Professional Documents
Culture Documents
(XU7JPL3)
Service Manual
Special tools
Chapter:
Product:
SAMAND XU7JPL3
Section:
Special Tools
SAMAND
Service Manual
Foreword:
This Service Manual contains descriptions of the following categories for the
Samand:
Special tools
Tool name
Tool code
243 02 001
243 02 002
243 03 001
244 01 001
244 02 001
244 02 002
244 02 003
244 03 002
244 04 001
10
244 07 001
11
244 08 001
12
244 08 007
13
244 08 008
14
244 08 009
15
244 09 001
16
Flywheel locker
244 10 001
17
244 12 004
18
244 12 005
19
Piston support
244 12 006
20
244 12 008
21
244 12 009
22
Piston support
244 12 017
23
244 13 014
24
244 14 001
25
244 15 001
26
244 15 002
27
244 15 004
28
244 16 006
29
Valve lifter
244 16 007
30
244 17 002
Tool name
Tool code
31
244 18 001
32
244 19 001
33
244 19 002
34
244 25 001
35
246 01 001
36
Cutting blade
246 04 002
37
Scraping blade
246 04 003
38
246 04 005
39
246 06 001
40
249 01 002
41
249 01 003
42
249 01 006
43
249 01 010
44
249 03 001
45
249 03 002
46
249 04 003
47
249 04 005
48
249 04 006
49
249 04 009
50
250 03 002
51
250 03 003
52
251 01 001
53
Set of 4 straps
251 01 005
54
Locking cone
251 02 001
55
251 02 002
56
251 02 003
57
251 02 008
58
Thrust button
251 02 009
59
251 02 016
60
251 02 017
Tool name
Tool code
61
251 02 018
62
251 02 019
63
Thrust plate
251 02 020
64
251 03 003
65
252 02 002
66
254 05 001
67
254 05 002
68
Thrust button
254 07 001
69
254 08 001
70
Adjustment spacer
254 09 001
71
Adjustment spacer
254 09 002
72
Adjustment spacer
254 09 003
73
254 12 002
74
254 12 003
75
254 12 004
76
254 12 005
77
254 12 006
78
254 12 008
79
254 12 009
80
254 12 010
81
254 12 011
82
255 02 001
83
257 01 003
84
Dial gauge
257 02 002
85
Connector
265 01 002
86
265 01 003
87
265 01 004
88
Reducing adaptor
265 01 006
89
Graduated beaker
265 01 007
90
265 01 008
Tool name
Tool code
91
265 01 009
92
265 01 010
93
Washer
265 01 011
94
265 01 012
95
Regulator retainer
265 01 013
96
266 01 001
97
266 01 002
98
268 01 001
99
268 02 001
100
268 03 001
101
268 04 001
102
268 04 002
Tool drawing :
Workshop section
Mechanical
Remarks :
Tool drawing :
Workshop section
Mechanical
Remarks :
Tool Drawing :
Workshop section
Mechanical
Remarks :
Usage : It is explained in the engine workshop manual with old document code
1303R00201851/1 or new code no. 000235 on page 47.
By aligning the camshaft gear hole with the pin hole on the cylinder head, the adjusted timing of
camshaft is locked by this pin.
Tool drawing :
Workshop section
Mechanical
Remarks :
Tool drawing :
Workshop section
Mechanical
Remarks :
Usage : It is used for measuring surface level difference of liners, with each other and with
cylinder block surface.
Tool drawing :
Workshop section
Mechanical
Remarks :
Usage : It is explained in the engine workshop manual with old document code
1303R00201851/1 or new document code 000235 on page 80.
This tool is used as a stand and as the base surface, to compare and adjust the surface level
differences of cylinder liners and cylinder block.
Tool drawing :
Workshop section
Mechanical
Remarks :
Tool drawing :
Workshop section
Mechanical
Remarks :
Usage : It is used for removing and tightening crankcase oil draining plug.
Tool drawing :
Workshop section
Mechanical
Remarks :
Workshop section
Mechanical
Remarks :
10
Tool drawing :
Workshop section
Mechanical
Remarks :
11
Usage : It is explained in the engine workshop manual with old document code 1303
R00201851/1 or new document code 000235 on page 66.
When installing the crankshaft rear end oil seal, it is used to push oil seal into its seat safely and
up to the suitable limit.
Tool drawing :
Workshop section
Mechanical
Remarks :
12
Workshop section
Mechanical
Remarks :
13
Usage : Since tightening torques of some bolts are given in degrees of angle, this tool is used to
tighten bolts on the basis of degrees of angle.
