Page 642 of 1254

CRANKCASE 
EMISSION CONTROL  SYSTEM
Thissysrem  rctuns 
b ow-bygasb  bolh lhe nlake  manilotdand
The  positive 
cankese  venliaton (P 
C.V.)  valv6  s provid€d 
ro
@nductcrankcase  blow'by gas 
to th€  inlak6  man iold.
Dufng  padiallhone 
opealion ol lhe  efglne.  lhe intake  man
ilold  sucks  lhe b ow-by  gas 
lhrough  the P.C.V.  valve.
Normally,lhe  capaciq/ ol lhe  valve  is sufticienl  lo hande  any
blow-by  and a smal  amou.l  ol ventlating  an.
The  ventlaiing  air slhen  dEwn lbm lh€ an nlerlubes,lhrough
fte  hose  conn€ctng  an nd  Iubas  lo rocker 
cover, i.lo lhe
Under  iull-lhrctlle 
coidilion, lho manilold  vacuum is nsuliiclenl
lo  daw  lho bowby  llow lhouqh  lh€ valve, 
and is llow  goes
lhrcugh  lh6 hos€  conn€ciion  in lhe  reveBe 
dnedion.
On  v6h  cl€s  wilh an.rc.ssiv6  y 
hiqh  b ow.by  sone ot lhe  ltow
willgolhbugh  th€ hose 
connection  lo fie  an inlel  lubes  und6r
Inspection
P.C,V,  (PciriE 
crdkes€  Ventitatbn)
Wilh  enqne  running  al idl€,  €mov€  P.C.V. valv€ lrom 
ro.ker
cover  il lh€  vav€  is wo*inq  pope 
y, 
a hlssinq  noise wilt be
head  as aif  passes 
lhrough  it and  a sl@ngvacuum  shou d be
rell  imnediately 
when a fngef  is placed 
ov€r valve  inl6l.
Description
EF  & EC-341 
     
        
        Page 683 of 1254
INJECTION 
NOZZLE
Tesl  and Adiunmenl
wten  clng node  tester,  be @r€t!t  noi to dtow  dt€Bt  tu€l
lpbyed  lrofi n@b  ro 6lnEr  your 
h.nd.  or body, 
od mal.c
sE  your 
€y€3  rE p.opery 
pdecled 
wnh qoggl6,
NJECNON  PFESSURE  TEST
1.  Inslall 
nozzle  lo injection  nozzlBlesld  5.d bl6ed 
an lrom
2.  Plmp 
ihe lesier  handle  slowly (onc€ 
p* 
se@nd)  and
waEn  oe piessurc 
qa!s6.
3.  Fead  ihe p@ssure 
sausBwh€n  rh€ 
injecllon  pressucjlsl
hili.l  ini6ction  pt€5!e:
12C59  - 
13?39  kP5 (1225 
- 
l3:t,4  bar. 125 - 
i35
ksbrnl  1,7t3 - 
1,92O  psl)
13,239  - 
14,024  kPa 
032.4  - 
140,  hd, 
135 - 
143
kg/m",  I,Co.2,033  p6i)
Atwarys  chek Initi.l lnjecrlon  pllgF 
u6lng a tu  |Ete
a.  To adjust  injeclion  p€ssur€, 
change adjustins  shims.
..  Inc|@lnq  116 lhickE  or 
.dlBtlng  .hlns ircE.s 
hi
tal  lnlrclion  pEsue. 
[email protected]  michs rqtuG 
tnl al
b.  A 3hh  rhblfts  or 0.04 
nm (00016 
in) @nEponds
6p9rorinEr€ly  to r dltleEG  ot 471  kPa 
{471  bar, 
43
kg/cnz,63  p6l) 
In hldal  ini6crion  p.€sue.
Rd€r  ro s.D.s. 
id adiumng  shin.
EF  & EC{42 
     
        
        Page 708 of 1254
SEBVICE 
DATA AND SPECIFICATIONS  TS.D.S.)
Inieclion  Pump (Confd)
Pobr  ionPrer  adiustner
'' 
unoer  ttre lottow 
ng 
conoillons.  adjusl the poientomele/s 
insiallarion pcilion 
so thal  lhe oulpul  vo tag6
eolals  lhe soeciried  value.
Ir.p vonaos 
rovt
1.  Al 
a pump 
speed  ol 14.3  - 
16.3  m(0.50lo  0.57 mp U ozll,000  st, adiusl  lh€ dummy 
& thai  it is
against  lhe @nftllev€f,  and lhon  seurc  il usng  th€ locknul.
2.  Thon,  adiusl  lh6 polBntiomaler 
so lh.t  rhe 
output  is 
6.29  - 
6.35  V.
3.  Aft.f  m.kinq  adiush€nt,  remove 
lhe dumdy  boli and @nlnm  fial lh6 polenliomeref 
ourpur voltage
is  as  sp€cif.d  abov€ when 
lhe conibl  ever is in the  ide posilion.
EF  & EC-407 
     
        
        Page 724 of 1254
INSPECTION 
AND 
ADJUSTMEiIT
Bleedlng  Procedu|e
L  Blsd  an trom  clulch  opeBling 
cylinder a@rding  ro th€
cr.lully  noilo. 
nuld Lsl n nard  .yiftr*  dudns 
bteedt.g
Too  !D r6$ruoir  wilh €@hme.ded 
bEke lllld.
Conn@r  a lrmspa€nt  vinyl 
tube to air  bt6.d.f  vatve 
ol
clutch  op€EtnA  cylind€r.
Fully  d6pEs. 
clulch p6dal 
s6v€El  rimes.
Wilh  clulch  pedal 
depess€d,  op6n bl€€der  valve 
to rcte6g
e.  Close  bl€€d$  valve.
L  Rapeat 
steps c though  e abov€  unrit b6k. 
nuid ttows  nom
air  bleeder  valvo wirhout  an 
blbbles.
2.  Bleed  air lrcm  clutch  damp.r 
ac@ding  lo lh€  abov.  pro-
6du€  (SB2oDE 
enqlne moderonty).
3.  R€p6al  th€ 
abov.  bleeding  prcc.durc. 
1 and  2 *veEl 
     
