Samand: Service Manual

SAMAND
(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
This manual should be used as service manual and s workbook for

training instructors and technicians. We reserve the right to introduce
change without prior notice.
List of Special Tools for Peugeot 405, Pars and Samand

S.no.
Tool name
Tool code
Pliers for 'clic' collars
243 02 001
Pliers for 'oetiker" collars
243 02 002
Seal removing pliers
243 03 001
Camshaft gear timing pin
244 01 001
Dial gauge support rod
244 02 001
Dial gauge plate
244 02 002
Dial gauge support
244 02 003
Spark plug wrench
244 03 002
Drain plug wrench
244 04 001
10
Cup ress (valve spring compressor component)
244 07 001
11
Cylinder head bolts socket wrench
244 08 001
12
Crankshaft rear oil seal drift
244 08 007
13
Set of 2 cylinder head releasing levers (cylinder head lifters)
244 08 008
14
Angular tightening tool
244 08 009
15
Liner retaining clamps
244 09 001
16
Flywheel locker
244 10 001
17
Piston pin installing device
244 12 004
18
Piston pin inserter
244 12 005
19
Piston support
244 12 006
20
Piston pin inserter handle
244 12 008
21
Gudgeon pin guide (piston pin inserter)
244 12 009
22
Piston support
244 12 017
23
Engine lifting equipment
244 13 014
24
Tool for fitting rear main bearing seals
244 14 001
25
Crankshaft front end oil seal drift
244 15 001
26
Camshaft oil seal drift
244 15 002
27
Tool for fitting rear main bearing seals
244 15 004
28
Valve stem seal drift
244 16 006
29
Valve lifter
244 16 007
30
Fuel hose clip pliers
244 17 002

S.no.
Tool name
Tool code
31
Filling cylinder for bleeding cooling system (coolant charger)
244 18 001
32
Wrench for tightening flexible engine mounting
244 19 001
33
Flexible-bush extraction and fitting tool
244 19 002
34
Crankshaft pulley extractor
244 25 001
35
Pliers for removing blanks and clips from trim
246 01 001
36
Cutting blade
246 04 002
37
Scraping blade
246 04 003
38
Adhesive tape cutting and scrapping blade driver
246 04 005
39
Fuel tank sender unit wrench
246 06 001
40
Set of four setting rods (height gauge)
249 01 002
41
Set of clamps of front springs
249 01 003
42
Front spring compression plate
249 01 006
43
Spring compressor alone
249 01 010
44
Suspension clamping equipment
249 03 001
45
Set of four shackles
249 03 002
46
Tool for opening pivot (knuckle widener)
249 04 003
47
Sliding hammer adopter
249 04 005
48
Dummy shock absorber
249 04 006
49
Spring retaining cables
249 04 009
50
Ball bearing drift
250 03 002
51
Thrust cup fitting drift
250 03 003
52
Pivot ball joint wrench
251 01 001
53
Set of 4 straps
251 01 005
54
Locking cone
251 02 001
55
Set of two halves
251 02 002
56
Thrust plate for bearing extractor
251 02 003
57
Hub and bearing extractor nut
251 02 008
58
Thrust button
251 02 009
59
Hub retaining tool body
251 02 016
60
Hub retaining tool extension
251 02 017

S.no.
Tool name
Tool code
61
Hub and bearing extractor bolt
251 02 018
62
Thrust plate for bearing extractor
251 02 019
63
Thrust plate
251 02 020
64
Propeller shaft support
251 03 003
65
Dipstick for checking compressor oil level
252 02 002
66
Splitter/extractor for over hauling gearbox
254 05 001
67
Fifth speed synchronizer hub extractor
254 05 002
68
Thrust button
254 07 001
69
Sling for gearbox/final drive
254 08 001
70
Adjustment spacer
254 09 001
71
Adjustment spacer
254 09 002
72
Adjustment spacer
254 09 003
73
Input shaft rear bearing outer race drift
254 12 002
74
Selector and engagement shaft oil seal drift
254 12 003
75
Differential bearing drift
254 12 004
76
Input & output shafts bearing outer race drift
254 12 005
77
Input & output shafts bearing outer race drift
254 12 006
78
Gear lever pin puller
254 12 008
79
Clutch sleeve oil seal drift
254 12 009
80
Final-drive left side oil seal drift
254 12 010
81
Final-drive right side oil seal drift
254 12 011
82
Clutch centering mandrel
255 02 001
83
Vacuum and pressure gauge
257 01 003
84
Dial gauge
257 02 002
85
Connector
265 01 002
86
Hose for checking fuel pump output
265 01 003
87
Six bar pressure gauge
265 01 004
88
Reducing adaptor
265 01 006
89
Graduated beaker
265 01 007
90
Hose for helping in fuel system adjustment, 6mm diameter
265 01 008

