Valve Body

VALVE BODY





Components

Valve Body Disassembly





1. REMOVE DETENT SPRING





2. REMOVE MANUAL VALVE
3. REMOVE LOWER VALVE BODY COVER





a. Remove the 8 bolts and lower valve body cover.





b. Remove the 2 gaskets and plate.





c. Remove the 4 check balls.





d. Remove the retainer and 3 pins.





4. REMOVE LOWER VALVE BODY PLATE





5. REMOVE BOLTS FROM LOWER VALVE BODY
Remove the 3 bolts.





6. REMOVE BOLTS FROM FRONT AND REAR UPPER VALVE BODIES
a. Turn over the valve body.
b. Remove the 5 bolts from the front upper valve body, and remove the 5 bolts from the rear upper valve body.
7. LIFT OFF FRONT AND REAR UPPER VALVE BODIES AND PLATE AS A SINGLE UNIT





a. Hold the valve body plate to the upper valve bodies and lift off the upper valve bodies.

HINT: Be careful that the check balls and retainers do not fall out.





b. Remove the 2 gaskets and plate.

Valve Body Assembly
1. POSITION NEW NO. 2 GASKET AND PLATE ON LOWER VALVE BODY





a. Place a new No.2 gasket and plate on the lower valve body.





HINT: Since No. 1 gasket and No.2 gasket look similar, use the illustrations to differentiate between them.





b. Temporarily secure the plate with the 2 bolts.

HINT: Use the two bolts for the oil strainer.





2. POSITION NEW NO.1 GASKET ON PLATE





3. PLACE LOWER VALVE BODY WITH PLATE AND GASKETS ON REAR UPPER VALVE BODY
Hold the lower valve body, plate and gaskets securely so they do not separate. Align each bolt hole in the valve bodies with the gaskets and plate.
4. INSTALL AND FINGER TIGHTEN BOLTS IN LOWER VALVE BODY TO SECURE REAR UPPER VALVE BODY





a. Install and finger tighten the bolt.

HINT: Bolt length (mm, inch) is indicated in the illustration.

b. Hold the rear upper valve body and lower valve body, turn over the assembly.





c. Install and finger tighten the 5 bolts.

HINT: Each bolt length (mm, inch) is indicated in the illustration.





d. Remove the temporarily installed bolts.





5. PLACE LOWER VALVE BODY AND REAR UPPER VALVE BODY ON FRONT UPPER VALVE BODY
Align each bolt hole in the valve bodies with the gaskets and plate.
6. INSTALL AND FINGER TIGHTEN BOLTS IN LOWER VALVE BODY TO SECURE FRONT UPPER VALVE BODY





a. Install and finger tighten the 2 bolts.

HINT: Each bolt length (mm, inch) is indicated in the illustration.

b. Hold the front upper valve body and lower valve body, turn over the assembly.





c. Install and finger tighten the 5 bolts.

HINT: Each bolt length (mm, inch) is indicated in the illustration.

7. TIGHTEN BOLTS OF UPPER AND LOWER VALVE BODIES





a. Tighten the 10 bolts in the upper valve bodies.

Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)





b. Tighten the 3 bolts in the lower valve body.

Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)





8. INSTALL LOWER VALVE BODY PLATE

HINT: Each bolt length (mm, inch) is indicated in the illustration.

9. INSTALL LOWER VALVE BODY COVER





a. Install the retainer and 3 pins.

Retainer:
Height 8.5 mm (0.335 inch)
Width 5.0 mm (0.197 inch)
Thickness 3.2 mm (0.126 inch)





b. Install the 4 check balls.

Check ball:
Rubber ball diameter 5.5 mm (0.217 inch)





c. Place new No.3 and No.4 gaskets and plate on the lower valve body.





HINT: Since No.3 gasket and No.4 gasket look similar, use the illustrations to differentiate between them.

d. Install the lower valve body cover.





e. Install and tighten the 8 bolts.

HINT: Each bolt length (mm, inch) is indicated in the illustration.

Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)





10. INSTALL MANUAL VALVE





11. INSTALL DETENT SPRING

HINT: Bolt length (mm, inch) is indicated in the illustration.

Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)

12. MAKE SURE MANUAL VALVE MOVES SMOOTHLY