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SAMAND(XU7JPL3
)
Service Manual
Special tools
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Chapter: Section:
Product:
SAMAND XU7JPL3
Special Tools
I
SAMANDService Manual
Foreword:
This Service Manual contains descriptions of the following categories for theSamand:
Special tools
This manual should be used as service manual and s workbook fortraining instructors and technicians. We reserve the right to introducechange without prior notice.
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List of Special Tools for Peugeot 405, Pars and Samand
S.no. Tool name Tool code
1 Pliers for 'clic' collars 243 02 001
2 Pliers for 'oetiker" collars 243 02 002
3 Seal removing pliers 243 03 001
4 Camshaft gear timing pin 244 01 001
5 Dial gauge support rod 244 02 001
6 Dial gauge plate 244 02 002
7 Dial gauge support 244 02 003
8 Spark plug wrench 244 03 002
9 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
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List of Special Tools for Peugeot 405, Pars and Samand
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
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List of Special Tools for Peugeot 405, Pars and Samand
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 00384 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
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List of Special Tools for Peugeot 405, Pars and Samand
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
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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 306Usage location: Front axle
Mechanical
Remarks :
1
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Special code : 243 02 002
Tool name :Pliers for 'oetikar' 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 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sareer /Samand ELbi-fuel.
Usage location: Front axle
Mechanical
Remarks :
2
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Special code :243 03 001
Tool name :Seal removing pliers
Usage :It is used for removing valve stem oil seals.
Tool Drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
3
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Special code :244 01 001
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405GLX-XU92CUsage location: Engine
Mechanical
Remarks :
4
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Special code :244 02 001
Tool name :Dial gauge support rod
Usage :It is used for measuring crankshaft horizontal play.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
5
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Special code :24402002
Tool name :Dial gauge plate
Usage :It is used for measuring surface level difference of liners, with each other and withcylinder block surface.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 206 TU3JP+MA5/Peugeot 405GL-XU52C /Peugeot 405-GLX-XU92C/Peugeot Pars XU7JP/K /Peugeot 405GLX-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 Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
6
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Special code :244 02 003
Tool name :Dial gauge support
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Engine
Mechanical
Remarks :
7
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Special code :244 03 002
Tool name :Spark plug wrench
Usage :It is used for removing and installing spark plugs.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
8
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Special code :244 04 001
Tool name :Drain plug wrench.
Usage :It is used for removing and tightening crankcase oil draining plug.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
9
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Special code :244 07 001
Tool name :Cup ress (valve springcompressor component)
Usage :It is explained in the engine workshop manual with old document code1303R00201851/1 or new document code 000235 on page 49, and on pages 10 and 12 ofspecial tools guide with old document code 1303R02501841 or new document code 000250During the removal and installation of intake and exhaust valves, it is used along with the valvespring compressor tool, part no. 24407003, to compress valve spring so that the locking cottersaround the valve stems may be removed or installed.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX
/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
10
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Special code :244 08 001
Tool name :Cylinder head bolts socketwrench
Usage :It is used for fastening and removing cylinder head bolts.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sareer /Samand ELbi-fuel.Usage location: Engine
Mechanical
Remarks :
11
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Special code :244 08 007
Tool name :Crankshaft rear oil seal drift
Usage :It is explained in the engine workshop manual with old document code 1303R00201851/1 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 andup to the suitable limit.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Engine
Mechanical
Remarks :
12
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Special code :244 08 008
Tool name :Cylinder head releasing levers(cylinder head lifters)
Usage :It is explained in the engine workshop manual with old document code1303R00201851/1 or new document code 000235 on page 38.It is used to separate cylinder head from cylinder block.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.
Usage location: Engine
Mechanical
Remarks :
13
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Special code :244 08 009
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine.
Mechanical
Remarks :
14
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Special code :244 09 001
Tool name :Liner retaining clamps
Usage :It is explained in the engine workshop manual with old document code1303R00201851/1 on page 38.It is used to keep the cylinder liners fixed in the cylinder block.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.