S.no.
Tool name
Tool code
91
Pressure gauge connector
265 01 009
92
Fuel system adjustment tool kit
265 01 010
93
Washer
265 01 011
94
Injector rail pressure regulator unit
265 01 012
95
Regulator retainer
265 01 013
96
Hose blocking clamp (26mm diameter)
266 01 001
97
Hose blocking clamp (70 mm diameter)
266 01 002
98
A/C compressor pressure plate extractor
268 01 001
99
Overhaul kit for Sanden compressor
268 02 001
100
Adjustable lug wrench
268 03 001
101
Pipe disconnector (1/2 blue)
268 04 001
102
Pipe disconnector (5/18 black)
268 04 002
Special code : 243 02 001

Tool name : Pliers for 'clic' collars
Usage : It is used for installing and removing driveshaft gaiter clips.
Tool drawing :
Vehicle model & usage location
Workshop section
Peugeot 405 GL-XU52C /Peugeot 806

/Peugeot 306
Usage location: Front axle
Mechanical
Remarks :

Tool name : Pliers for 'oetikar' collars
Usage : It is used for installing and removing driveshaft gaiter clips.
Tool drawing :
Workshop section
Peugeot 405 GL-XU52C /Peugeot 405GLX-XU92C /Peugeot Pars XU7JP/K

/Peugeot 405 GLX-XU7JP/K /Peugeot Pars
XU7JP4/L4 /Peugeot 405 GLI /Peugeot
Pars XU7JP/L3 /Peugeot Pars ELX
/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405
bi-fuel CNG /Samand XU7JP/K /Samand
XU7JP/L3 /Samand CNG /Samand LX
/Samand EL /Samand Sareer /Samand EL
bi-fuel.
Usage location: Front axle
Mechanical
Remarks :

Tool name : Seal removing pliers
Usage : It is used for removing valve stem oil seals.
Tool Drawing :
Workshop section

/Samand EL /Samand Sarir /Samand EL bifuel.
Usage location: Engine
Mechanical
Remarks :

Tool name : Camshaft gear timing pin
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

GLX-XU92C
Mechanical
Remarks :

Tool name : Dial gauge support rod
Usage : It is used for measuring crankshaft horizontal play.
Tool drawing :
Workshop section

Mechanical
Remarks :
Special code : 24402002

Tool name : Dial gauge plate
Usage : It is used for measuring surface level difference of liners, with each other and with
cylinder block surface.
Tool drawing :
Workshop section
Peugeot 206 TU3JP+MA5/Peugeot 405

GL-XU52C
/Peugeot
405-GLX-XU92C
/Peugeot Pars XU7JP/K /Peugeot 405
GLX-XU7JP/K /Peugeot Pars XU7JP4/L4
/Peugeot 405 GLI /Peugeot Pars XU7JP/L3
/Peugeot Pars ELX /Peugeot 405 GLXXU7JP/L3 /Peugeot 405 bi-fuel CNG
/Samand XU7JP/K /Samand XU7JP/L3
/Samand CNG /Samand LX /Samand EL
/Samand Sarir /Samand EL bi-fuel.
Mechanical
Remarks :

Tool name : Dial gauge support
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
Peugeot 405 GL-XU52C

Mechanical
Remarks :

Tool name : Spark plug wrench
Usage : It is used for removing and installing spark plugs.
Tool drawing :
Workshop section

Mechanical
Remarks :

Tool name : Drain plug wrench.
Usage : It is used for removing and tightening crankcase oil draining plug.
Tool drawing :
Workshop section