Tool drawing :
Workshop section
Mechanical
Remarks :
14
Usage : It is explained in the engine workshop manual with old document code
1303R00201851/1 on page 38.
It is used to keep the cylinder liners fixed in the cylinder block.
Tool drawing :
Workshop section
Mechanical
Remarks :
15
Usage : It is used to lock flywheel and prevent flywheel and crankshaft from rotating when
loosening flywheel and clutch disc bolts.
Tool drawing :
Workshop section
Mechanical
Remarks :
16
Usage : This tool is used to align the holes of piston and connecting rod end, after alignment is
complete, the piston is fixed up in this position and the connecting rod small end is heated
indirectly (i.e. without having direct contact with flame) on an electric stove having a cast iron
heating plate and is heated to a temperature of about 273 degrees C. It is then placed in its
location in the piston with their holes aligned and the piston pin is then installed. Note that this
operation should be performed fast so that the heated connecting rod does not get cold before
the piston pin is installed in it.
Tool drawing :
Workshop section
Mechanical
Remarks :
17
Tool drawing :
Workshop section
Mechanical
Remarks :
18
Usage : This tool is placed between piston and the platform of piston pin installing device, so that
when the piston pin is installed it may sit into the piston with equal distance at both ends.
Tool drawing :
Workshop section
Mechanical
Remarks :
19
Usage : This tool is used as a handle and as a fixer of the piston pin between itself and the
inserter, which are then together inserted into the piston.
Tool drawing :
Workshop section
Mechanical
Remarks :
20
Usage : It is explained in the engine workshop manual with old document code
1303R00201851/1or new document code 000235 on page 71.
It is used along with the handle tool to install piston pin into piston and connecting rod.
Tool drawing :
Workshop section
Mechanical
Remarks :
21
Usage : This tool is placed between piston and the platform of piston pin installing device, so that
when the piston pin is installed it may sit into the piston with equal distance at both ends.
Tool drawing :
Workshop section
Mechanical
Remarks :
22
Usage : It is used for removing engine from vehicle and for installing it back, and also for shifting
engine in the workshop.
Tool drawing :
Workshop section
Mechanical
Remarks :
23
Installer plates
Workshop section
Mechanical
Remarks :
24
Tool drawing :
Workshop section
Mechanical
Remarks :
25
Usage : After the camshaft oil seal edge is smeared with oil and positioned on its installing
location, this tool is used to push it into its seat properly and safely.
Tool drawing :
Workshop section
Mechanical
Remarks :
26
Workshop section
Mechanical
Remarks :
27
Usage : By using this tool and a plastic hammer, the valve stem oil seal is installed.
Tool drawing :
Workshop section
Mechanical
Remarks :
28
Usage : This tool is used to replace the valve stem oil seal without the need of removing cylinder
head.
.
Tool drawing :
Workshop section
Mechanical
Remarks :
29
Usage : Since the fuel supply line is a safety issue, specially the hose clips, therefore during
repair works this special tool is used to remove and install the hose clips safely and prevents
them from getting overstretched and inefficient.
Tool drawing :
Workshop section
Mechanical
Remarks :
30
Workshop section
Mechanical
Remarks :
31
Workshop section
Mechanical
Remarks :
32
Workshop section
Mechanical
Remarks :
33
Usage : This tool is used for removing the crankshaft pulley by first removing the pulley retainer
bolt and then placing the pulley arm ends in the belt groove such that the extractor bolt sits on the
crankshaft head bolt. Then by tightening the extractor bolt the pulley is pulled out of its place.
Tool drawing :
Workshop section
Mechanical
Remarks :
34
Workshop section
Mechanical
Remarks :
35
Usage : This cutter blade is used after mounting it on the power tool, for removing the extra
adhesive from around the windshield glasses.
Tool drawing :
Workshop section
Mechanical
Remarks :
36
Usage : By mounting this blade on the power tool, the extra adhesive sticking on the windshield
glasses are scraped out.
Tool drawing :
Workshop section
Mechanical
Remarks :
37
Workshop section
Mechanical
Remarks :
38
Usage : This tool is used for removing and tightening the fuel gauge sender unit nut located in
fuel tank.
Tool drawing :
Workshop section
Mechanical
Remarks :
39
Workshop section
Mechanical
Remarks:
40
Usage : These forks along with plate and spring compressor device are used for compressing
springs of front suspension.
Tool drawing :
Workshop section
Mechanical
Remarks :
41
Usage : It is explained in the front and rear suspension workshop manual with old document
code 1303R01301891/1 or new document code 000241 on page 15.
