fe.pdf

ACCELERATOR CONTROL, FUEL &

EXHAUST SYSTEMS

SECTION FE

CONTENTS

Commercial 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

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

PREPARATION .............................................................18

Special Service Tool ..................................................18

PREPARATION

Special Service Tools

NJFE0029

Tool number

Tool name

Description

KV10114400

Heated oxygen sensor

wrench

Loosening or tightening front and rear

heated oxygen sensors

a: 22 mm (0.87 in)

NT636

KV999G0010

Fuel tank lock ring

socket

Removing and installing fuel tank lock

ring

NT057

Commercial Service Tools

NJFE0030

Tool number

Tool name

Description

Oxygen sensor thread

cleaner

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

AEM488

Anti-seize lubricant

(Permatex 133AR or

equivalent meeting MIL

specification MIL-A-

907)

Lubricating oxygen sensor thread cleaning

tool when reconditioning exhaust system

threads

AEM489

FE-2

ACCELERATOR CONTROL SYSTEM

Removal and Installation

NJFE0002

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.

YFE006

SEF793WB

Adjusting Accelerator Wire NJFE0003

MODELS WITH THROTTLE OPENER NJFE0003S01

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 (−400 mbar, −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-202, “Basic Inspection”.

If OK, go to following step.

FE-3

ACCELERATOR CONTROL SYSTEM

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.

SFE248AB

MODELS WITHOUT THROTTLE OPENER NJFE0003S02

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

Checking Fuel Lines

Checking Fuel Lines NJFE0009

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

NJFE0004

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 CO 2 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-40, “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

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