2 fire 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-43 (QG), EC-577 (SR) “Fuel Pressure Release”.
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.

FE-5
 FUEL SYSTEM QG/SR
Fuel Tank

Fuel Tank NLFE0006

YFE005

REMOVAL NLFE0006S01
1. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Drain fuel from fuel tank.
4. Remove rear seat cushion. Refer to BT-49, “Removal and
Installation”.
5. Remove inspection hole cover under the rear seat.

JFE613A

FE-6
 FUEL SYSTEM QG/SR
Fuel Tank (Cont’d)
6. Disconnect electrical connector.
7. Disconnect the quick connector as follows.
a. Put mating marks on tubes and connectors for correct instal-
lation.

SFE639A

SFE640A

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
SFE562A removal.
8. 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.

SFE650A

9. Remove exhaust center tube.

SFE642A

FE-7
 FUEL SYSTEM QG/SR
Fuel Tank (Cont’d)
10. Remove heat insulators from fuel tank side.

SFE643A

11. Set a suitable transmission jack under fuel tank.

12. Remove fuel tank mounting band bolts while supporting fuel
tank.
13. Remove fuel tank.

SFE644A

INSTALLATION NLFE0006S02
To install, reverse the removal procedure. Connect the quick con-
nector as follows:
+ Align mating marks on tubes and connectors for correct instal-
lation.
+ Insert tube into the center of the connector until you hear a
click.

NFE069

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.

NFE070

FE-8
 FUEL SYSTEM QG/SR
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter

Fuel Pump, Fuel Level Sensor Unit and Fuel

Filter NLFE0007

NFE065

REMOVAL NLFE0007S01
1. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Remove rear seat cushion. Refer to BT-49, “Removal and
Installation”.
4. Remove inspection hole cover under the rear seat.

JFE613A

5. Disconnect electrical connector.

6. Disconnect the quick connectors.
+ For disconnect of quick connectors, refer to step 7. of “Fuel
Tank Removal”.

SFE639A

FE-9
 FUEL SYSTEM QG/SR
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter (Cont’d)
7. Remove lock ring using a lock ring socket (SST).

SFE376A

8. Pull out the fuel level sensor unit and fuel pump.
+ Do not damage the arm of the fuel level sensor unit and
fuel tank temperature sensor.
INSTALLATION NLFE0007S02
Installation is in reverse order of removal.

SFE648A

FE-10
 EXHAUST SYSTEM QG/SR
Checking Exhaust System

Checking Exhaust System NLFE0010

Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, chafing or deterioration.

SMA211A

Removal and Installation NLFE0005

CAUTION:
+ Always replace exhaust gaskets with new ones when
reassembling.
+ 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
noise or vibration.
+ 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.
+ Before installing a new oxygen sensor, clean exhaust sys-
tem threads using oxygen sensor thread cleaner tool and
apply anti-seize lubricant.
+ Do not overtorque the oxygen sensor. Doing so may
cause damage to the oxygen sensor, resulting in the MI
coming on.
+ Be sure to use genuine exhaust system parts which are
designed especially for heat resistance, corrosion
resistance, and shape.
+ Perform the operation with the exhaust system fully
cooled down because the system will be heated just after
the engine stops.
+ Be careful not to cut your hand on the insulator edge.

FE-11
 EXHAUST SYSTEM QG/SR
Removal and Installation (Cont’d)

YFE003

FE-12
 PREPARATION YD
Special Service Tool

Special Service Tool NLFE0031

Tool number
Description
Tool name

KV999G0010 Removing and installing fuel tank lock

Fuel tank lock ring ring
socket

NT057

Commercial Service Tool NLFE0027

Tool name Description

Fuel filter wrench Removing fuel filter

a: Max. 100 mm (3.94 in) dia.

NT553

FE-13
 ACCELERATOR CONTROL SYSTEM YD
Removal and Installation

Removal and Installation NLFE0013

CAUTION:
+ Do not disassemble the accelerator pedal assembly. Do not remove the sensors and the switches
from the assembly.
+ Avoid impact from dropping etc. during handling.
+ Be careful to keep the assembly away from water.
+ Do not adjust the adjusting screw (painted white) of the accelerator work unit.
+ When the connector of the accelerator sensor is disconnected, reconnect the connector, and touch
“CLEAR” in “OFF ACCEL PO SIG” of the active test using the CONSULT-II. Or, warm up the engine,
then leave it idling for approximately 10 minutes.

NFE067

Inspection NLFE0020
+ Check that the accelerator pedal moves smoothly within the
whole operation range.
+ Check that the accelerator pedal securely returns to the origi-
nal position.
+ Check that the drum of the accelerator work unit can be fully
opened.
+ Refer to EC-1113, “Basic Inspection” for the inspection of the
accelerator work unit and the accelerator pedal switch.

FE-14
 FUEL SYSTEM YD
Checking Fuel Lines

Checking Fuel Lines NLFE0019

Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, chafing and deterioration.
If necessary, repair or replace.

SMA803A

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.

MMA104A

Water Draining from Fuel Filter NLFE0028

DRAINING WATER NLFE0028S01
Open drain valve at the bottom of fuel filter.
FUEL FILTER CHECK NLFE0028S02
Check fuel filter for fuel leakage, damage and other abnormal
sings.

SMA794C

Changing Fuel Filter NLFE0021

REMOVAL NLFE0021S01
1. Take out air duct and upper air cleaner case.
2. Remove connector from water in fuel filter sensor.
3. Remove fuel filter using a fuel filter wrench (commercial ser-
vice tool).
CAUTION:
Do not spill the fuel during removal. If the fuel is spilt, imme-
diately wipe it off. Be especially careful to prevent the fuel
from adhering to the insulators of the engine mounts.
JFE598A
4. Remove water in fuel filter sensor from fuel filter.

