Fe PDF

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS GI
MODIFICATION NOTICE:
SECTION FE MA
EM
LC
I Exhaust system has been changed on models with three way catalyst. (Except for Europe)
EC
CONTENTS
QG ACCELERATOR CONTROL SYSTEM .........................24 CL
Removal and Installation ...........................................24
PREPARATION ...............................................................2
Inspection...................................................................25
Special Service Tools ..................................................2
FUEL SYSTEM ..............................................................26 MT
Commercial Service Tools ...........................................2
Checking Fuel Lines ..................................................26
ACCELERATOR CONTROL SYSTEM ...........................3
Water Draining from Fuel Filter .................................26
Removal and Installation .............................................3
DRAINING WATER ..................................................26
AT
Adjusting Accelerator Wire ..........................................3 FUEL FILTER CHECK ..............................................26
FUEL SYSTEM ................................................................5 Changing Fuel Filter ..................................................26
Checking Fuel Lines ....................................................5 REMOVAL ...............................................................26
AX
Removal and Installation .............................................5 INSTALLATION........................................................27
Fuel Tank .....................................................................6 Bleeding Fuel Filter....................................................27
REMOVAL .................................................................7
SU
Checking Priming Pump ............................................27
INSTALLATION........................................................11 Checking Fuel Filter Switch.......................................28
Fuel Pump, Fuel Level Sensor Unit and Fuel Removal and Installation ...........................................28 BR
Filter ...........................................................................12 Fuel Tank ...................................................................29
REMOVAL ...............................................................12 REMOVAL ...............................................................31
INSTALLATION........................................................14 INSTALLATION........................................................34 ST
EXHAUST SYSTEM ......................................................15 Fuel Level Sensor Unit ..............................................35
Checking Exhaust System.........................................15 REMOVAL ...............................................................36
Removal and Installation ...........................................15 INSTALLATION........................................................37 RS
EXHAUST SYSTEM ......................................................38
YD Checking Exhaust System.........................................38
BT
Removal and Installation ...........................................38
PREPARATION .............................................................23
Special Service Tool ..................................................23
Commercial Service Tool...........................................23 HA
SC
EL
IDX
PREPARATION QG
Special Service Tools
Special Service Tools NJFE0029
Tool number
Description
Tool name
KV10117200 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 NJFE0030
Tool name Description
Oxygen sensor thread Reconditioning the exhaust system threads

cleaner before installing a new heated oxygen sen-
sor (Use with anti-seize lubricant shown
below.)
a: 18 mm dia. with pitch 1.5 mm for zir-
conia heated oxygen sensor
b: 12 mm dia. with pitch 1.25 mm for
titania heated oxygen sensor
AEM488
Anti-seize lubricant Lubricating heated oxygen sensor thread

(Permatex 133AR or cleaning tool when reconditioning exhaust
equivalent meeting MIL system threads
specification MIL-A-
907)
AEM489
FE-2
ACCELERATOR CONTROL SYSTEM QG
Removal and Installation
Removal and Installation NJFE0002

CAUTION:
I When removing accelerator wire, make a mark to indicate lock nut’s initial position. GI
I Make sure throttle valve opens fully when accelerator pedal is fully depressed. Also make sure it
returns to idle position when pedal is released.
MA
I Check accelerator control parts for improper contact with any adjacent parts.
I When connecting accelerator wire, be careful not to twist or scratch wire.
EM
LC
EC
CL
MT
AT
AX
SU
BR
JFE606A
ST
RS
BT
HA
Adjusting Accelerator Wire NJFE0003

SC
1. Remove the vacuum hose connected to the throttle opener.
2. Connect suitable vacuum hose to vacuum pump as shown left.
EL
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. IDX
Make sure that there is clearance between the throttle
drum and rod.
If NG, refer to EC-645, “Basic Inspection”.
If OK, go to following step.
SEF793WB
FE-3
ACCELERATOR CONTROL SYSTEM QG
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
FE-4
FUEL SYSTEM QG
Checking Fuel Lines
Checking Fuel Lines NJFE0009