Usage location: Engine.
Mechanical
Remarks :
15
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Special code :244 10 001
Tool name :Flywheel locker
Usage :It is used to lock flywheel and prevent flywheel and crankshaft from rotating whenloosening flywheel and clutch disc bolts.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
16
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Special code :244 12 004
Tool name :Piston pin installing device
Usage :This tool is used to align the holes of piston and connecting rod end, after alignment iscomplete, the piston is fixed up in this position and the connecting rod small end is heatedindirectly (i.e. without having direct contact with flame) on an electric stove having a cast ironheating plate and is heated to a temperature of about 273 degrees C. It is then placed in itslocation in the piston with their holes aligned and the piston pin is then installed. Note that thisoperation should be performed fast so that the heated connecting rod does not get cold beforethe piston pin is installed in it.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /Samand
XU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
17
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Special code :244 12 005
Tool name :Gudgeon pin guide (piston pininserter)
Usage :Before the piston pin is inserted into the piston it should be first fixed to this tool and thenafter aligning the connecting rod end hole with the piston hole, it is inserted into the piston.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405GLX-XU92CUsage location: Engine.
Mechanical
Remarks :
18
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Special code :244 12 006
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Engine
Mechanical
Remarks :
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Special code :244 12 008
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 theinserter, which are then together inserted into the piston.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot ParsXU7JP/K /Peugeot 405 GLX-XU7JP/K/Peugeot Pars XU7JP/L3 /Peugeot 405GLX-XU7JP/L3 /Peugeot 405 bi-fuel CNG/Samand XU7JP/K /Samand XU7JP/L3/Samand CNG /Samand LX /Samand EL/Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
20
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Special code : 244 12 009
Tool name :Piston pin inserter XU7
Usage :It is explained in the engine workshop manual with old document code1303R00201851/1or 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 :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Peugeot Pars XU7JP/L3/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
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Special code :244 12 017
Tool name :Piston support
Usage : This tool is placed between piston and the platform of piston pin installing device, so thatwhen the piston pin is installed it may sit into the piston with equal distance at both ends.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Peugeot Pars XU7JP/L3/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
22
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Special code :244 13 014
Tool name :Engine lifting equipment
Usage :It is used for removing engine from vehicle and for installing it back, and also for shiftingengine in the workshop.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Engine
Mechanical
Remarks :
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Special code :244 14 001
Tool name :Tool for fitting rear mainbearing linear seals
Usage :It is explained in the engine workshop manual with old document code1303R00201851/1 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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
24
Installer plates
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Special code :244 15 001
Tool name :Crankshaft front end oil sealdrift
Usage :It is used for pushing oil seal into its seat safely and up to the right depth.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Engine
Mechanical
Remarks :
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Special code :244 15 002
Tool name :Camshaft oil seal drift
Usage :After the camshaft oil seal edge is smeared with oil and positioned on its installinglocation, this tool is used to push it into its seat properly and safely.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
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Special code :244 15 004
Tool name :Tool for fitting rear mainbearing 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 secureits position in the cylinder block. Fasten the two bolts belonging to the shells. Then pull out thetool from side of the shells without dislodging shells and rubber.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-
fuel.Usage location: Engine
Mechanical
Remarks :
27
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Special code :244 16 006
Tool name :Valve stem seal drift
Usage :By using this tool and a plastic hammer, the valve stem oil seal is installed.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 206 TU3JP+MA5Usage location: Engine
Mechanical
Remarks :
28
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Special code :244 16 007
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot GLX-XU92CUsage location: Engine
Mechanical
Remarks :
29
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Special code :244 17 002
Tool name :Fuel hose clip pliers
Usage :Since the fuel supply line is a safety issue, specially the hose clips, therefore duringrepair works this special tool is used to remove and install the hose clips safely and preventsthem from getting overstretched and inefficient.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
30
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Special code :244 18 001
Tool name :Filling cylinder for bleedingcooling system (coolant charger)
Usage :It is used during bleeding operation of cooling system. The radiator cap is removed andthe coolant charger is fitted on its place. Then, while maintaining coolant at top level in thecharger reservoir, the draining tap on the cylinder block is loosened and the coolant allowed toflow until it is free from air bubbles. The tap is then closed and the charger is removed andradiator cap is put back.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-
