Chapter 2 SERVICE DATA
2.8 General Union Bolt
Strength classification
Thread size
Width across flats
Dia. × Pitch 4T
(mm) [in.]
(M-thread)
N·m kgf·m lbf·ft
8 × 1.25 12 [0.47] 8±1 0.8 ± 0.1 5.90 ± 0.73
10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11.06 ± 1.47
12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18.44 ± 2.21
14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25.08 ± 2.95
16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32.45 ± 3.68
18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 54.58 ± 3.68
20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72.28 ± 7.37
24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108.42 ± 11.06
27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 166.69 ± 14.75
(Dry)
2.9 General Union Nut
Cap nut thread size
Width across flats
Nominal Dia. × Pitch N·m kgf·m lbf·ft
(mm) [in.]
(M-thread)
63 14 × 1.5 19 [0.75] 39 4 28.76
80 16 × 1.5 22 [0.87] 49 5 36.14
100 20 × 1.5 27 [1.06] 78 8 57.53
120 22 × 1.5 30 [1.18] 98 10 72.28
150 27 × 1.5 32 [1.26] 157 16 115.80
180 30 × 1.5 36 [1.42] 196 20 144.56
200 30 × 1.5 36 [1.42] 196 20 144.56
220 33 × 1.5 41 [1.61] 245 25 180.70
254 36 × 1.5 41 [1.61] 294 30 216.84
(Maximum tolerance value: ±10%, dry condition)
2-16
Chapter 3 SERVICE TOOLS
1. Special Tools............................................................................................................ 3-3
3-1
Chapter 3 SERVICE TOOLS
Maintenance
Tool name Part No. Illustration Usage
item
Basic engine Eye bolt 45815-32301 Piston - Remove
M10 × 1.5
37591-02500 Lifting of cylinder head, main bearing
cap and others
M10 × 1.25
05930-00200 Lifting of cylinder head, gear case and
others
M12 × 1.25
Eye nut 37591-02400 Fly wheel and damper removal
M14 × 1.5
Jack bolt 64362-68500 Fly wheel and damper removal
M12 × 1.25 - 95mm
Nozzle remover 36291-00900 Main bearing cap removal
M18×1.5
Adapter 32591-04300 Main bearing cap removal
M10 × 1.25
M18 × 1.5
Valve spring pusher 35C91-04010 Valve spring installing and removal
assembly
Valve guide remover 33591-04300 Valve guide removal
ø17 × L100 Applicable valve guide inside X out-
side diam
ø10× ø18 mm [ø0.39 × ø0.71 in.]
ø10 × L50
3-3
Chapter 3 SERVICE TOOLS
Maintenance
Tool name Part No. Illustration Usage
item
Basic engine Guide and seal installer 32591-10300 Valve guide and stem seal installing
Guide height : 27.5 mm [1.08 in.]
Stem seal height : 30.3 mm [1.19 in.]
Valve lapper 30091-08800 Valve lapping
Sucking disk ø40 [ø1.57 in.]
Valve lapper 30091-07500 Valve lapping
Sucking disk ø35 [ø1.38 in.]
Valve seat cutter 37591-06400 Valve seat refacing
(shaft) Guide shaft diam ø10 [ø0.39]
Width across flats : 32 mm [1.26 in.]
W1 1/8 -18
Valve seat cutter 37591-06430 Valve seat refacing
Seat angle θ=30°
Applicable seat inside/outside diame-
ter: ø45 to ø66 [ø1.77 to ø 2.60]
W1 1/8 -18
θ㧩30°
Valve seat puller 32591-04200 Valve seat removal
Cupper tube pusher 35B91-06600 Cylinder head cupper tube removal
(MUI)
Hand cupper tube 35C91-01500 Cylinder head cupper tube installation
installer A (MUI),(ECUI)
Cupper tube installer B 35C91-21010 Cylinder head cupper tube
installation and caulking (MUI)
3-4
Chapter 3 SERVICE TOOLS
Maintenance
Tool name Part No. Illustration Usage
item
Basic engine Stainless steel tube installer 35C91-00600 Cylinder head stainless steel tube
installation and removal (ECUI)
Rocker bushing installer 35C91-01800 Rocker bushing replacement
Bushing inside and outside diameters
ø44×ø48 [ø1.73 × ø1.89 in.]
Follower bushing installer 35C91-01700 Cam follower bushing replacement
Bushing inside and outside diameters
ø30×ø34 [ø1.18 × ø1.34 in.]
Idler bushing puller 32591-02500 Idler bushing replacement
Bushing inside and outside diameters
ø50×ø55 [ø1.97 × ø2.17 in.]
Front seal installer assem- 37591-05010 Front oil seal installing
bly Applicable engine models: SH and SR
Rear seal installer assembly 35B91-06010 Rear oil seal installing
Ring expander 37191-03200 Piston ring installing and removal
Applicable diameter ø102 to ø177
[ø4.02 to ø6.97 in.]
Piston installer 37191-07100 Piston installing
Applicable piston diameter: ø89 to
ø178 [ø3.50 to ø7.01 in.]
