Valve Body Assembly

(Assembly of Valve Body)






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 below to differentiate them.











(b) Temporarily secure the plate with the two 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, in.) is indicated in the figure.






(b) Hold the rear upper valve body and lower valve body, turn over the assembly.
(c) Install and finger tighten the five bolts.

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






(d) Remove the two temporary 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 two bolts.

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






(b) Hold the front upper valve body and lower valve body, turn over the assembly.
(c) Install and finger tighten the five bolts.

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






7. TIGHTEN BOLTS OF UPPER AND LOWER VALVE BODIES
(a) Tighten the ten bolts in the upper valve bodies.
Torque: 55 kg-cm (48 in.-lb, 5.4 N.m)






(b) Tighten the three bolts in the lower valve body.
Torque: 55 kg-cm (48 in.-lb, 5.4 N.m)






8. INSTALL LOWER VALVE BODY PLATE

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






9. INSTALL LOWER VALVE BODY COVER
(a) Install the retainer and three pins.
Retainer:
Height 8.5 mm (0.335 in.)
Width 5.0 mm (0.197 in.)
Thickness 3.2 mm (0.126 in.)






(b) Install the four check balls.
Check ball: Rubber ball Diameter 5.5 mm (0.217 in.)






(c) Place a 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 below to differentiate them.











(d) Install the lower valve body cover.
(e) Install and tighten the eight bolts.

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

Torque: 55 kg-cm (48 in.-lb, 5.4 N.m)






10. INSTALL MANUAL VALVE






11. IN STALL DETENT SPRING

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

Torque: 55 kg-cm (48 in.-lb, 5.4 N.m)
12. MAKE SURE MANUAL VALVE MOVES SMOOTHLY