Valve Body

Valve Body:

COMPONENTS

DISASSEMBLY OF VALVE BODY

1. NOTE NUMBERS OF ADJUSTING RINGS

HINT: Count the number of adjusting rings before disassembly of the valve body because the throttle pressure is changed according to the number. (Some of the valve bodies do not have any adjusting rings.)

2. NOTE POSITION OF PLUNGER SLEEVE
Note which step at the end of the plunger sleeve is in contact with the valve body.

HINT: Be certain to check this before disassembly because the line pressure changes according to the part of the plunger sleeve which comes into contact with the valve body.

3. REMOVE SOLENOID
a. Remove the solenoids.
b. Remove the O-rings from the each solenoids.

4. REMOVE LOWER VALVE BODY COVER

(A241L, A243L)
Remove the seventeen bolts and the lower valve body cover.

(A241 E)
Remove the ten bolts and the lower valve body cover.

5. REMOVE GASKETS, PLATE AND STRAINER

a. Remove the two gaskets and plate.

b. Remove the strainer. (A241L, A243L only)

6. REMOVE BOLTS FROM UPPER VALVE BODY
Remove the eight bolts from the upper valve body.

7. REMOVE BOLTS FROM LOWER VALVE BODY

Remove the five bolts from the lower valve body.
(A241L, A243L)

Remove the nine bolts from the lower valve body.
(A241 E)

8. LIFT OFF LOWER VALVE BODY AND PLATE AS SINGLE UNIT
Hold the plate to the lower valve body and lift off the lower valve body.

HINT: Be careful that the valves, springs and strainer do not fall out.

9. REMOVE PLATE AND GASKETS FROM LOWER VALVE BODY

ASSEMBLY OF VALVE BODY

1. POSITION PLATE AND NEW GASKETS ON LOWER VALVE BODY
Position the new No.2 gasket, the plate and then the new No.1 gasket on the lower valve body.

HINT: Since the No.1 gasket and No.2 gasket are similar use the illustration to discriminate between them.

2. PLACE LOWER VALVE BODY WITH PLATE AND GASKETS ON UPPER VALVE BODY

HINT: Hold the lower valve body, gaskets and plate securely so they do not separate.

Align each bolt hole in the valve bodies with the gaskets and plate.

3. INSTALL AND FINGER TIGHTEN BOLTS IN LOWER VALVE BODY TO SECURE UPPER VALVE BODY

Install and finger tighten the five bolts. (A241L, A243L)

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

Install and finger tighten the nine bolts. (A241E)

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

4. INSTALL LOWER VALVE BODY COVER

a. Install the strainer. (A241L, A243L only)

b. Position a new gasket and plate and then another new gasket.

c. Position the lower valve body cover.
d. Install and finger tighten the seventeen bolts. (A241L, A243L)

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

e. Install and finger tighten the ten bolts. (A241E)

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

5. INSTALL AND FINGER TIGHTEN BOLTS IN UPPER VALVE BODY
Install and finger tighten the eight bolts.

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

6. TIGHTEN BOLTS OF UPPER AND LOWER VALVE BODIES

a. Tighten the twenty-two bolts in the lower valve body. (A241L, A243L)

Torque: 65 kg-cm (56 in.lb, 6.4 N.m)

b. Tighten the nineteen bolts in the lower valve body. (A241E)

Torque: 65 kg-cm (56 in.lb, 6.4 N.m)

c. Tighten the eight bolts in the upper valve body.

Torque: 65 kg-cm (56 in.lb, 6.4 N.m)

7. INSTALL SOLENOID

a. Install the new 0-rings on the each solenoids.

b. Install the solenoids.

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

Torque: 65 kg-cm (56 in.lb. 6.4 N.m)

Torque: A 65 kg-cm (56 in.lb, 6.4 N.m)
B 100 kg-cm (7 ft-lb, 10 N.m)