ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS SECTION F E ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS SECTION F E CONTENTS ACCELERATOR CONTROL SYSTEM FUEL SYSTEM reeset EXHAUST SYSTEM sn. FE-5001ACCELERATOR CONTROL SYSTEM We aeewa| Adjusting Accelerator Cable =~ 1. Insert grooved abutment of accelerator cable into rubber bush. 2. Make sure fuel pump lever is in fully shut position and con- nect inner cable end in hole closest to grooved abutment. 3. Pull back grooved abutment until inner cable free play is taken up and fuel pump lever starts to move. From that position, move grooved abutment forward one complete 4 \ groove to achieve free play. Co eel ae ae 4. Insert spring clip in first visible groove behind rubber bush NFEOA (make sure arrow on spring clip points in direction shown) Ensure spring clip fully engages grooved abutment behind rubber bush. Feel pu over ceooven Saring ep abutment FE-5002FUEL SYSTEM Wiz Fuel Gauge Sender Unit Removal Procedure is identical to petrol engine models procedure. Refer to “Fuel Gauge Sender Unit Removal’, page FE-S. Before re-installing the fuel gauge sender unit, ensure filter in chamber is clean and chamber is free from debris. FE-5003EXHAUST SYSTEM uae CAUTION: * Always replace exhaust gaskets with new ones when re-assembling. * When removing manifold nuts use lubricant. Replace manifold nuts with now ones when ro-as- sembling. Fasten manifold nuts 2 or 3 threads by hand before tightening at specified torque. Tighten manifold nuts before fastening bolt between front exhaust tube A and exhaust mounting bracket. * After installation, check that mounting brackets and mounting insulator are free from undue stress. If any of the above parts are not installed properly, excessive noise or vibration may be transmitted to the vehicle body. DIESEL engine models Tio. 16113-16,98-118 cata convener Medel wah cae WY tenvanee hmm tom, ~ nt exh ie & 3:09 note (2. 53,304- 364) NeEo4s FE-5004EXHAUST SYSTEM Viz ) Installation ae ‘© Install mounting bolt with large diameter spherical joint spring fhe | < cee sido facing front exhaust tube A ease nero ] © Install front exhaust tube B so that mounting bolt passes through the middie of flange hole. Mounting bolt: 1 1): 43 - 55 Nem (4.4 - 5.6 kg-m, 92 - 40 ft-lb) he ~ Shera ant i Front exhaust — tbo Front exhaust be 8 Nero4s FE-5005ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS seo E CONTENTS PREPARATION FE. 2 ACCELERATOR CONTROL SYSTEM ..... . veeseenese FE. 3 FUEL SYSTEM o...sccos FE. 4 EXHAUST SYSTEM FE-10PREPARATION SPECIAL SERVICE TOOL ‘Too! number Description Tool name: xve90G0070 Fuel tank lock ring socket Ss FE-2ACCELERATOR CONTROL SYSTEM ‘© When removing accelerator cable, make a mark to indicate lock nut's initial position * Check that throttle valve fully opens when accelerator pedal is fully depressed and that it returns to idle position when pedal is released. «Adjust accelerator cable according to the following procedure. Tighten “adjusting nut” until “throttle drum” starts to move. From that position turn back “adjusting nut” 1.5 to 2 turns, and fasten it with a lock nut. © Check accelerator control parts for improper contact with any adjacent parts. «When connecting accelerator cable, be careful not to twist or scratch the inner cable. ‘Accelerator cable Accelerator pedal 1 97-50038-051.28-37) Ped s09 Byron. me) UFe04s FE-3FUEL SYSTEM WARNING: ‘When replacing fuel line parts, be sure to observe the following: Put a “CAUTION: INFLAMMABLE” sign in workshop. Be sure to furnish workshop with a CO, fire extinguisher. Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. Be sure to disconnect battery ground cable before carrying out operations. Put drained fuel in an explosion-proof container and put lid on securely. caumion: Before disconnecting fue! hose, release fuel pressure from fuel line. Refer to “Fuel Pressure Release” in this section. «The fuel tank should be emptied using “Consult” or by removing the fuel tank access cover and pumping out the tank through the fuel tank access aperture. Refer to “Fuel Gauge Sender Unit Removs ‘Do not disconnect any fuel line unless absolutely necessary. Plug hose and pipe openings to prevent entry of dust or dirt. ‘Always replace O-ring and clamps with new ones. Do not kink or twist hose and tube when they are installed. Do not tighten hose clamps excessively to avoid damaging hoses. When installing fuel check valve, be careful of its designated direction. (Refer to section EF & EC.) After assembly, run engine and check for leaks at connections. Fier _-B) 26-26 27-37.20-27) wee RY mounting bana Ph o7-50 (038-051 | 28-37 i, , | 78-98 (8-10,6-6) — ventiaton nose Ph: 8 kom. tie) FE-4FUEL SYSTEM WARNING: Before disconnecting any fuel line, release fuel pressure. Fie. FRED FEL Fuel PUM ILL eae stat lived Fuel Pressure Release Edi FEU TIHES we ree tte HAL | 1. Perform “FUEL PRESSURE RELEASE” in | & “WORK SUPPORT" mode and release fuel pres- sure to zero 2. Tum ignition switch off Remove fuse for fuel pump. Start engine. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. Turn ignition switch off and install fuse for fuel pump. - ens Fuel Gauge Sender Unit Removal 1. Remove fuel filler cap. 2. Release fuel pressure from fuel feed hose. Refer to “Fuel Pressure Release” 3. If “Consult” is available, disconnect fuel hose from fuel fil- ter and empty fuel tank in “Active Test” mode (Fuel pump relay “ON"). Reconnect fuel hose. If “Consult” is not available, go to step 4 4. Disconnect battery. 5. Remove rear seat cushion. Fold towards front seats or remove altogether, depending on specification. 6. Remove fuel tank access plate. 7. Disconnect fuel gauge connector and fuel pump connector through aperture. 8. Disconnect fuel feed hose and fuel return hose through aperture. Note that ports and hoses are marked to facilitate correct re-assembly. Plug hose and pipe openings to pre- vent entry of dust and dirt FE-5FEO oS Feo UFOs FUEL SYSTEM Fuel Gauge Sender Unit Removal (Contd) 9. Remove the locking ring from the fuel tank, using SST kVv999G0010. 10. Lift fuel tank access cover and disconnect hoses and con- nectors from the underside. 11. If “Consult” is not available, pump out the tank through the tank access aperture 12. The fuel gauge sender unit is fitted onto the fuel pump support bracket. Remove fuel gauge by pulling the clip as indicated and move the fuel gauge sender unit upwards. The “Low Fuel” warning light switch is fitted onto the fuel gauge sender unit. Fuel Gauge Sender Unit Installation Fit fuel gauge sender unit onto the fuel pump housing. Fit new seal to fuel tank as shown Ensure all seal contact faces are damage free. Connect hoses and connectors to the fuel tank access cover. Ensure that the fuel hoses are fitted correctly. Check artows on the ports on top of the access cover. vena FESFUEL SYSTEM Fuel Gauge Sender Unit Installation (Cont'd) 4, Fit access cover to fuel tank, ensuring that arrow on access cover aligns with mark on tank. «Be sure not to disturb the position of the seal 5, Fit and torque-tighten the locking ring, using SST KV 99960010. (2180 - 35 Nem (3.1 - 3.6 kg-m, 22 - 26 fb) 6. Recheck alignment of access cover marking and fuel tank marking 7. Refit fuel gauge connector and fuel pump connector. 8. Refit yellow-marked fuel feed hose to fuel feed port, and white-marked fuel retum hose to fuel return port. Both ports are marked with an arrow to indicate the direc- tion of the fuel flow. «Hose fitting clips should not touch any part of fuel tank and should be 2 to 10 mm (0.08 to 0.39 in) from hose ends. 9. Refit inspection hole plate. 10. Refit rear seat cushion. 11. Reconnect battery. 12. Refit fuel filler cap. Fuel Pump Removal 1. Remove fuel tank access cover. Refer to “Fuel Gauge ‘Sender Unit Removal”. 2. If “Consult” is not available, pump out the tank through the tank access aperture. 