Inspect fuel lines, fuel filler cap and tank for improper attachment,
leaks, cracks, damage, loose connections, chafing or deterioration. GI
If necessary, repair or replace these parts.
MA
EM
SMA803A LC
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end. EC
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
CL
MMA104A
MT
WARNING: AT
When replacing fuel line parts, be sure to observe the following.
I Put a “CAUTION: INFLAMMABLE” sign in workshop.
AX
I Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
I Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
CAUTION: SU
I 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-526, “Fuel Pressure Release”.
BR
c) Disconnect battery ground cable.
I Always replace O-ring and clamps with new ones. ST
I Do not kink or twist tubes when they are being installed.
I Do not tighten hose clamps excessively to avoid damaging hoses.
I After installing tubes, run engine and check for fuel leaks at connections.
RS
I Use only a Genuine NISSAN fuel filler cap as a replacement.
BT
HA
SC
EL
IDX
FE-5
FUEL SYSTEM QG
Fuel Tank
Fuel Tank NJFE0006
JFE607A
FE-6
FUEL SYSTEM QG
Fuel Tank (Cont’d)
GI
MA
EM
LC
EC
CL
MT
AT
AX
SU
BR
ST
SFE649A
RS
BT
HA
REMOVAL NJFE0006S01
SC
For Sedan NJFE0006S0101
1. Release fuel pressure from fuel line.
Refer to EC-526, “Fuel Pressure Release”. EL
2. Disconnect battery ground cable.
3. Open fuel filler lid and fuel filler cap. IDX
4. Drain fuel from fuel tank.
5. Remove rear seat cushion. Refer to BT-65, “Removal and
Installation”.
JFE613A
6. Remove inspection hole cover under the rear seat.
FE-7
FUEL SYSTEM QG
7. Disconnect electrical connector.
8. Disconnect the quick connector as follows.
a. Put mating marks on tubes and connectors for correct
installation.
JFE608A
b. Hold the connector while pushing in tabs, and pull out the tube.
CAUTION:
I The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
I Do not use any tools to remove the quick connector.
I Keep the resin tube away from heat. Be especially careful
when welding near the tube.
I Prevent acid liquid such as battery electrolyte etc. from
getting on the resin tube.
I Do not bend or twist the tube during installation and
SFE562A removal.
I Only when the tube is replaced, remove the remaining
retainer.
I When the tube is replaced, also replace the retainer with
a new one.
Retainer color:
Orange (Feed hose side)
White (Return hose side)
JFE628A
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.
JFE609A
11. Set a suitable transmission jack under fuel tank.

12. Remove fuel tank mounting band bolts while supporting fuel
tank.
JFE610A
FE-8
FUEL SYSTEM QG
13. Lower the fuel tank by 70 to 80 mm (2.76 to 3.15 in), remove
the nuts and clips holding the protector, and then remove the
protector. GI
I To remove the clips, use pliers to squeeze the extensions as
shown by the arrows in the figure at left, and then remove the
clip from above. MA
14. Remove fuel tank.
EM
JFE611A LC
For Hatchback NJFE0006S0102
1. Disconnect battery ground cable. EC
2. Open fuel filler lid and fuel filler cap.
Installation”.
CL
JFE613A
MT
7. Disconnect the quick connector as follows. AT
a. Put mating marks on tubes and connectors for correct instal-
lation.
AX
SU
BR
SFE639A
ST
RS
BT
HA
SFE640A
b. Hold the connector while pushing in tabs, and pull out the tube. SC
CAUTION:
depressed. Do not twist it more than necessary. EL
when welding near the tube.
IDX
I Do not bend or twist the tube during installation and
SFE562A removal.
FE-9
FUEL SYSTEM QG
8. From rear left area of fuel tank, remove filler hose, vent hose,
and EVAP hose.
CAUTION:
SFE650A
SFE642A
10. Remove heat insulators from fuel tank side.
SFE821A

