ACCELERATOR CONTROL, FUEL AND EXHAUST SYSTEMS

SECTION FE
CONTENTS
PRECAUTIONS AND PREPARATION FUEL TANK
Precaution .................................................................... 2 Removal • Installation ................................................ 9
Preparation ................................................................... 2 Inspection after Installation .................................... 10
ACCELERATOR CONTROL SYSTEM EXHAUST SYSTEM
Accelerator Control System ...................................... 3 Removal • Installation .............................................. 11
FUEL SYSTEM Inspection after Installation .................................... 12
Fuel System ................................................................. 5 SERVICE DATA
FUEL LEVEL GAGE • FUEL FILTER Accelerator Control System .................................... 13
• FUEL PUMP ASSEMBLY Fuel Tank .................................................................... 13
Tightening Torque ..................................................... 13
Fuel Level Gage • Fuel Filter
Exhaust System ......................................................... 13
• Fuel Pump Assembly ............................................... 6
Inspection after Installation ...................................... 8
[QG15] PRECAUTIONS AND PREPARATION
Precaution
SRS Airbag • Pretensioner Seatbelt
WARNING:

To install/remove the SRS airbag, pretensioner seatbelt system related components and harness,
turn the ignition switch “OFF”, disconnect the battery terminals and wait over 3 minutes. (This is
to discharge all the remaining electricity in the airbag sensor unit’s auxiliary power circuit.)

Do not use air impact or electrical tools when installing/removing the components.

Do not use any hand-held tools for harness used in SRS airbag and pretensioner seatbelt systems.
Be careful with the harness not to tangle with or interfere with other components.

Do not use any electrical test equipments such as circuit tester when inspecting the SRS airbag
and pretensioner seatbelt circuit while installed unless the Service Manual instructs to do so. (The
weak current in the tester can cause the SRS airbag to operate.)

Do not insert any foreign materials such as a screwdriver in the airbag module and pretensioner
seatbelt connector in order to prevent unintended operation due to static electricity.

The harnesses used in SRS airbag and pretensioner are covered with yellow insulation for easy
identification.

Refer to “RS Restraint System” in this Service Manual for safe airbag system service information.

Preparation
Special Service Tool
Item Description

KV999G0010 Removing/installing fuel tank

Fuel tank lock ring
socket

FE-2
 ACCELERATOR CONTROL SYSTEM [QG15]
Accelerator Control System
Removal • Installation

REMOVAL
1. Loosen the lock nuts and take off the accelerator cable from the throttle drum.
2. Remove the accelerator cable from the accelerator pedal.
3. Remove the accelerator cable bracket bolts and pull out the accelerator cable from interior.
4. Remove the accelerator pedal bracket bolts and remove the accelerator pedal bracket assembly.
5. Take out the accelerator pedal from the accelerator pedal bracket.

INSTALLATION

Install in the reverse order of removal following the below cautions.

CAUTION:

Be careful not to bend or damage the accelerator cable wire.

Be sure to lubricate every location while installation. However, do not lubricate the cable inside.

Check that the accelerator pedal is interfering with other components.

Coat multi-purpose grease on the return spring.

Inspection after Installation

Check if every systems, including the throttle drum, operates smoothly when accelerator pedal is
depressed.

Accelerator Cable Adjustment

CAUTION:

Adjust the cable while engine idling.

FE-3
[QG15] ACCELERATOR CONTROL SYSTEM

After loosening the accelerator cable enough, pull the outer

case towards accelerator pedal by using the adjust nut. If
the throttle drum starts to move (the clearance is 0), rotate
the adjust nut 1.5 - 2 turns and then tighten it with lock nut.

CAUTION:

When tightening the lock nut, hold the adjust nut with a
wrench so it does not move and tighten it so that the
insulator does not rotate.

FE-4
 FUEL SYSTEM [QG15]
Fuel System
Fuel Leakage Inspection
Visually inspect the following items.

Inspect for fuel leakage after starting the engine and increasing the engine speed.

Inspect if fuel hose has any damages or deterioration.

Check if the hose clamps are loose.

Check if the filler cap sealant has any deterioration, cracks or damages.

Check if the fuel tube fixing clip has any cracks or peels.

FE-5
[QG15] FUEL LEVEL GAGE • FUEL FILTER • FUEL PUMP ASSEMBLY
Fuel Level Gage • Fuel Filter • Fuel Pump Assembly
Removal • Installation

REMOVAL

WARNING:
Obey the following instructions when replacing the fuel line components.

Caution: Stick the “flammable” warning label.

Perform any service that can cause fire or spark in an open area away from the workshop.

Always be near the fire extinguisher.

CAUTION:

Disconnect the negative (-) battery terminal.

Be careful not to entangle the hose and the tube while installing.

Do not excessively tighten the hose clamp to prevent the hose damage.

1. Completely release the fuel pressure.

2. Open the fuel filler lid.
3. Open the fuel filler cap and release the fuel tank pressure.
4. Remove the rear seat.

FE-6
FUEL LEVEL GAGE • FUEL FILTER • FUEL PUMP ASSEMBLY [QG15]

5. Remove the inspection hole cover (3 bolts).

6. Remove the harness connector and fuel hose.

Remove the quick connector as below.

- Remove the connector while pressing the retainer with
hand.
- If cannot remove the connector and sender unit’s tube,
press and pull them several times until move. Then re-
move them.

CAUTION:

Do not place the resin tube near the fire. Be extra careful
when performing welding near it.