Mechanical
Remarks :

Tool name : Cup ress (valve spring
compressor component)
1303R00201851/1 or new document code 000235 on page 49, and on pages 10 and 12 of
special tools guide with old document code 1303R02501841 or new document code 000250
During the removal and installation of intake and exhaust valves, it is used along with the valve
spring compressor tool, part no. 24407003, to compress valve spring so that the locking cotters
around the valve stems may be removed or installed.
Tool drawing :
Workshop section

Mechanical
Remarks :
10

Tool name : Cylinder head bolts socket
wrench
Usage : It is used for fastening and removing cylinder head bolts.
Tool drawing :
Workshop section

/Samand EL /Samand Sareer /Samand EL
bi-fuel.
Mechanical
Remarks :
11

Tool name : Crankshaft rear oil seal drift
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

Tool name : Cylinder head releasing levers
(cylinder head lifters)
It is used to separate cylinder head from cylinder block.
Tool drawing :
Workshop section

Mechanical
Remarks :
13

Tool name : Angular tightening tool
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

Usage location: Engine.
Mechanical
Remarks :
14

Tool name : Liner retaining clamps
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

Tool name : Flywheel locker
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

Tool name : Piston pin installing device
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 name : Gudgeon pin guide (piston pin
inserter)
Usage : Before the piston pin is inserted into the piston it should be first fixed to this tool and then
after aligning the connecting rod end hole with the piston hole, it is inserted into the piston.
Tool drawing :
Workshop section

GLX-XU92C
Mechanical
Remarks :
18

Tool name : Piston support
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

Tool name : Piston pin inserter handle
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
Peugeot 405 GL-XU52C /Peugeot Pars

XU7JP/K /Peugeot 405 GLX-XU7JP/K
/Peugeot Pars XU7JP/L3 /Peugeot 405
GLX-XU7JP/L3 /Peugeot 405 bi-fuel CNG
/Samand EL bi-fuel.
Mechanical
Remarks :
20

Tool name : Piston pin inserter XU7
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
Peugeot Pars XU7JP/K /Peugeot 405 GLXXU7JP/K

/Peugeot
Pars
XU7JP/L3
/Samand EL /Samand EL bi-fuel.
Mechanical
Remarks :
21

Tool name : Piston support
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
Peugeot Pars XU7JP/K /Peugeot 405 GLXXU7JP/K

/Peugeot
Pars
XU7JP/L3
/Samand EL /Samand EL bi-fuel.
Mechanical
Remarks :
22

Tool name : Engine lifting equipment
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
Peugeot 405 GLX-XU92C

Mechanical
Remarks :
23

Tool name : Tool for fitting rear main
bearing linear seals
1303R00201851/1 or new document code 000235 on page 77 and 78.
By mounting these plates on installing tool, the rear bearing shell linear rubber seals are installed.
Tool drawing :
Installer plates
Workshop section

Mechanical
Remarks :
24

Tool name : Crankshaft front end oil seal
drift
Usage : It is used for pushing oil seal into its seat safely and up to the right depth.
Tool drawing :
Workshop section

Mechanical
Remarks :
25

Tool name : Camshaft oil seal drift
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

Tool name : Tool for fitting rear main
bearing seals
Usage : For installing rear bearing shell rubber.
Apply oil to surface of plates (1) which are mounted on the rubber holding tool. Harness the shells
(2) between the plates. Then install the shells in their location along with the rubbers and secure
its position in the cylinder block. Fasten the two bolts belonging to the shells. Then pull out the
tool from side of the shells without dislodging shells and rubber.
Tool drawing :
Workshop section

Mechanical
Remarks :
27

Tool name : Valve stem seal drift
Usage : By using this tool and a plastic hammer, the valve stem oil seal is installed.
Tool drawing :
Workshop section
Peugeot 206 TU3JP+MA5

Mechanical
Remarks :
28

Tool name : Valve lifter
Usage : This tool is used to replace the valve stem oil seal without the need of removing cylinder
head.
.
Tool drawing :
Workshop section
Peugeot 405 GL-XU52C /Peugeot GLXXU92C

Mechanical
Remarks :
29

Tool name : Fuel hose clip pliers
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