tank.
SFE644A
FE-10
FUEL SYSTEM QG
INSTALLATION NJFE0006S02
To install, reverse the removal procedure. Connect the quick con-
nector as follows: GI
I Align mating marks on tubes and connectors for correct instal-
lation.
I Insert tube into the center of the connector until you hear a
MA
click.
EM
SFE560AA LC
EC
CL
SFE657A
MT
After connecting quick connector, make sure the connection is
firmly made using the following method. AT
I Pull on the fuel tube and connector to make sure they are firmly
connected.
I Start the engine, increase engine speed and verify that there AX
are no leaks.
SU
BR
SFE561AA
ST
RS
BT
HA
SFE658A
SC
EL
IDX
FE-11
FUEL SYSTEM QG
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter
Fuel Pump, Fuel Level Sensor Unit and Fuel

Filter NJFE0007
SFE671A
REMOVAL NJFE0007S01
1. Release fuel pressure from fuel line.
Refer to EC-526, “Fuel Pressure Release”.
Installation”.
JFE613A

7. Disconnect the quick connectors.
I For disconnect of quick connectors, refer to step 8. of “Fuel
Tank Removal”.
8. Remove the six screws and retainer.
CAUTION:
Use genuine bolts only when fixing retainer.
JFE608A
FE-12
FUEL SYSTEM QG
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter (Cont’d)
9. Pull out the fuel level sensor unit and fuel pump.
I Do not damage the arm of the fuel level sensor unit and
fuel tank temperature sensor. GI
MA
EM
SFE564A LC
10. Remove fuel pump as shown in the figure at left.
I Put mating marks on fuel pump and fuel filter for correct instal-
lation.
EC
CL
JFE614A
MT
11. Disconnect fuel pump harness connector.
AT
AX
SU
BR
JFE615A
12. Remove fuel filter from fuel level sensor unit as shown in the
figure at left. ST
I Put mating marks on fuel filter and fuel level sensor unit for
correct installation.
RS
BT
HA
JFE616A

SC
EL
Installation”.
4. Remove inspection hole cover under the rear seat. IDX
JFE613A
FE-13
FUEL SYSTEM QG
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter (Cont’d)
Tank Removal”.
SFE639A
7. Remove lock ring using a lock ring socket (SST).
SFE376A
I Do not damage the arm of the fuel level sensor unit and
fuel tank temperature sensor.
Installation is in reverse order of removal.
SFE648A
FE-14
EXHAUST SYSTEM QG
Checking Exhaust System
Checking Exhaust System NJFE0010

Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, chafing or deterioration. GI
MA
EM
SMA211A LC
CAUTION: EC
I Always replace exhaust gaskets with new ones when
reassembling.
I With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
I Check to ensure that mounting brackets and mounting
insulators are installed properly and free from undue CL
stress. Improper installation could result in excessive
noise or vibration.
I Discard any heated oxygen sensor which has been MT
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.
AT
I Before installing a new heated oxygen sensor, clean
exhaust system threads using heated oxygen sensor
thread cleaner tool and apply anti-seize lubricant. AX
I Do not overtorque the heated oxygen sensor. Doing so
may cause damage to the heated oxygen sensor, resuiting
in the MIL coming on. SU
I Be sure to use genuine exhaust system parts which are
designed especially for heat resistance, corrosion
resistance, and shape. BR
I Perform the operation with the exhaust system fully
cooled down because the system will be heated just after
the engine stops. ST
I Be careful not to cut your hand on the insulator edge.
RS
BT
HA
SC
EL
IDX
FE-15
EXHAUST SYSTEM QG
Removal and Installation (Cont’d)
SFE772AA
FE-16
EXHAUST SYSTEM QG
GI
MA
EM
LC
EC
CL
MT
AT
AX
SU
BR
ST
RS
BT
SFE773AA
HA
SC
EL
IDX
FE-17
EXHAUST SYSTEM QG
SFE774A
FE-18
EXHAUST SYSTEM QG
GI
MA
EM
LC
EC
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
SFE617AB
EL
IDX
FE-19
EXHAUST SYSTEM QG
SFE627AB
FE-20
EXHAUST SYSTEM QG
GI
MA
EM
LC
EC
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
SFE632AA
EL
IDX
FE-21
EXHAUST SYSTEM QG
SFE673A
FE-22
PREPARATION YD
Special Service Tool
Special Service Tool NJFE0031
Tool number
Description GI
Tool name
KV999G0010 Removing and installing fuel tank lock

