Usage:
Remove Brakesaver Control Valve
1. Drain the oil from the oil pan.
2. Remove two short bolts (1) and two longer bolts (3) from manifold (2) and BrakeSaver housing. Remove manifold (2). Remove the O-ring seals from the manifold.
3. Remove oil temperature sensing unit (4) from the BrakeSaver control valve.
4. Disconnect air line (5) and hose assembly (6) from the BrakeSaver control valve.
5. Remove bolt (7) and retainer (8) that hold the oil lines in the BrakeSaver control valve.
6. Disconnect oil lines (9) and (10) from the oil cooler. Remove oil lines (9) and (10) from the BrakeSaver control valve.
7. Remove bolts (12) and BrakeSaver control valve (11) from under the oil pan. The weight is 48 lb. (22 kg).
8. Remove elbow (13) from the BrakeSaver control valve. Remove the O-ring seals.
Install Brakesaver Control Valve
1. Inspect the O-ring seals for damage and make replacements if needed. Put clean oil on the O-ring seals.
2. Install the O-ring seals and elbow (3) on the BrakeSaver control valve.
3. Make sure the O-ring seals are in position on the face of the BrakeSaver control valve. Put BrakeSaver control valve (1) in position under the oil pan. Install bolts (2) that hold the BrakeSaver control valve to the oil pan.
4. Install oil temperature sensing unit (4) in the BrakeSaver control valve.
5. Connect air line (5) and hose assembly (6) to the BrakeSaver control valve.
6. Install O-ring seals (7) and (8) on manifold (9). Install manifold (9) in the BrakeSaver control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.
7. Make sure the O-ring seals are in place on the oil lines and install oil lines (10) and (11).
8. Install retainer (12) to hold the oil lines in the BrakeSaver control valve.
NOTE: If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Pipe Sealant on the threads and tighten the plug to a torque of 60 ± 8 lb. ft. (80 ± 11 N·m).
9. Fill the engine with oil. See LUBRICATION AND MAINTENANCE GUIDE.
Disassemble Brakesaver Control Valve
start by:
a) remove BrakeSaver control valve
1. Remove O-ring seals (1) from the valve body.
| NOTICE |
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Spring force is behind the cover at removal. |
2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.
3. Remove cover (3) and the seal from the opposite end of the valve body.
4. Remove spool (8) as an assembly.
5. Remove spring (7), stop (10), spring (6) and slug (9).
6. Remove the O-ring seals and sleeve (5).
7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Make an inspection of the pin on the spool, and make a replacement of the pin if there is damage or wear.
Assemble Brakesaver Control Valve
1. Install diaphragm (4) and plate (8) on valve spool (3). Make alignment of the hole in the plate valve with the pin on the spool. Install the bolt that holds the plate and the diaphragm in position.
| NOTICE |
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When the diaphragm (4) is installed on the valve spool (3), make sure the fabric side is pulled down over the valve spool to make contact with it and the smooth (rubber coated) side is next to valve body. |
2. Install sleeves (1) and the seals in the valve body.
3. Install the valve spool as an assembly into the valve body. As the valve is installed, make sure the edge at the diaphragm makes contact all the way around with the groove in the valve body. At this time the valve spool end must extend about 1.50 in. (38.1 mm) from the valve body. Push the valve spool about .25 in. (6.4 mm) - .50 in. (12.7 mm) farther into the valve body until a curved depression is caused between the valve spool and valve body. Make sure there are no wrinkles in the diaphragm.
4. Put cover (9) in position. Install the four bolts that hold the cover on the valve body. Move the valve spool in the valve body several times to make sure it moves freely. Move the valve spool all the way against the cover (5).
5. Install spring (7), stop (2), spring (6) and slug (5) in the spool through the opening in the opposite end of the valve. Install the cover on the opposite end of the valve body. Hold the cover down to put the springs under compression. Install the four bolts that hold the cover.
6. Install the three O-ring seals for the three valve body (ports) openings.
end by:
a) install BrakeSaver control valve