Chapter 3 SERVICE TOOLS

1. Special Tools............................................................................................................ 3-3

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 Chapter 3 SERVICE TOOLS

1. Special Tools
Chapter 3 SERVICE TOOLS

Maintenance Tool name Part No. Illustration Usage

item
Basic engine Rocker bushing tool 37591-02600 Rocker Bushing - Replace
Bushing inside diam : ø36 X 40 mm
[1.38 X1.57 in.]

Front 32591-02500 Front Idler Bushing - Replace

Idler bushing puller Bushing inside diam : ø50 X 55 mm
[1.97 X 2.17 in.]

Rear 37791-02500 Rear Idler Bushing - Replace

Idler bushing Bushing inside/outside diam : ø65 X
installer 70 mm [2.56 x 2.76 in.]

Eye bolt 37591-02500 Piston - lift

M10 × 1.25

Eye bolt 05930-00200 Gear case - lift

M12 × 1.25

Eye bolt 45815-32301 Piston - lift

M10 × 1.5

Eye bolt 37791-02100 Main bearing cap -

Remove

M27 × 1.5

Eye nut 37591-02400 Cylinder head assembly - install/

remove

M14 × 1.5

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Chapter 3 SERVICE TOOLS

Maintenance Tool name Part No. Illustration Usage

item
Basic engine Front seal 37591-05010 Front oil seal - install
Installer assembly

Rear seal installer assembly 37791-06010 Rear oil seal - install

Slinger installer 37491-02100 Rear slinger - Press-in

With installer guide

installer guide 37491-02200

Valve guide remover 33591-04300 Valve guide - remove

ø17 × L100 Applicable valve guide inside/outside
diam:
ø10 X 18 mm [0.39 X 0.71 in.]

ø10 × L50

Guide and 37191-11500 Valve guide and stem seal -

seal installer Install
Guide height: 31.5 mm [1.240 in.]
Stem seal height: 34.3 mm [1.350 in.]
Inlet and exhaust
With single valve spring

Guide and 37591-12300 Valve guide and stem seal -

seal installer Install
Exhaust double valve spring spec

Valve seat 37591-04010 Valve seat - press-in

installer Big outside diam: ø59 mm [2.32 in.]
Small outside diam: ø48.5 mm
[19.095 in.]

Crankcase 37591-07010 Crankcase counterbore depth - reface

grinder

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 Chapter 3 SERVICE TOOLS

Maintenance Tool name Part No. Illustration Usage

item
Basic engine Connecting rod 37591-01010 Connecting rod bushing - Install and
bushing installer remove

Nozzle remover 33591-10101 Fuel injection nozzle - remove

Connecting rod Sheet thick- Connecting rod end play - Set

gauge ness : 0.5 mm
[0.02 in.]
37791-01500
Sheet thick-
ness : 0.6 mm
[0.024 in.]
37791-01600
Cylinder liner remover 37591-04100 Cylinder liner - Remove
Applicable cylinder liner inner diam:
ø170 mm [6.69 in.]

Jack bolt 37791-02200 Extra flywheel and damper - Remove

M12 × 1.25 - 190mm

Jack bolt 64362-68500 Water pump plate -

Remove

M12 × 1.25㨺95mm

Valve spring 33591-04500 Valve spring - install/remove

pusher

Valve lapper Suction cup Valve lapping

diam:
ø35 mm
[1.38 in.]
30091-07500
Suction cup
diam:
ø40 mm
[1.57 in.]
30091-08800

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Chapter 3 SERVICE TOOLS

Maintenance Tool name Part No. Illustration Usage

item
Basic engine Valve seat cutter Shaft Valve Seat - Reface
37591-06400 Width across flats: 32 mm [1.26 in.]
Applicable seat inside/outside diame-
ø10 mm ter: ø45 to 66 [1.77 to 2.60 in.]

W1 1/8 -18

Cutter
37591-06430

W1 1/8 -18
θ＝30°
Valve seat puller 32591-04200 Valve seat - remove

Head bolt plate 37598-08900 Cylinder head bolt - Tighten with con-
trolled angle

Projection 37598-09201 Depth of counterbore in crankcase -

Plate measure
L230 X W50 X T15 mm
[L9.06 X W1.97 X T0.59 in.]

Bolt 37591-06300 Cylinder liner flange

protrusion - measure
(Liner presser jig)

M22 × 2.5 - 115mm

Liner pusher 37591-06200 Cylinder liner flange

protrusion - measure
(Liner presser jig)

Ring expander 37191-03200 Piston ring - install/remove

Applicable diam: o101.6 to 177.8 mm
[4.00 to 7.00 in.]

Piston installer 37191-07100 Piston- Install

Applicable piston diam:
ø89 to 178 mm [3.50 to 7.01 in.]

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 Chapter 3 SERVICE TOOLS

Maintenance Tool name Part No. Illustration Usage

item
Fuel Nozzle tester 83091-03301 Fuel injection nozzle opening pressure
system - measure

Socket 58309-73100 Fuel injection

Pump gear and water pump gear -
install/remove

Fuel 37591-06100 Fuel injection pump coupling clear-

Injection pump coupling ance - adjust
gauge GO: 48.75 mm [1.9193 in.]
NO GO: 49.25 mm [1.9390 in.]

Gear stand 37891-06100 Feed pump bearing - Press-in

Bearing installer 37891-06200 Feed pump bearing - Press-in

Oil seal 37891-06300 Feed pump oil seal - Press-in

installer

Bearing installer 37891-06400 Feed pump bearing - Press-in

Feed pump 37891-06500 Backlash Between Feed Pump Drive

backlash tool Gear and Driven Gear - Measure

Cooling Water pump pliers 37591-03100 Water pump cover

system Hole snap ring - install/removal
Applicable diam:
ø180 to 300 [7.09 to 11.81 in.]

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Chapter 3 SERVICE TOOLS

Maintenance Tool name Part No. Illustration Usage

item
Cooling Impeller remover 37591-03200 Water pump impeller - pull-out
system M18 × 1.5 mm [0.059 in.]

Ring remover 37791-03400 Water pump Unit Seal - Remove

Unit seal 37191-06300 Water pump unit seal - Press-in

installer

Ring installer 37791-03300 water pump unit seal ring - Press-in

Seal ring 45B91-02100 Water pump unit seal - Install

installer

Inlet Exhaust manifold A 37791-08101 Exhaust connecter - Install/remove

Exhaust wrench Width across flats : 19mm [0.75 in.]
system Socket size : 12.7 mm [0.5 in.]

Exhaust manifold B wrench 37791-08201 Exhaust connecter - Install/remove

Width across flats : 19mm [0.75 in.]
Bolt across flats : 19 mm [0.75 in.]

Inspection and Compression gauge 33A91-01700 Compression Pressure - Measure

measurement Measurement range: 0 to 7 MPa
{0 to 71 kgf/cm2} [0 to 1015 psi]

Gauge adapter 37591-02200 Compression Pressure - Measure

U5/8-18

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 Chapter 3 SERVICE TOOLS

Maintenance Tool name Part No. Illustration Usage

item
Inspection and Belt gauge 32591-09100 Belt tension - measure
measurement 20
25
30

15
10
5

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