By selecting one of these plates depending on hole positions of the shock absorber counter plate
and fitting it on the spring compressor device, the spring is compressed and shock absorbers are
removed and installed.
This pressure plate is fitted on one side of the spring compressor device which is employed for
compressing the springs of the shock absorbers of the front axle. Without this plate and the forks,
the spring compressor device cannot be used.
Tool drawing :
Workshop section
Mechanical
Remarks :
42
Usage : It is explained in the front and rear suspension workshop manual with old document
code 1303R01301891/1 or new document code 000241 on pages 15 and 16.
By using this tool the front shock absorber spring is compressed to help removal and installation
of shock absorber and related parts.
Tool drawing :
Workshop section
Mechanical
Remarks :
43
Workshop section
Mechanical
44
Usage : This tool is part of the tool group having code no. 24903001, which is used for adjusting
distance between car body and ground.
Tool drawing :
Workshop section
Mechanical
Remarks :
45
Workshop section
Mechanical
Remarks :
46
Workshop section
Mechanical
Suspension
Remarks :
47
Usage : It is explained in the front and rear suspension workshop manual with old document
code 1303R01301891/1 or new document code 000241 on page 54.
With the help of this tool and using it as a substitute of shock absorber and adjusting its length,
the torsion bars can be removed and installed.
Tool drawing :
Workshop section
Mechanical
Suspension
Remarks :
48
Usage : It is explained in the front and rear suspension workshop manual with old document
code 1303R01301891/1 or new document code 000241 on page 11.
This cable is used when the front suspension spring is compressed for removing and installing
the shock absorber.
Tool drawing :
Workshop section
Mechanical
Suspension
Remarks :
49
Usage : It is used for installing the outer ball bearing of rear wheel flexible arm.
Tool drawing :
Workshop section
Mechanical
Suspension
Remarks :
50
Usage : It is used for installing the inner ball bearing of the rear wheel flexible arm. By using this
tool the ball bearing does not suffer any damage when being pushed into place with hammer
strokes.
Tool drawing :
Workshop section
Mechanical
Suspension
Remarks :
51
Usage : It is explained in the front and rear suspension workshop manual with old document
code 1303R1301891/1 or new document code 000241 on page 28.
This socket wrench along with a spanner is used to remove and install the ball joint located under
shock absorber.
Tool drawing :
Workshop section
Mechanical
Suspension
Remarks :
52
Usage: These straps along with some other tools are used to pull the suspension system
together during steering alignment operation.
.
Tool drawing :
Workshop section
Mechanical
Suspension
Remarks :
53
Usage : It is explained in the front and rear suspension workshop manual with old document
code 1303R01301891/1 or new document code 000241 on page 28.
This tool along with tool no. 25102002 is used for extracting front wheel ball bearing.
Tool drawing :
Workshop section
Mechanical
Remarks :
54
Usage : This tool along with other complementary tools is used for pulling out front wheel hub.
Tool drawing :
Workshop section
Mechanical
Remarks :
55
Workshop section
Mechanical
Remarks :
56
Usage : This tool along with complementary tools are used for installing inner ball bearing of the
front wheel flexible arm.
Tool drawing :
Workshop section
Mechanical
Remarks :
57
Usage : It is explained in the front and rear suspension workshop manual of Samand with old
document code 1303R01301891/1 or new document code 000241 on page 28.
It is used for extracting and installing front wheel hub ball bearing.
Tool drawing :
Workshop section
Mechanical
Remarks :
58
Usage : This tool is used for securing the front and the rear hubs.
Tool drawing :
Workshop section
Mechanical
Remarks :
59
Usage : This tool is used as a cross-bar to anchor wheel hub retainer tool.
Tool drawing :
Workshop section
Mechanical
Remarks :
60
Usage : This tool along with complementary tools is used to remove and install front wheel hub
and ball bearing.
Tool drawing :
Workshop section
Mechanical
Remarks :
61
Workshop section
Mechanical
Remarks :
62
Usage : This tool along with other components of tool set 7-0615 (special codes 25102003,
25102002, 25102001 and 25102019) is used for installing the front wheel hub ball bearing.
Tool drawing :
Workshop section
Mechanical
Remarks :
63
Usage : This tool is used to keep the driveshafts fixed in their positions during repair works.
Tool drawing :
Workshop section
Mechanical
Remarks :
64
Workshop section
Mechanical
Remarks :
65
Tool drawing :
Workshop section
Mechanical
Remarks :
66
Tool drawing :
Workshop section
Mechanical
Remarks :
67
Usage : This tool is used as a seat and under-pusher when installing and removing gearbox parts
under a press.