Cylinder liner remover 32591-14100 Cylinder liner removal
Applicable liner inside diameter: ø145
to ø150 [ø5.71 to ø5.91in.]
Applicable engine models: SA and SH
3-5
Chapter 3 SERVICE TOOLS
Maintenance
Tool name Part No. Illustration Usage
item
Basic engine Cylinder liner installer 32591-01800 Cylinder liner installing
Applicable liner inside diameter ø150
[ø5.91in.]
Connecting rod bushing 32591-18010 Connecting rod bushing replacement
installer Bushing inside and outside diameters
ø55×ø59 [ø2.17×ø2.32 in.]
ø58 × ø62 [ø2.28×ø2.44 in.]
ø65× ø70 [ø2.56×ø2.76 in.]
Applicable engine models: SB, SA,
SH and SN
Crankcase grinder 32591-04050 Crankcase liner counterbore refacing
Applicable engine models: SA and SH
Cam gear stop bolt 35B91-16500 Cam gear retaining to pull out only
camshaft
M12×1.25
Cam bushing installer 35B91-02010 Cam bushing replacement
Cam bushing installer 35C91-11600 Cam bushing replacement
Unit injector puller 35C91-11400 Unit injector removal
Liner pusher assembly 37591-06020 Cylinder liner flange protrusion mea-
surement
Unit injector Clamp 48749-01000 Fixing to vice
(MUI)
3-6
Chapter 3 SERVICE TOOLS
Maintenance
Tool name Part No. Illustration Usage
item
Unit injector Clamp 48493-01000 Fixing to vice
(ECUI)
Connector 48749-00101 Fuel injection valve opening pressure
adjustment
(MUI)
M45 × 1.5
M14 × 1.5
Connector 48493-00100 Fuel injection valve opening pressure
adjustment
(ECUI)
Height gauge 35C91-01900 Tappet height adjustment to install to
engine
81 mm [3.19 in.] at BTDC120°
(ECUI)
Height gauge 35C91-11100 Fuel injection timing adjustment to
install to engine
80 mm [3.15 in.] at the specified fuel
injection timing
(MUI)
O-ring tool 48493-00200 O-ring-install
(ECUI)
Spanner 48493-00500 Solenoid armature install / removal
(ECUI)
Lubrication Oil pump bushing puller MH061059 Oil pump bushing replacement
System Bushing inside and outside diameters
ø40×ø44 [ø1.57 × ø1.73 in.]
(Press-in only for S12H engine)
Cooling system Spring snap pliers 37591-03100 Water pump cover hole snap ring
installing and removal
Applicable ring diameter ø180 to ø300
[ø7.09 to ø11.81 in.]
3-7
Chapter 3 SERVICE TOOLS
Maintenance
Tool name Part No. Illustration Usage
item
Cooling system Impeller remover 37591-03200 Water pump impeller
pull-out
Jack bolt hole of applicable impeller
PCD=ø72, ø54, ø44 [ø2.83, ø2.13 and
ø1.73 in.]
Ring remover 37791-03400 Pull-out of water pump unit seal (rota-
tion side) ring
Ring installer 37791-03300 Press-in and positioning of water
pump unit seal (rotation side) ring
Inside and outside diameters ø33×ø45,
L80 [ø1.30 × ø1.77, L3.15]
Unit seal installer 37191-06300 Water pump ynit seal (stationary side)
press-in
Applicable seal case outside diameter
ø52 [ø52 in.]
Test and Projection plate 37598-09201 Crankcase counter bore depth mea-
adjustment surement
L 230 × W 50 × T 15 [9.06 × 1.97 ×
0.59 in.]
Connecting rod gauge 32691-01500 Connecting rod end play adjustment
Sheet thickness : 0.5 mm [0.02 in.]
Connecting rod gauge 32691-01600 Connecting rod end play adjustment
Sheet thickness : 0.6 mm [0.024 in.]
Nozzle tester 04239-00050 Injection valve opening pressure mea-
Nozzle connection pipe surement
Pressure range 0 to 50 MPa {0 to 510
kgf/cm2} [0 to 7252 psi]
Applicable engine models: SB, SA
M141.5
(Nozzle mounting side) and SH
Injection tester 48493-03000 Injection valve opening and quantity
adjustment
3-8
ChapChapter 3 SERVICE TOOL
Maintenance
Tool name Part No. Illustration Usage
item
Test and adjust- Compression gauge 33A91-03100 Compression pressure measurement
ment Pressure range 0 to 7 MPa
{0 to 71 kgf/cm2} [0 to 1015 psi]
Gauge adapter 35C91-12200 Compression pressure measurement
UNF 5/8 - 18
Spacer 35C91-02100 Compression pressure measurement
Remove UI rocker arm to install
Leak tester assembly 35C91-03010 Cylinder head hydraulic pressure test
Rack set jig 35B91-03010 to adjust rack 0 position
(MUI)
Service adapter 35B91-09100 Adapter between ECM3 and PC
(ECUI)
3-9