fuel.Usage location: Engine
Mechanical
Remarks :
31
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Special code: 244 19 001
Tool name :Wrench for tightening flexibleengine mounting
Usage :For removing and installing the engine right bracket damper.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 206 TU3JP+MA5 /Peugeot 405GL-XU52C /Peugeot 405-GLX-XU92C/Peugeot Pars XU7JP/K /Peugeot 405GLX-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 Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
32
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Special code :244 19 002
Tool name :Flexible bush extraction andfitting tool
Usage :It is used for replacing the engine bracket buffer.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
33
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Special code:244 25 001
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Engine
Mechanical
Remarks :
34
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Special code :246 01 001
Tool name :Pliers for removing blanks andclips from trim
Usage :For facilitating quick and easy removal of plugs and clips fastening the door insulation
panels.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Body hardware
Mechanical
Remarks :
35
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Special code :246 04 002
Tool name :Cutting blade
Usage :This cutter blade is used after mounting it on the power tool, for removing the extraadhesive from around the windshield glasses.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Body hardware
Mechanical
Remarks :
36
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Special code :246 04 003
Tool name :Scraping blade
Usage :By mounting this blade on the power tool, the extra adhesive sticking on the windshieldglasses are scraped out.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Body hardware
Mechanical
Remarks :
37
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Special code :246 04 005
Tool name :Adhesive cutting and scrapingblades' driver
Usage :This power tool along with its attachment blades is used for cutting and scraping off theextra adhesives remaining around windshield glass during replacement.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Body hardware
Mechanical
Remarks :
38
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Special code :246 06 001
Tool name :Fuel tank sender unit wrench
Usage :This tool is used for removing and tightening the fuel gauge sender unit nut located infuel tank.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Engine
Mechanical
Remarks :
39
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Special code :249 01 002
Tool name :Set of four setting rods (heightgauge)
Usage :For knowing height of vehicle body from the ground level, four tools of this kind areneeded. The tool height is graduated with centimeter scale. A spring is provided inside the toolwhich 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 tubein level with the outer tube. Then tighten release bolt and place tool below door column of vehiclebody. Follow this procedure also with other three tools by placing each under the other doorcolumn, between rear wheels and front wheels columns. Then loosen the release bolt as a resultof 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 andground is determined. If distances are not according to standard values, adjust them.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /Peugeot
Pars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Suspension
Mechanical
Remarks:
40
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Special code :249 01 003
Tool name :Set of clamps for front springs
Usage :These forks along with plate and spring compressor device are used for compressingsprings of front suspension.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Front suspension
Mechanical
Remarks :
41
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Special code :249 01 006
Tool name :Front spring compressor plate
Usage : It is explained in the front and rear suspension workshop manual with old documentcode 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 plateand fitting it on the spring compressor device, the spring is compressed and shock absorbers areremoved and installed.This pressure plate is fitted on one side of the spring compressor device which is employed forcompressing 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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405
bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Front suspension
Mechanical
Remarks :
42
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Special code :249 01 010
Tool name :Spring compressor
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX
/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Front suspension
Mechanical
Remarks :
43
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Special code :249 03 001
Tool name :Suspension clampingequipment
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 replacinga new one tie the nuts but dont tighten them. Employ front suspension aligner and then byputting force on the rear axle align it in such a manner that the distance between upper and lowerpivots 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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405
bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Suspension
Mechanical
Remarks :
44
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Special code :249 03 002
Tool name :Set of four shackles
Usage :This tool is part of the tool group having code no. 24903001, which is used for adjustingdistance between car body and ground.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Suspension
Mechanical
Remarks :
45
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Special code :249 04 003
Tool name :Tool for opening pivot(knuckle widener)
Usage :For widening of the front axle knuckle gap so that the shock absorber can be easilyremoved from the knuckle.