Tool drawing :
Workshop section
Mechanical
Remarks :
68
Usage : This tool is used for easy lifting and shifting of gearbox.
Tool drawing :
Workshop section
Mechanical
Remarks :
69
Usage : By placing this shim on the outer race of gearbox input shaft ball bearing, and then by
installing the clutch bearing sleeve, the suitable sized shim is selected for adjustment of
clearance and is then taken out.
Tool drawing :
Workshop section
Mechanical
Remarks :
70
Usage : This tool is used for adjustment of tachometer gear clearance in the gearbox.
Tool drawing :
Workshop section
Mechanical
Remarks :
71
Usage : This shim is used for determining size of the main shim behind ball bearing of input
shaft.
Tool drawing :
Workshop section
Mechanical
Remarks :
72
Workshop section
Mechanical
Remarks :
73
Tool drawing :
Workshop section
Mechanical
Remarks :
74
Usage : By using this tool under a press, roller bearings of the differential carrier are installed.
Tool drawing :
Workshop section
Mechanical
Remarks :
75
Workshop section
Mechanical
Remarks :
76
Workshop section
Mechanical
Remarks :
77
Usage : By combining this tool with a sliding hammer, the splined pin of clutch release fork is
removed.
Tool drawing :
Workshop section
Mechanical
Remarks :
78
Usage : This tool is used for undamaged and reliable pushing of the clutch release sleeve oil seal
into its seat.
Tool drawing :
Workshop section
Mechanical
Remarks :
79
Workshop section
Mechanical
Remarks :
80
Workshop section
Mechanical
Remarks :
81
Usage : For centering clutch disc and clutch plate on the flywheel.
Tool drawing :
Workshop section
Mechanical
Remarks :
82
Usage : For measuring the brake booster vacuum, braking pressure and fuel supply pressure
(fuel pressure regulator performance) (L6A).
Tool drawing :
Workshop section
Mechanical
Remarks :
83
Usage : It is explained in the engine workshop manual with old document code
1303R00201851/1 or new document code 000235 on page 46 and 78.
It is used for measuring the crankshaft horizontal play and as well as warping level of parts such
as discs, etc.
Tool drawing :
Workshop section
Mechanical
Remarks :
84
Tool drawing :
Workshop section
Mechanical
Remarks :
85
Workshop section
Mechanical
Remarks :
86
Usage : It is used for measuring pressure of fuel supply system. By using a three way connector
it is included in the system before fuel injector rack and the system pressure is then measured
with this tool.
Tool drawing :
Workshop section
Mechanical
Remarks :
87
Usage : This tool is used for connecting pressure gauge to fuel supply hoses for measuring fuel
pressure.
Tool drawing :
Workshop section
Mechanical
Remarks :
88
Usage : It is used when testing fuel pump performance, for measuring the amount of fuel which is
pumped by the fuel pump in a given period of time. A hose is connected to the pressure regulator
and the other end of hose is put into a graduated beaker. The fuel pump is put to work by turning
on the ignition switch for 15 seconds. The amount of fuel pumped in this period should be at least
540 cc.
Tool drawing :
Workshop section
Mechanical
Remarks :
89
Workshop section
Mechanical
Remarks :
90
Usage : It is used for connecting pressure gauge to fuel system in front of injector rack. One end
of it is connected to the rack vent and to its upper end the pressure gauge is connected and the
fuel supply pressure is measured.
Tool drawing :
Workshop section
Mechanical
Remarks :
91
Workshop section
Mechanical
Remarks :
92
Usage : This washer is used as a sealing ring when connecting pressure gauge to fuel supply
system adaptor.
Tool drawing :
Workshop section
Mechanical
Remarks :
93
Injector
rack
pressure
Usage : This equipment is used for measuring fuel pressure inside the fuel feed rack.
Tool drawing :
Workshop section
Mechanical
Remarks :
94
Usage : This tool is used for fixing the pressure regulator unit on heat shield inside the engine
chamber.
Tool drawing :
Workshop section
Mechanical
Remarks :
95
Tool drawing :
Workshop section
Mechanical
Remarks :
96
Workshop section
Mechanical
Remarks :
97
Tool drawing :
Workshop section
Mechanical
Remarks :
98
Tool drawing :
Workshop section
Mechanical
Remarks :
99
Usage : This tool is used for holding the A/C compressor clutch to facilitate clutch bolt removal.
Tool drawing :
Workshop section
Mechanical
Remarks :
100
Workshop section
Mechanical
Remarks :
101
Tool drawing :
Workshop section
Mechanical
Remarks :
102
SAMAND
Service Manuals
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