Fuel tank lock ring ring MA
socket
NT057 EM
LC
Commercial Service Tool NJFE0027
Tool name Description EC

Fuel filter wrench Removing fuel filter
a: Max. 100 mm (3.94 in) dia.
CL
NT553
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FE-23
ACCELERATOR CONTROL SYSTEM YD
Removal and Installation

CAUTION:
I Do not disassemble the accelerator pedal assembly. Do not remove the sensors and the switches
from the assembly.
I Avoid impact from dropping etc. during handling.
I Be careful to keep the assembly away from water.
I Do not adjust the adjusting screw (painted white) of the accelerator work unit.
I 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.
SFE651A
SFE629A
FE-24
ACCELERATOR CONTROL SYSTEM YD
Inspection
Inspection NJFE0020
I Make sure the accelerator pedal moves smoothly within the
whole operation range. GI
I Make sure the accelerator pedal securely returns to the origi-
nal position.
MA
I Make sure the drum of the accelerator work unit can be fully
opened.
I Refer to EC-322, “Basic Inspection” for the inspection of the EM
accelerator work unit and the accelerator pedal switch.
LC
EC
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FE-25
FUEL SYSTEM YD
Checking Fuel Lines
Checking Fuel Lines NJFE0019

Inspect fuel lines, fuel filler cap and tank for improper attachment,
leaks, cracks, damage, chafing and deterioration.
If necessary, repair or replace these 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
Water Draining from Fuel Filter NJFE0028

DRAINING WATER NJFE0028S01
1. Prepare a tray at the drain hose open end.
2. Loosen drain cock turning counterclockwise in view from
bottom, and operate priming pump to drain water from fuel fil-
ter.
CAUTION:
I Water in filter is drained with fuel. Prepare larger capacity
tray than fuel filter volume.
I Drained water is mixed with fuel. Prevent fuel from adher-
SMA794C
ing to rubber parts such as engine mount insulator.
3. After draining, close drain plug by hand.
CAUTION:
If drain plug is tightened excessively, it may be damaged and
fuel will leak. Do not use tools to tighten drain plug.
4. Bleed air in fuel piping and check for fuel leakage. Refer to
FE-27, “Bleeding Fuel Filter”.
5. Start engine.
FUEL FILTER CHECK NJFE0028S02
Check fuel filter for fuel leakage, damage and other non-standard
conditions.
Changing Fuel Filter NJFE0021
REMOVAL NJFE0021S01
1. Remove air duct and upper air cleaner case.
2. Remove connector from fuel-level warning 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
FE-26
FUEL SYSTEM YD
Changing Fuel Filter (Cont’d)
4. Remove fuel-level warning sensor from fuel filter.
GI
MA
EM
LC
I Install in the reverse order of removal. EC
I Replace the O-ring of the fuel level warning sensor with a new
one.
I Tighten the fuel filter so that the sealing face contacts the
packing, then retighten it manually by approximately 2/3 turn.
I After installation, operate the priming pump vertically to per-
form air bleeding. CL
Refer to FE-27, “Bleeding Fuel Filter”.
JFE624A
MT
Bleeding Fuel Filter NJFE0023
After fuel filter is replaced and after fuel system components are AT
removed/installed, bleed air from fuel path as follows.
1. Move priming pump up and down to bleed air from fuel path.
AX
2. When air is bled, pumping of priming pump becomes heavy
stop operation at that time.
3. Crank the engine until it starts. Do not crank the engine for SU
more than 30 seconds.
4. If the engine does not start, stop cranking and repeat step 1
above. BR
5. If the engine does not operate smoothly after it has started,
race it two or three times.
6. If air cannot be bled easily (pumping of priming pump does not
ST
become heavy), disconnect feed-side of hose between fuel fil-
ter and electronically controlled fuel injection pump. After that, RS
operate priming pump and confirm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to BT
rubber parts, especially the engine mount insulator.
HA
Checking Priming Pump NJFE0024