Tool name : Filling cylinder for bleeding
cooling system (coolant charger)
Usage : It is used during bleeding operation of cooling system. The radiator cap is removed and
the coolant charger is fitted on its place. Then, while maintaining coolant at top level in the
charger reservoir, the draining tap on the cylinder block is loosened and the coolant allowed to
flow until it is free from air bubbles. The tap is then closed and the charger is removed and
radiator cap is put back.
Tool drawing :
Workshop section

Mechanical
Remarks :
31

Tool name : Wrench for tightening flexible
engine mounting
Usage : For removing and installing the engine right bracket damper.
Tool drawing :
Workshop section
Peugeot 206 TU3JP+MA5 /Peugeot 405

GL-XU52C
/Peugeot
405-GLX-XU92C
/Samand Sarir /Samand EL bi-fuel.
Mechanical
Remarks :
32

Tool name : Flexible bush extraction and
fitting tool
Usage : It is used for replacing the engine bracket buffer.
Tool drawing :
Workshop section

Mechanical
Remarks :
33

Tool name : Crankshaft pulley extractor
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

Tool name : Pliers for removing blanks and
clips from trim
Usage : For facilitating quick and easy removal of plugs and clips fastening the door insulation
panels.
Tool drawing :
Workshop section

Usage location: Body hardware
Mechanical
Remarks :
35

Tool name : Cutting blade
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

Tool name : Scraping blade
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
Tool name : Adhesive cutting and scraping

blades' driver
Usage : This power tool along with its attachment blades is used for cutting and scraping off the
extra adhesives remaining around windshield glass during replacement.
Tool drawing :
Workshop section

Mechanical
Remarks :
38

Tool name : Fuel tank sender unit wrench
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

Tool name : Set of four setting rods (height
gauge)
Usage : For knowing height of vehicle body from the ground level, four tools of this kind are
needed. The tool height is graduated with centimeter scale. A spring is provided inside the tool
which helps tool to attain the height to be known. The usage procedure of this tool is as follows:
First loosen release bolt of tool and then by pressing with your palm bring down the central tube
in level with the outer tube. Then tighten release bolt and place tool below door column of vehicle
body. Follow this procedure also with other three tools by placing each under the other door
column, between rear wheels and front wheels columns. Then loosen the release bolt as a result
of which the central tube rises under the spring pressure and touches the columns above it. At
this stage by looking at the graduated scale present on tool, the distance between car body and
ground is determined. If distances are not according to standard values, adjust them.
Tool drawing :
Workshop section

Usage location: Suspension
Mechanical
Remarks:
40
Tool name : Set of clamps for front springs
Usage : These forks along with plate and spring compressor device are used for compressing
springs of front suspension.
Tool drawing :
Workshop section

Usage location: Front suspension
Mechanical
Remarks :
41
Tool name : Front spring compressor plate
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

Tool name : Spring compressor
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

Tool name : Suspension clamping
equipment
Usage : The components accompanying the height gauge include the following:
1- Front suspension aligner. 2- Shackles. 3- Straps.
It is better if a four pole jack lifter is used when performing this operation.
Remove upper and lower nuts of shock absorber. After repairing old shock absorber or replacing
a new one tie the nuts but dont tighten them. Employ front suspension aligner and then by
putting force on the rear axle align it in such a manner that the distance between upper and lower
pivots of the shock absorber X equals to 317/5.
Tightening torque for upper nut of shock absorber is 7 da.Nm and for the lower nut it is 15 da.Nm.
Tool drawing :
Workshop section

Remarks :
Mechanical
44
Tool name : Set of four shackles
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
Tool name : Tool for opening pivot

(knuckle widener)
Usage : For widening of the front axle knuckle gap so that the shock absorber can be easily
removed from the knuckle.
Tool drawing :
Workshop section

Mechanical
Remarks :
46

Tool name : Mandrel (sliding hammer
adopter)
Usage : It is explained in the rear and front suspension workshop manual with old document
This tool along with the sliding hammer is used for removing and as well as for installing the
torsion bars.
.
Tool drawing :
Workshop section

Mechanical
Suspension
Remarks :
47

Tool name : Dummy shock absorber
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