Completely cover with the vinyl or so to prevent from dam-

age or staining.

7. Remove the fuel pump cover using fuel tank lock ring socket
(SST: KV999G0010).
8. Remove the fuel level gage, fuel filter and fuel pump as-
sembly.

CAUTION:

Be careful not to bend the front arm when removing.

Be careful not to drop or exert any shock.

FE-7
[QG15] FUEL LEVEL GAGE • FUEL FILTER • FUEL PUMP ASSEMBLY

INSTALLATION
Install in the reverse order of removal following the below cautions.

Install the fuel module’s hose connector so that it faces the
vehicle front.

Connect the quick connector in the following orders.
- Check if the connection has any damages or stains from
foreign particles.
- Insert the tube all the way so that a “click” sound is heard
by aligning with the connector.
- In order to secure the connection, check as below.

Be sure to check the secured connection by pulling the tube
and connector.

Inspection after Installation

Check for fuel leakage by running the engine.

The fuel pump and fuel filter are integrated in an assembly. They cannot be disassembled/assembled.

FE-8
 FUEL TANK [QG15]
Fuel Tank
Removal • Installation

REMOVAL
WARNING:
Obey the following instructions when replacing the fuel line components.

Caution: Stick the “flammable” warning label.

Perform any service that can cause fire or spark in an open area away from the workshop.

Always be near the fire extinguisher.

Store the removed fuel to a safe place.
CAUTION:

Disconnect the negative (-) battery terminal.

Be careful not to entangle the hose and the tube while installing.

Do not excessively tighten the hose clamp to prevent the hose damage.
1. Follow the steps from 1 to 8 in “Fuel Pump Assembly Removal (FE-6)”.
2. Check the fuel level and drain if necessary.
3. Remove the exhaust sub muffler assembly.
4. Remove the filler hose, vent hose and evaporator hose from
the rear left of the fuel tank.

FE-9
[QG15] FUEL TANK

5. Remove the fuel tank protector.

a. Remove the protector by loosening the 3 screws located
under the fuel tank.
b. Support the fuel tank with a transmission jack and remove
the fuel tank mounting bolts.

6. Take off the fuel tank installation band.

7. Move the parking brake cable from the fuel tank front.
8. Cautioning not to touch other components, remove the fuel
tank by lowering the mission jack.

INSTALLATION
Install in the reverse order of removal following the below cautions.

Insert respective hoses up to below lengths and fasten them
firmly with clamp.
Filler hose: 35 mm
Others: 25 mm

Do not install the clamp on the bead of the tube.

Install the fuel filler hose clamp (both ends) 8 to 10 mm away
from the hose end.

For quick connector installation, refer to “Installation” in “Fuel
Level Gage • Fuel Filter • Fuel Pump Assembly (FE-8)”.

Inspection after Installation

Check for fuel leakage by running the engine.

FE-10
 EXHAUST SYSTEM [QG15]
Exhaust System
Removal • Installation
CAUTION:

Be sure to use genuine components for exhaust system since they are unique in heat-resist-
ing and anticorrosion characteristics and in shape.

Exhaust system is extremely hot right after the engine stop. Perform the service when it is
completely cooled down.

Be careful not to get hurt by the insulator edges.

FE-11
[QG15] EXHAUST SYSTEM

REMOVAL

Remove the system by disconnecting each connection.

INSTALLATION

Install after checking for any foreign particles in the sealing
surfaces such as gasket so that no gas leakage occurs after
installation.

To install the exhaust pipe assembly, temporarily tighten the

mounting bolts to the exhaust manifold and vehicle then
check for normal installation. After checking, tighten to speci-
fied torque.

Install the clamps by aligning the clamp hole with the protru-
sion of the insulator.

Be careful not to twist or pull the mounting rubbers while
installation.

Install the manifold side front tube as described below.

1. Insert the ring gasket firmly on the catalytic converter side

as illustrated.
2. Tighten the spring with bolts by positioning the wider diam-
eter towards flange.

CAUTION:

The mounting bolts should not interfere with the flange.

CAUTION:

Apply the specified torque’s mean value when tighten-
ing with special tool. (Avoid the highest value.)

REFERENCE:

Due to length of the special tool, there could be torque
differences causing over tightening.

Inspection after Installation

Inspect the pipe connections while engine running and check
for exhaust gas leakage and other noises.

FE-12
 SERVICE DATA [QG15]
Service Data
Accelerator Control System
Unit: N•m (kgf-m)

Accelerator cable lock nut 7.8 - 10.8 (0.8 - 1.1)

Accelerator cable bracket 4.3 - 5.9 (0.44 - 0.6)
Accelerator pedal bracket 4.3 - 5.9 (0.44 - 0.6)
Dynamic damper 4.4 - 5.9 (0.45 - 0.6)

Fuel Tank
Fuel tank capacity (L) 55

Tightening Torque
Unit: N•m (kgf-m)

Fuel pump module 6 - 7 (58.8 - 68.6)

Fuel tank mounting band 3.8 - 5.0 (37 - 49)
Filler tube 1.3 - 3.7 (0.13 - 0.38)
Fuel tank protector 2 - 2.9 (0.2 - 0.3)

Exhaust System
Unit: N•m (kgf-m)

Exhaust system
Between the manifold side catalytic converter and 43.1 - 54.9 (4.4 - 5.6)
exhaust sub muffler assembly
Between the exhaust sub muffler assembly and main 33.3 - 43.1 (3.4 - 4.4)
muffler

FE-13