FE-15
 FUEL SYSTEM YD
Changing Fuel Filter (Cont’d)
INSTALLATION NLFE0021S02
+ Install in the reverse order of removal.
+ Replace the O-ring of the fuel level warning sensor with a new
one.
+ Tighten the fuel filter so that the sealing face contacts the
packing, then retighten it manually by approximately 2/3 turn.
+ After installation, operate the priming pump vertically to per-
form air bleeding.
Refer to FE-16, “Bleeding Fuel Filter”.

JFE624A

Bleeding Fuel Filter NLFE0023

1. After the repair, bleed air from the piping by pumping the prim-
ing pump up and down until it becomes heavy.
2. To start the engine, rotate the starter for a maximum of 30
seconds.
To start the engine more quickly, crank the engine while pump-
ing the priming pump (requires two workers).
3. If the engine does not start after rotating the starter for a maxi-
mum of 30 seconds, stop it once, and pump the priming pump
again until it becomes heavy.
4. Rotate the starter again until the engine starts running.
5. After the engine starts, let it idle for at least 1 minute to stabi-
lize the behavior.
+ When air is bled completely, the pumping of the priming
pump suddenly becomes heavy. Stop the operation at that
time.
+ If it is difficult to bleed air by the pumping of the priming
pump (the pumping of the priming pump does not become
heavy), disconnect the fuel supply hose between the fuel
filter and the injection pump. Then, perform the operation
described above, and make sure that fuel comes out. (Use
a pan, etc. so as not to spill fuel. Do not let fuel get on
engine and other parts.) After that, connect the hose, then
bleed air again.
+ Start engine and let it idle for at least one minute after
performing air bleeding.

Checking Priming Pump NLFE0024

Before checking priming pump, make sure that fuel filter is
filled with fuel.
1. Disconnect fuel return hose.
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows from the
hose end. If not, replace priming pump.

DEF017

FE-16
 FUEL SYSTEM YD
Checking Water in Fuel Filter Sensor (where fitted)

Checking Water in Fuel Filter Sensor (where

fitted) NLFE0025
1. Remove the connector from filter and water in fuel filter sen-
sor.
2. Turn the key switch “ON”. Lift the float to ensure that the
warning lamp turns on.
Water in fuel filter sensor tightening torque:
: 3.9 - 5.9 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb)
Discard the old O-ring and replace it with a new one.
SEF122U

Removal and Installation NLFE0015

WARNING:
When replacing fuel line parts, be sure to observe the following.
+ Put a “CAUTION: FLAMMABLE” sign in workshop.
+ Be sure to furnish workshop with a CO2 fire 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) 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.

FE-17
 FUEL SYSTEM YD
Fuel Tank

Fuel Tank NLFE0016

NFE081

FE-18
 FUEL SYSTEM YD
Fuel Tank (Cont’d)
REMOVAL NLFE0016S01
1. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Drain fuel from fuel tank.
4. Remove rear seat cushion. Refer to BT-49, “Removal and
Installation”.
5. Remove inspection hole cover under the rear seat.
6. Disconnect electrical connector.
7. Disconnect the quick connector as follows.
a. Put mating marks on tubes and connectors for correct instal-
JFE613A
lation.

SFE639A

SFE640A

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
SFE562A removal.
8. 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.

SFE641A

FE-19
 FUEL SYSTEM YD
Fuel Tank (Cont’d)
9. Remove exhaust center tube.

SFE642A

10. Remove heat insulators from fuel tank side.

SFE643A

11. Set a suitable transmission jack under fuel tank.

12. Remove fuel tank mounting band bolts while supporting fuel
tank.
13. Remove fuel tank.

SFE644A

INSTALLATION NLFE0016S02
To install, reverse the removal procedure. Connect the quick con-
nector as follows:
+ Align mating marks on tubes and connectors for correct instal-
lation.
+ Insert tube into the center of the connector until you hear a
click.

NFE072

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.

NFE073

FE-20
 FUEL SYSTEM YD
Fuel Level Sensor Unit

Fuel Level Sensor Unit NLFE0032

NFE074

REMOVAL NLFE0032S01
1. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Remove rear seat cushion. Refer to BT-49, “Removal and
Installation”.
4. Remove inspection hole cover under the rear seat.

JFE613A

5. Disconnect electrical connector.

6. Disconnect the quick connectors.
+ For disconnect of quick connectors, refer to step 7. of “Fuel
Tank Removal”.

SFE639A

FE-21
 FUEL SYSTEM YD
Fuel Level Sensor Unit (Cont’d)
7. Remove lock ring using a lock ring socket (SST).

SFE376A

8. Pull out the fuel level sensor unit and fuel pump.
+ Do not damage the arm of the fuel level sensor unit.
INSTALLATION NLFE0032S02
Installation is in reverse order of removal.

SFE648AA

FE-22
 EXHAUST SYSTEM YD
Checking Exhaust System

Checking Exhaust System NLFE0022

Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, chafing or deterioration.

SMA211A

Removal and Installation NLFE0018

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.
+ Be sure to use genuine exhaust system parts which are
designed especially for heat resistance, corrosion
resistance, and shape.
+ Perform the operation with the exhaust system fully
cooled down because the system will be heated just after
the engine stops.
+ Be careful not to cut your hand on the insulator edge.

FE-23
 EXHAUST SYSTEM YD
Removal and Installation (Cont’d)

YFE004

FE-24