Usage location: Rear suspension
Mechanical
Suspension
Remarks :
48

Tool name : Spring retaining cables
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
Tool name : Ball bearing drift
Usage : It is used for installing the outer ball bearing of rear wheel flexible arm.
Tool drawing :
Workshop section

Mechanical
Suspension
Remarks :
50

Tool name : Thrust cup fitting drift
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

Tool name : Pivot ball joint wrench
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

Tool name : Set of four straps
Usage: These straps along with some other tools are used to pull the suspension system
together during steering alignment operation.
.
Tool drawing :
Workshop section
Peugeot 405 GLX-XU92C /Peugeot 405

GL-XU52C /Peugeot 206 TU3JP+MA5
Mechanical
Suspension
Remarks :
53

Tool name : Locking cone
This tool along with tool no. 25102002 is used for extracting front wheel ball bearing.
Tool drawing :
Workshop section

Mechanical
Remarks :
54
Tool name : Set of two halves
Usage : This tool along with other complementary tools is used for pulling out front wheel hub.
Tool drawing :
Workshop section

Mechanical
Remarks :
55

Tool name : Thrust plate for bearing
extractor
Usage : This tool along with complementary tools, are used for extracting front wheel ball
bearing.
Tool drawing :
Workshop section

Mechanical
Remarks :
56

Tool name : Hub and bearing extractor nut
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

Tool name : Thrust button
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

Tool name : Hub retaining tool body
Usage : This tool is used for securing the front and the rear hubs.
Tool drawing :
Workshop section

Mechanical
Remarks :
59

Tool name : Hub retaining tool extension
Usage : This tool is used as a cross-bar to anchor wheel hub retainer tool.
Tool drawing :
Workshop section

Mechanical
Remarks :
60

Tool name : Hub and bearing extractor bolt
Usage : This tool along with complementary tools is used to remove and install front wheel hub
and ball bearing.
Tool drawing :
Workshop section

Usage location: Front suspension.
Mechanical
Remarks :
61

Tool name : Thrust plate for bearing
extractor
Usage : This tool along with other tools of the corresponding set are used to remove and install
the front wheel hub ball bearing.
Tool drawing :
Workshop section
Peugeot 405 GLX-1600

Mechanical
Remarks :
62

Tool name : Thrust plate
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

Usage location: Front suspension.
Mechanical
Remarks :
63

Tool name : Propeller shaft support
Usage : This tool is used to keep the driveshafts fixed in their positions during repair works.
Tool drawing :
Workshop section

Mechanical
Remarks :
64

Tool name : Dipstick for checking
compressor oil level
Usage : This tool is used to check compressor oil level after compressor or A/C system repairs.
Tool drawing :
Workshop section
Peugeot 206 TU3JP+MA5 /Peugeot 405

GL-XU52C
/Peugeot
405-GLX-XU92C
/Samand Sarir /Samand EL bi-fuel. Usage
location: A/C system
Mechanical
Remarks :
65

Tool name : Splitter/extractor for
overhauling gearbox
Usage : This tool set is used for dismantling gearbox parts such as gears, ball bearings, etc.
Tool drawing :
Workshop section

Usage location: Clutch and manual gearbox
Mechanical
Remarks :
66

Tool name : Fifth speed synchronizer hub
extractor
Usage : It is used for separating fifth gear hub from gearbox.
Tool drawing :
Workshop section

Mechanical
Remarks :
67

Tool name : Thrust button
Usage : This tool is used as a seat and under-pusher when installing and removing gearbox parts
under a press.
Tool drawing :
Workshop section

TU3JP+MA5 /Peugeot 205
Mechanical
Remarks :
68

Tool name : Sling for gearbox/final drive
Usage : This tool is used for easy lifting and shifting of gearbox.
Tool drawing :
Workshop section

Mechanical
Remarks :
69

Tool name : Adjustment spacer
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

Tool name : Input shaft rear bearing outer
race drift
Usage : For safely pushing out and installing the rear outer race of the ball bearing of gearbox
input shaft.
Tool drawing :
Workshop section