SC
Before checking priming pump, make sure that fuel filter is
filled with fuel.
1. Disconnect fuel return hose.
EL
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows from the IDX
hose end. If not, replace priming pump.
DEF017
FE-27
FUEL SYSTEM YD
Checking Fuel Filter Switch
Checking Fuel Filter Switch NJFE0025

1. Remove the connector from filter and fuel filter switch.
2. Turn the key switch “ON”. Lift the float to ensure that the
warning lamp turns on.
Fuel filter switch 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

WARNING:
When replacing fuel line parts, be sure to observe the following.
I Put a “CAUTION: FLAMMABLE” sign in workshop.
I Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
I Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
CAUTION:
I 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.
I Always replace O-ring and clamps with new ones.
I Do not kink or twist tubes when they are being installed.
I Do not tighten hose clamps excessively to avoid damaging hoses.
I After installing tubes, run engine and check for fuel leaks at connections.
I Use only a Genuine NISSAN fuel filler cap as a replacement.
FE-28
FUEL SYSTEM YD
Fuel Tank
Fuel Tank NJFE0016
GI
MA
EM
LC
EC
CL
MT
AT
AX
SU
SFE599AA
BR
ST
RS
BT
HA
SC
EL
IDX
FE-29
FUEL SYSTEM YD
SFE638A
FE-30
FUEL SYSTEM YD
REMOVAL NJFE0016S01
For Sedan
NJFE0016S0101
GI
3. Drain fuel from fuel tank. MA
Installation”.
5. Remove inspection hole cover under the rear seat. EM
JFE613A LC
a. Put mating marks on tubes and connectors for correct
installation.
EC
CL
SFE600A
MT
AT
AX
SU
BR
SFE601A
CAUTION:
ST
depressed. Do not twist it more than necessary. RS
when welding near the tube. BT
I Do not bend or twist the tube during installation and HA
SFE562A removal.
I Only when the tube is replaced, remove the remaining SC
retainer.
I When the tube is replaced, also replace the retainer with
a new one. EL
Retainer color:
Orange (Feed hose side)
White (Return hose side)
IDX
JFE628A
FE-31
FUEL SYSTEM YD
9. From rear left area of fuel tank, remove filler hose, vent hose,
and EVAP hose.
CAUTION:
SFE602A

tank.
JFE610A
12. Lower the fuel tank by 70 to 80 mm (2.76 to 3.15 in), remove

the nuts and clips holding the protector, and then remove the
protector.
I To remove the clips, use pliers to squeeze the extensions as
shown by the arrows in the figure at left, and then remove the
clip from above.
JFE611A
FE-32
FUEL SYSTEM YD
2. Open fuel filler lid and fuel filler cap. GI
4. Remove rear seat cushion. Refer to BT-65, “Removal and MA
Installation”.
6. Disconnect electrical connector. EM
a. Put mating marks on tubes and connectors for correct instal-
JFE613A
lation. LC
EC
CL
SFE639A
MT
AT
AX
SU
BR
SFE640A
CAUTION:
ST
depressed. Do not twist it more than necessary. RS
when welding near the tube. BT
I Do not bend or twist the tube during installation and HA
SFE562A removal.
8. From rear left area of fuel tank, remove filler hose, vent hose, SC
and EVAP hose.
CAUTION:
To prevent fuel from flowing out, install a blind cap immedi- EL
IDX
SFE641A
FE-33
FUEL SYSTEM YD
SFE642A
10. Remove heat insulators from fuel tank side.
SFE821A