        
        Page 747 of 1254
DISASSEMBLY
Shift  Corftol  Components  (Cont'd)
3.  D ve  oul  Eiaininq  pins. 
Then  dive olt lolk  rods  and
rcmovo  inlB ock balls.
Geat  Componenls
1.  Belore  disassembly,  measu€ 
each gear 
6nd plsy.
.  lt€.d  play 
is norwilhin 
the specitiod  timil, dis.s@nbte 
and
.  Roplace  any panwhl.h 
is wom  o.dsmag.d.
5. M4h 
2nd End  Ev66e  geai, 
the. daw  out counter 
lont
beadng  wilh su labl€  puller.
Bemov.  snap nq 
and  then  renove  sub,A€ar  bEcket, 
sub-
gear  spfng  ano 
.uo-gear.
D6w  oul 
@unle'  drve gear 
w[h main 
drve qear 
assem,
Wh.n  dEoing  out min  dd€  ger 
@nbty,  b. eBtut  nor
to  d@p 
Falot bearlng 
6nd b.ulk  dng.
F€mov€  snap ing and  d6w  out3d 
& 4th 
synchrcniz€rand
Oisassemble  parls 
al r6af  ol 
adaFter  otale as 
tottow.:
Felease  staking on counteEhatl 
nut and  mainshalt 
nui and
Mal..hait  nd: L3fi.h.nd 
th@d
6.
i[T-l4 
     
        
        Page 776 of 1254
DISASSEMBLY
Model R2m
Difierential  Carrier
1.  Usino  lwo 45 
mm  (1.77 
in) spa@6,
T6l  nunbcr:  Kv3a100€0o
Pre-inspec{ion
A€loe  disassemblin!,inald  ve, periom 
the lottowing  inspec-
1)  Tum  drve  pinion 
in borh 
dnecions  seve€t iim6s ro 
s.l
2)  Chek  iolal preload 
wi r Too.
T6l  nunber: 
SI!127S{D0
(15-  25 kgrcm,13,5-  2t.5 in.tb)
B  n9  g€ar 
lo drlve  pinion 
backtash
Check  ng geaFlo-ddv€ 
pinion 
back ash wlh  a diatindica-
0.13  - 
0.1a  nm (0d139  - 
0.0059  tn)
Check  runoutol  nq gear 
wilh a dialindic.tor
0,05  mm (0.0020 
In)
ch€ck  loolh @ntact.  (R€l€rro 
adjusrmenr.)
2.  Paint  or punch 
matchharks  on one 
side  ot
ng  €p  so il 
€n  be p@p€dy 
€insiated.
a@nng  ep6 
.e llneb@rd  during 
mnutactuE.
in  rheir  prcoer 
ocgitionE.
ir
Plll l 
     
        
        Page 780 of 1254
NSPECION 
0itgdd R200u
Contact  Surtao€s
1  . 
Cl6n  lhe dlsasmbl€d  pais 
in 6una6t€  $tvBnt 
and btow
dry  wllh  cohp6.@d 
aii
2.  lf followinq 
.urta@s are tound  lo be 
b!red  of sc€tch6d,
.moorh  wirh oll srone.
3.  Check  vb6us 
@Jprinq  tor 
ortteakrga  tl 
I is 
fautty, 
r€pts€
PBl5 
     
        
        Page 800 of 1254

LIMITED 
SUP DIFFEREI'ITIAL  (For 
Hl 9OA)
Disassembly
L  R6mov6  side bear ng inner 
cone with Tool.
2.  Remove 
ing gear 
by spGadinq  oul lockslEps,
3.  Lo6en  ing gear 
b.lls  in 
a c  ss-cross  iashion.
4.  Tap  .g g€ar 
otf gear 
@se  with a son  hammol
T.p  snly 
.ll dound  ro pevdl 
ring g€.r 
lrcn  bindlng,
5.  Femoee  dife€nta  €se by spreading 
oul look  straps.
6.  Bemove  coupla bolls 
on dillerential  c6es A and  B 
with  a
T@l  number:  s'830a10@
7.  Sepa€te  difl6Gnria 
@e a 
and  B.
0€w  oul @mpon6  pans 
(dis 
and prales, 
6ic.).
Put  na*s  d g€@ 
.nd p|€ge 
dn$ $ thar  rh.y 
en b.
rdmt  ll.d in rh.ir 
odglnal  pcifoE 
trcm which 
rhey reE
|nspection
COMIACT  SURFACES
1.  Cl6anlhe 
diessembled  parts 
in suiiabte  sotvenl and btow
dry  with  comprsss€d 
air.
2.  lf lolowinq 
6urfa@s are lound  with bur. 
or scratohes,
.mooth  wilh oi slono.
C)  Ditle@nt 
al c666  A
O  oitlereni 
al c6se  B
O  Pinion 
nate gear
@  Pinion 
nale shaft
O  Fdction 
plale 
quide
OISC  AND PLAIE
1.  Clean 
the discs  and plal€s 
in suiiabte  so v€nl  and btow 
dry
wih  @hpr€ss6d  air
2.  Inspacl 
dis and plates 
lorw€ar,  nicks and burs.
#
Y
*f
e@ d,$
PD€5