Tool drawing:
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
46
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Special code :249 04 005
Tool name :Mandrel (sliding hammeradopter)
Usage : It is explained in the rear and front suspension workshop manual with old documentcode 1303R01301891/1 or new document code 000241 on page 52.This tool along with the sliding hammer is used for removing and as well as for installing thetorsion bars..Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Suspension
MechanicalSuspension
Remarks :
47
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Special code :249 04 006
Tool name :Dummy shock absorber
Usage :It is explained in the front and rear suspension workshop manual with old documentcode 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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Rear suspension
MechanicalSuspension
Remarks :
48
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Special code :249 04 009
Tool name :Spring retaining cables
Usage : It is explained in the front and rear suspension workshop manual with old documentcode 1303R01301891/1 or new document code 000241 on page 11.This cable is used when the front suspension spring is compressed for removing and installingthe shock absorber.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.
Usage location: Front suspension
MechanicalSuspension
Remarks :
49
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Special code :250 03 002
Tool name :Ball bearing drift
Usage :It is used for installing the outer ball bearing of rear wheel flexible arm.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Rear suspension
MechanicalSuspension
Remarks :
50
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Special code :250 03 003
Tool name :Thrust cup fitting drift
Usage :It is used for installing the inner ball bearing of the rear wheel flexible arm. By using thistool the ball bearing does not suffer any damage when being pushed into place with hammerstrokes.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Rear suspension
MechanicalSuspension
Remarks :
51
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Special code :251 01 001
Tool name :Pivot ball joint wrench
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
MechanicalSuspension
Remarks :
52
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Special code :251 01 005
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92C /Peugeot 405GL-XU52C /Peugeot 206 TU3JP+MA5Usage location: Front suspension
MechanicalSuspension
Remarks :
53
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Special code :251 02 001
Tool name :Locking cone
Usage : It is explained in the front and rear suspension workshop manual with old documentcode 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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
54
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Special code :251 02 002
Tool name :Set of two halves
Usage :This tool along with other complementary tools is used for pulling out front wheel hub.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
55
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Special code :251 02 003
Tool name :Thrust plate for bearingextractor
Usage :This tool along with complementary tools, are used for extracting front wheel ball
bearing.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
56
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Special code :251 02 008
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
57
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Special code :251 02 009
Tool name :Thrust button
Usage :It is explained in the front and rear suspension workshop manual of Samand with olddocument 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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
58
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Special code :251 02 016
Tool name :Hub retaining tool body
Usage :This tool is used for securing the front and the rear hubs.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
59
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Special code :251 02 017
Tool name :Hub retaining tool extension
Usage :This tool is used as a cross-bar to anchor wheel hub retainer tool.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension
Mechanical
Remarks :
60
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Special code :251 02 018
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension.
Mechanical
Remarks :
61
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Special code :251 02 019
Tool name :Thrust plate for bearingextractor
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-1600Usage location: Front suspension
Mechanical
Remarks :
62
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Special code :251 02 020
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GLX-XU92CUsage location: Front suspension.