Mechanical
Remarks :
73

Tool name : Selector and engagement
shaft oil seal drift
Usage : It is used for safe and reliable installation of oil seal of gear select shaft.
Tool drawing :
Workshop section
Peugeot 405-GLX-1600 /Peugeot

205/Peugeot 605 /Peugeot 806 /Peugeot
406 /Peugeot 306 /Peugeot 206
TU3JP+MA5
Mechanical
Remarks :
74

Tool name : Differential bearing drift
Usage : By using this tool under a press, roller bearings of the differential carrier are installed.
Tool drawing :
Workshop section
Peugeot 306 /Peugeot 605 /Peugeot 205

/Peugeot 806 /Peugeot 206 TU3JP+MA5 /
Mechanical
Remarks :
75

Tool name : Input and output shafts
bearing outer race drift
Usage : It is explained in the gearbox workshop manual with old document code
It is used for installing the roller bearing and the front and rear ball bearings of the input and
output shafts of gearbox.
Tool drawing :
Workshop section
Peugeot 605 /Peugeot 405 GL-XU52C

/Peugeot 205 /Peugeot 406 /Peugeot 806
/Peugeot 306 /Peugeot 206 TU3JP+MA5
Mechanical
Remarks :
76

Tool name : Input and output shafts
bearing outer race drift
It is used for installing the front and rear ball bearings of input and output shafts of gearbox.
Tool drawing :
Workshop section

GL-XU52C /Peugeot 206 TU3JP+MA5
Mechanical
Remarks :
77

Tool name : Gear lever pin puller
Usage : By combining this tool with a sliding hammer, the splined pin of clutch release fork is
removed.
Tool drawing :
Workshop section

GL-XU52C
Mechanical
Remarks :
78

Tool name : Clutch sleeve oil seal drift
Usage : This tool is used for undamaged and reliable pushing of the clutch release sleeve oil seal
into its seat.
Tool drawing :
Workshop section

GL-XU52C
Mechanical
Remarks :
79

Tool name : Final-drive left side oil seal
drift
It is used for safe and reliable installation of the drive shaft oil seals.
Tool drawing :
Workshop section

/Samand EL /Samand Sarir /Samand EL bifuel
Mechanical
Remarks :
80

Tool name : Final-drive right side oil seal
drift
It is used for safe and reliable installation of the drive shaft oil seals.
Tool drawing :
Workshop section

Mechanical
Remarks :
81

Tool name : Clutch plate centering mandrel
Usage : For centering clutch disc and clutch plate on the flywheel.
Tool drawing :
Workshop section

Mechanical
Remarks :
82

Tool name : Vacuum and pressure gauge
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

Tool name : Dial gauge
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 name : Connector
Usage : It is used as a connector between pressure hose and pressure regulator.
Tool drawing :
Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLXXU7JP/K /Samand XU7JP/K

Mechanical
Remarks :
85

Tool name : Hose for checking fuel pump
output
Usage : During test operations this hose is used to direct fuel overflow to a safe place. For
example when testing the fuel pump output one end of this hose is connected to the pressure
regulator and the other end is put into a graduated beaker.
Tool drawing :
Workshop section

Mechanical
Remarks :
86

Tool name : Six bar pressure gauge
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
Tool name : Reducing adaptor
Usage : This tool is used for connecting pressure gauge to fuel supply hoses for measuring fuel
pressure.
Tool drawing :
Workshop section

Usage: Engine
Mechanical
Remarks :
88

Tool name : Graduated beaker
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

Tool name : Hose for helping in fuel
system adjustment, (6mm diameter)
Usage : This hose is used to direct fuel overflow from the three way connector into the graduated
beaker.
Tool drawing :
Workshop section

Mechanical
Remarks :
90

Tool name : Pressure gauge connector
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

Tool name : Fuel system adjustment tool
box
Usage : This particular tool box is used for keeping all special tools required for fuel system
adjustment.
Tool drawing :
Workshop section

Mechanical
Remarks :
92

Tool name : Washer
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

Tool name
regulator unit
Injector
rack
pressure
Usage : This equipment is used for measuring fuel pressure inside the fuel feed rack.
Tool drawing :
Workshop section