3. Push the clips as shown and remove fuel pump and its housing from the support bracket. FE-7Breather Fue filer hose FUEL SYSTEM Fuel Pump Installation 1. Slide the fuel pump in its housing into the support bracket. Ensure seoure fit. 2. For installation of fuel tank access cover and fuel tank access plate, refer to “Fuel Gauge Sender Unit Installa- tion” Fuel Tank Removal 1. Release fuel pressure. Reter to “Fuel Pressure Release”. 2. Disconnect fuel gauge connector and fuel pump connector from fuel tank access cover. Refer to “Fuel Gauge Sender Unit Removal”. 3. If “Consult” is not available and fuel tank is not empty, remove fuel tank access cover, and pump out the tank through access aperture. Refer to “Fuel Gauge Sender Unit Removal” 4. Disconnect fuel feed hose, fuel return hose, and breather hose from pipes at underside of vehicle. Plug hose and pipe ‘openings to prevent entry of dust or dirt. 5. Disconnect fuel filler hose and ventilation hose in rear left wheelarch. Prevent dirt ingress while disconnecting, and plug hose and pipe ends afterwards. 6. Pull ventilation hose through the innerwing aperture towards fuel tank. FESFUEL SYSTEM Fuel Tank Removal (contd) 7. Remove heat shields in between fuel tank and exhaust. 8. Support fuel tank with transmission jack. 9. Remove fuel tank mounting band bolts. 10, Remove fuel tank Fuel Tank Installation «Installation is basically the reverse order of removal. Clips on fuel tines should not touch any parts of the fuel tank and should be 2 to 10 mm (0.08 to 0.39 in) from hose ends. «Refer to “Fuel Gauge Sender Unit Installation”. «Tighten fuel tank mounting band bolts to specified torque. (0)26 - 36 N-m (2.7 - 3.7 kg-m, 20 - 27 ftb) FE-9EXHAUST SYSTEM CAUTION: Always replace exhaust gaskets with new ones when re-assembling. ¢ Check all tube connections for exhaust gas leaks, and entire system for unusual noises, with engine running. After installation, check that mounting brackets and mounting insulator are free from undue stress. it any of the above parts are not installed properly, excessive noise or vibration may be transmitted to the vehicle body. 338 _ 4 teneee-1y OSE 1 @ SS | < comer pe tx — < rane Sorade ay a Comer pne . renee 0G130E ™ a - 20-39 a [pies 55 144-50, 22 40) i303, 22-20) >. a" ON fo — PON ieee ee ‘° \ pss (44-88, 32-40) FE-10Large aiameter FT Front tube ce 4 t Le ie eon) Calalyie converter EXHAUST SYSTEM Installation through the middle of flange hole. Mounting bott: Dy: 43-- 55 Nem (4.4- 5.6 kg-m, 32 - 40 fib) FE-11 Install exhaust front tube mounting bolt with the large diam- eter spring side facing the front tube flange. Install exhaust front tube so that mounting bolt passeseee ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS SECTION F E | CONTENTS ACCELERATOR CONTROL SYSTEM FUEL SYSTEM = EXHAUST SYSTEM FE-5001Nero? FUEL SYSTEM cr Fuel Gauge Sender Unit Removal Procedure is identical to petrol engine models procedure. Refer to “Fuel Gauge Sender Unit Removal", page FE-5. Before re-installing the fuel gauge sender unit, ensure filter in chamber is clean and chamber is free from debris. FE-5003EXHAUST SYSTEM viz CAUTION: * Always replace exhaust gaskets with new ones when reassembling, * When removing manifold nuts use lubricant. Replace manifold nuts with new ones when re-as- sembling. Fasten manifold nuts 2 or 3 threads by hand before tightening at specified torque. Tighten manifold nuts before fastening bolt between front exhaust tube A and exhaust mounting bracket. * After installation, check that mounting brackets and mounting insulator are free from undue stress. If any of the above parts are not installed properly, excessive noise or vibration may be transmitted to the vehicle body. DIESEL engine models Dy s-s8(13-16,96- 118) (aE @ Bee F< eee a) {alte converter (8 cast Models with eatayte S comer nm tom, me) Ph arz-s20, ~ Font exnaus tube & (59 00 not (62-55,904-304) lL Nreoes FE-5004EXHAUST SYSTEM WIZ age darter Installation '* Install mounting bolt with large diameter spherical joint spring side facing front exhaust tube A. ‘@ Install front exhaust tube B so that mounting bolt passes through the middle of flange hole. Mounting bolt: (Dy: 43 - 55 Nem (4.4 - 5.6 kg-m, 32 - 40 ft-lb) FE-5005