Valve Body Assembly Components: Assembly

Place separator plate and new lower valve body gasket on lower valve body assembly and tighten installation of front upper valve body assembly with 2 bolts (1) temporarily.

Fig 1: Placing Separator Plate
Courtesy of SUZUKI OF AMERICA CORP.
Place new upper valve body gasket on lower valve body assembly.

Fig 2: Placing New Upper Valve Body Gasket On Lower Valve Body
Courtesy of SUZUKI OF AMERICA CORP.
While holding upper valve body gasket and lower valve body assembly (1) together, install it on rear upper valve body assembly (2).

Fig 3: Holding Upper & Lower Valve Body Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Tighten 3 bolts indicated in the figure temporarily.

Fig 4: Tightening Bolts Temporarily
Courtesy of SUZUKI OF AMERICA CORP.
Turn over lower valve body assembly and tighten 4 bolts indicated in the figure temporarily.

Fig 5: Turning Over Lower Valve Body
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2 bolts tightened temporarily in 1.
NOTE: Be careful not to damage gasket.

Fig 6: Removing Bolts Tightened Temporarily
Courtesy of SUZUKI OF AMERICA CORP.
Install lower valve body assembly (1) on front upper valve body (2).

Fig 7: Installing Lower Valve Body
Courtesy of SUZUKI OF AMERICA CORP.
Tighten 3 bolts indicated in the figure temporarily.

Fig 8: Tightening Bolts Temporarily
Courtesy of SUZUKI OF AMERICA CORP.
Turn over control valve lower body and tighten 5 bolts indicated in the figure temporarily.

Fig 9: Turning Over Control Valve Lower Body
Courtesy of SUZUKI OF AMERICA CORP.
Tighten bolts on upper valve body side to specified torque.
NOTE: Tighten bolts by a certain amount of torque evenly and repeat it several times till specified torque is attained.

Tightening torque
1. Upper valve body bolt: 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
Fig 10: Tightening Bolts On Upper Valve Body Side
Courtesy of SUZUKI OF AMERICA CORP.
Tighten bolts on lower valve body inside to specified torque.
NOTE: Tighten bolts by a certain amount of torque evenly and repeat it several times till specified torque is attained.

Tightening torque
1. Lower valve body bolt: 5.5 N.m (0.55 kg-m, 4.0 lb-ft)
Fig 11: Tightening Bolts Evenly
Courtesy of SUZUKI OF AMERICA CORP.
After installing manual valve (3), install detent spring (2) and plate (1) and tighten detent spring bolt to specified torque.
Tightening torque
1. Detent spring bolt: 5.5 N.m (0.55 kg-m, 4.0 lb-ft)

Fig 12: Installing Detent Spring & Plate

Courtesy of SUZUKI OF AMERICA CORP.