tank.
SFE644A
To install, reverse the removal procedure. Connect the quick con-
nector as follows:
I Align mating marks on tubes and connectors for correct instal-
lation.
I Insert tube into the center of the connector until you hear a
click.
SFE560AB
SFE657AA
FE-34
FUEL SYSTEM YD
After connecting quick connector, make sure the connection is
firmly made using the following method.
I Pull on the fuel tube and connector to make sure they are firmly GI
connected.
I Start the engine, increase engine speed and verify that there
are no leaks. MA
EM
SFE561AB LC
EC
CL
SFE658AA
MT
Fuel Level Sensor Unit NJFE0032
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
SFE645A
IDX
FE-35
FUEL SYSTEM YD
Fuel Level Sensor Unit (Cont’d)
REMOVAL NJFE0032S01
Installation”.
JFE613A

Tank Removal”.
7. Remove the six screws.
CAUTION:
Use genuine bolts only when fixing retainer.
8. Remove retainer.
SFE600A
9. Pull out the fuel level sensor unit.

I Do not damage the arm of the fuel level sensor unit.
SFE646A

Installation”.
JFE613A

Tank Removal”.
SFE639A
FE-36
FUEL SYSTEM YD
Fuel Level Sensor Unit (Cont’d)
7. Remove lock ring using a lock ring socket (SST).
GI
MA
EM
SFE376A LC
I Do not damage the arm of the fuel level sensor unit.
EC
Installation is in reverse order of removal.
CL
SFE648AA
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FE-37
EXHAUST SYSTEM YD
Checking Exhaust System
Checking Exhaust System NJFE0022

Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, chafing or deterioration.
SMA211A

CAUTION:
I Always replace exhaust gaskets with new ones when
reassembling. If gasket remains on flange surface, scrape
off completely as shown at left.
I With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
I 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.
I Be sure to use genuine exhaust system parts which are
designed especially for heat resistance, corrosion
resistance, and shape.
I Perform the operation with the exhaust system fully
cooled down because the system will be heated just after
the engine stops.
I Be careful not to cut your hand on the insulator edge.
SFE604AB
FE-38
EXHAUST SYSTEM YD
GI
MA
EM
LC
EC
CL
MT
AT
SFE630A
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FE-39
NOTES

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ACCELERATOR CONTROL, FUEL &

Special Service Tools NJFE0029

KV10117200 Loosening or tightening front and rear

KV999G0010 Removing and installing fuel tank lock

Commercial Service Tools NJFE0030

Tool name Description

Oxygen sensor thread Reconditioning the exhaust system threads

Anti-seize lubricant Lubricating heated oxygen sensor thread

Removal and Installation NJFE0002

Adjusting Accelerator Wire NJFE0003

Checking Fuel Lines NJFE0009

Fuel Tank NJFE0006

9. Remove exhaust center tube.

11. Set a suitable transmission jack under fuel tank.

9. Remove exhaust center tube.

10. Remove heat insulators from fuel tank side.

11. Set a suitable transmission jack under fuel tank.

Fuel Pump, Fuel Level Sensor Unit and Fuel

6. Disconnect electrical connector.

For Hatchback NJFE0007S0102

7. Remove lock ring using a lock ring socket (SST).

Checking Exhaust System NJFE0010

Special Service Tool NJFE0031

KV999G0010 Removing and installing fuel tank lock

Tool name Description EC

Removal and Installation NJFE0013

Checking Fuel Lines NJFE0019

Water Draining from Fuel Filter NJFE0028

Checking Priming Pump NJFE0024

Checking Fuel Filter Switch NJFE0025

Removal and Installation NJFE0015

Fuel Tank NJFE0016

10. Set a suitable transmission jack under fuel tank.

12. Lower the fuel tank by 70 to 80 mm (2.76 to 3.15 in), remove

10. Remove heat insulators from fuel tank side.

11. Set a suitable transmission jack under fuel tank.

5. Disconnect electrical connector.

9. Pull out the fuel level sensor unit.

For Hatchback NJFE0032S0102

5. Disconnect electrical connector.

Checking Exhaust System NJFE0022

Removal and Installation NJFE0018

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