Mechanical
Remarks :
63
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Special code :251 03 003
Tool name :Propeller shaft support
Usage :This tool is used to keep the driveshafts fixed in their positions during repair works.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Front suspension
Mechanical
Remarks :
64
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Special code :252 02 002
Tool name :Dipstick for checkingcompressor oil level
Usage :This tool is used to check compressor oil level after compressor or A/C system repairs.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 206 TU3JP+MA5 /Peugeot 405GL-XU52C /Peugeot 405-GLX-XU92C/Peugeot Pars XU7JP/K /Peugeot 405GLX-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 Sarir /Samand EL bi-fuel. Usagelocation: A/C system
Mechanical
Remarks :
65
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Special code :254 05 001
Tool name :Splitter/extractor foroverhauling gearbox
Usage :This tool set is used for dismantling gearbox parts such as gears, ball bearings, etc.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Clutch and manual gearbox
Mechanical
Remarks :
66
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Special code :254 05 002
Tool name :Fifth speed synchronizer hubextractor
Usage :It is used for separating fifth gear hub from gearbox.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Clutch and manual gearbox
Mechanical
Remarks :
67
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Special code :254 07 001
Tool name :Thrust button
Usage :This tool is used as a seat and under-pusher when installing and removing gearbox partsunder a press.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 206TU3JP+MA5 /Peugeot 205Usage location: Clutch and manual gearbox
Mechanical
Remarks :
68
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Special code :254 08 001
Tool name :Sling for gearbox/final drive
Usage :This tool is used for easy lifting and shifting of gearbox.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Clutch and manual gearbox
Mechanical
Remarks :
69
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Special code :254 09 001
Tool name :Adjustment spacer
Usage :By placing this shim on the outer race of gearbox input shaft ball bearing, and then byinstalling the clutch bearing sleeve, the suitable sized shim is selected for adjustment ofclearance and is then taken out.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.
Usage location: Clutch and manual gearbox
Mechanical
Remarks :
70
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Special code :254 09 002
Tool name :Adjustment spacer
Usage :This tool is used for adjustment of tachometer gear clearance in the gearbox.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Clutch and manual gearbox
Mechanical
Remarks :
71
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Special code :254 09 003
Tool name :Adjustment spacer
Usage :This shim is used for determining size of the main shim behind ball bearing of input
shaft.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Clutch and manual gearbox
Mechanical
Remarks :
72
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Special code :254 12 002
Tool name :Input shaft rear bearing outerrace drift
Usage :For safely pushing out and installing the rear outer race of the ball bearing of gearboxinput shaft.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Clutch and manual gearbox
Mechanical
Remarks :
73
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Special code :254 12 003
Tool name :Selector and engagementshaft oil seal drift
Usage :It is used for safe and reliable installation of oil seal of gear select shaft.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405-GLX-1600 /Peugeot205/Peugeot 605 /Peugeot 806 /Peugeot406 /Peugeot 306 /Peugeot 206TU3JP+MA5Usage location: Clutch and manual gearbox
Mechanical
Remarks :
74
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Special code :254 12 004
Tool name :Differential bearing drift
Usage :By using this tool under a press, roller bearings of the differential carrier are installed.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 306 /Peugeot 605 /Peugeot 205/Peugeot 806 /Peugeot 206 TU3JP+MA5 /Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.
Usage location: Clutch and manual gearbox
Mechanical
Remarks :
75
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Special code :254 12 005
Tool name :Input and output shaftsbearing outer race drift
Usage :It is explained in the gearbox workshop manual with old document code1303R0051881/1 or new document code 000237 on page 55.It is used for installing the roller bearing and the front and rear ball bearings of the input andoutput shafts of gearbox.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 605 /Peugeot 405 GL-XU52C/Peugeot 205 /Peugeot 406 /Peugeot 806/Peugeot 306 /Peugeot 206 TU3JP+MA5Usage location: Clutch and manual gearbox
Mechanical
Remarks :
76
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Special code :254 12 006
Tool name :Input and output shaftsbearing outer race drift
Usage :It is explained in the gearbox workshop manual with old document code
1303R00501881/1 or new document code 000237 on page 55.