Mechanical
Remarks :
94

Tool name : Regulator retainer
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 name : Hose blocking clamp (26mm
diameter)
Usage : For temporary blocking of fuel supply hose when fuel output is being measured.
Tool drawing :
Workshop section

Mechanical
Remarks :
96

Tool name : Hose blocking clamp (70 mm
diameter)
Usage : For temporary blocking of coolant hoses during replacement of cooling system parts
such as radiator, etc.
Tool drawing :
Workshop section

Mechanical
Remarks :
97

Tool name : A/C compressor pressure
plate extractor
Usage : For removing compressor drive pulley from its shaft.
Tool drawing :
Workshop section

Usage location: A/C system
Mechanical
Remarks :
98

Tool name : Overhauling kit for Sanden
compressor
Usage : This tools set is used for repairing Sanden A/C compressors of model SD508/510/709.
Tool drawing :
Workshop section

Mechanical
Remarks :
99

Tool name : Adjustable lug wrench
Usage : This tool is used for holding the A/C compressor clutch to facilitate clutch bolt removal.
Tool drawing :
Workshop section

Mechanical
Remarks :
100

Tool name : Pipe disconnector (1/2 blue
pipe)
Usage : This adaptor is used for disconnecting pump pipes from inside the evaporator pipe.
Tool drawing :
Workshop section

Mechanical
Remarks :
101

Tool name : Pipe disconnector (5/18 black
pipe)
Usage : This adopter is used for disconnecting pump pipe from inside evaporator pipe.
Tool drawing :
Workshop section

TU3JP+MA5
Mechanical
Remarks :
102
SAMAND
Service Manuals
The intellectual property rights pertaining to the technical information in

this document are the sole property of the manufacturer. No parts of this
information mar be reproduced of distributed in any from or by any
means, without the prior written consent of the manufacturer.
This document is strictly confidential and reserved for the in-house use
of the IKCO company network.
IKCO after Sales Services Department
SAMAND building (No. 5)
14KM Karaj highway - Tehran - Iran
Tel: +98 21 48909353
Fax: +98 21 48909360
Http://Iksa.ikco.com/Export

Samand: Service Manual

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SAMAND

This manual should be used as service manual and s workbook for

List of Special Tools for Peugeot 405, Pars and Samand

Pliers for 'clic' collars

Pliers for 'oetiker" collars

Seal removing pliers

Camshaft gear timing pin

Dial gauge support rod

Dial gauge plate

Dial gauge support

Spark plug wrench

Drain plug wrench

Cup ress (valve spring compressor component)

Cylinder head bolts socket wrench

Crankshaft rear oil seal drift

Set of 2 cylinder head releasing levers (cylinder head lifters)

Angular tightening tool

Liner retaining clamps

Piston pin installing device

Piston pin inserter

Piston pin inserter handle

Gudgeon pin guide (piston pin inserter)

Engine lifting equipment

Tool for fitting rear main bearing seals

Crankshaft front end oil seal drift

Camshaft oil seal drift

Tool for fitting rear main bearing seals

Valve stem seal drift

Fuel hose clip pliers

List of Special Tools for Peugeot 405, Pars and Samand

Filling cylinder for bleeding cooling system (coolant charger)

Wrench for tightening flexible engine mounting

Flexible-bush extraction and fitting tool

Crankshaft pulley extractor

Pliers for removing blanks and clips from trim

Adhesive tape cutting and scrapping blade driver

Fuel tank sender unit wrench

Set of four setting rods (height gauge)

Set of clamps of front springs

Front spring compression plate

Spring compressor alone

Suspension clamping equipment

Set of four shackles

Tool for opening pivot (knuckle widener)

Sliding hammer adopter

Dummy shock absorber

Spring retaining cables

Ball bearing drift

Thrust cup fitting drift

Pivot ball joint wrench

Set of two halves

Thrust plate for bearing extractor

Hub and bearing extractor nut

Hub retaining tool body

Hub retaining tool extension

List of Special Tools for Peugeot 405, Pars and Samand

Hub and bearing extractor bolt

Thrust plate for bearing extractor

Propeller shaft support

Dipstick for checking compressor oil level

Splitter/extractor for over hauling gearbox

Fifth speed synchronizer hub extractor

Sling for gearbox/final drive