It is used for installing the front and rear ball bearings of input and output shafts of gearbox.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 605 /Peugeot 205 /Peugeot 406/Peugeot 806 /Peugeot 306 /Peugeot 405GL-XU52C /Peugeot 206 TU3JP+MA5Usage location: Clutch and manual gearbox
Mechanical
Remarks :
77
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Special code :254 12 008
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 :
Vehicle model & usage location Workshop section
Peugeot 605 /Peugeot 205 /Peugeot 406/Peugeot 806 /Peugeot 306 /Peugeot 405GL-XU52CUsage location: Clutch and manual gearbox
Mechanical
Remarks :
78
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Special code :254 12 009
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 :
Vehicle model & usage location Workshop section
Peugeot 605 /Peugeot 205 /Peugeot 406/Peugeot 806 /Peugeot 306 /Peugeot 405GL-XU52CUsage location: Clutch and manual gearbox
Mechanical
Remarks :
79
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Special code :254 12 010
Tool name :Final-drive left side oil sealdrift
Usage :It is explained in the gearbox workshop manual with old document code1303R00501881/1 or new document code 000237 on page 68.It is used for safe and reliable installation of the drive shaft oil seals.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel
Usage location: Clutch and manual gearbox
Mechanical
Remarks :
80
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Special code :254 12 011
Tool name :Final-drive right side oil sealdrift
Usage :It is explained in the gearbox workshop manual with old document code1303R00501881/1 or new document code 000237 on page 68.It is used for safe and reliable installation of the drive shaft oil seals.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52CUsage location: Clutch and manual gearbox
Mechanical
Remarks :
81
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Special code :255 02 001
Tool name :Clutch plate centering mandrel
Usage :For centering clutch disc and clutch plate on the flywheel.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Clutch and manual gearbox
Mechanical
Remarks :
82
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Special code :257 01 003
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 :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
83
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Special code :257 02 002
Tool name : Dial gauge
Usage :It is explained in the engine workshop manual with old document code1303R00201851/1 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 suchas discs, etc.Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.
Usage location: Engine
Mechanical
Remarks :
84
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Special code :265 01 002
Tool name :Connector
Usage :It is used as a connector between pressure hose and pressure regulator.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
85
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Special code :265 01 003
Tool name :Hose for checking fuel pumpoutput
Usage : During test operations this hose is used to direct fuel overflow to a safe place. Forexample when testing the fuel pump output one end of this hose is connected to the pressureregulator and the other end is put into a graduated beaker.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
86
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Special code :265 01 004
Tool name :Six bar pressure gauge
Usage :It is used for measuring pressure of fuel supply system. By using a three way connectorit is included in the system before fuel injector rack and the system pressure is then measuredwith this tool.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: Engine
Mechanical
Remarks :
87
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Special code :265 01 006
Tool name :Reducing adaptor
Usage :This tool is used for connecting pressure gauge to fuel supply hoses for measuring fuelpressure.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage: Engine
Mechanical
Remarks :
88
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Special code :265 01 007
Tool name :Graduated beaker
Usage :It is used when testing fuel pump performance, for measuring the amount of fuel which ispumped by the fuel pump in a given period of time. A hose is connected to the pressure regulatorand the other end of hose is put into a graduated beaker. The fuel pump is put to work by turningon the ignition switch for 15 seconds. The amount of fuel pumped in this period should be at least540 cc.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
89
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Special code :265 01 008
Tool name :Hose for helping in fuelsystem adjustment, (6mm diameter)
Usage :This hose is used to direct fuel overflow from the three way connector into the graduatedbeaker.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
90
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Special code :265 01 009
Tool name :Pressure gauge connector
Usage :It is used for connecting pressure gauge to fuel system in front of injector rack. One endof it is connected to the rack vent and to its upper end the pressure gauge is connected and thefuel supply pressure is measured.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
91
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Special code :265 01 010
Tool name : Fuel system adjustment toolbox
Usage : This particular tool box is used for keeping all special tools required for fuel system
adjustment.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
92
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Special code :265 01 011
Tool name :Washer
Usage :This washer is used as a sealing ring when connecting pressure gauge to fuel supplysystem adaptor.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
93
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Special code :265 01 012
Tool name : Injector rack pressureregulator unit
Usage :This equipment is used for measuring fuel pressure inside the fuel feed rack.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
94
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Special code :265 01 013
Tool name :Regulator retainer
Usage :This tool is used for fixing the pressure regulator unit on heat shield inside the enginechamber.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot Pars XU7JP/K /Peugeot 405 GLX-XU7JP/K /Samand XU7JP/KUsage location: Engine
Mechanical
Remarks :
95
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Special code :266 01 001
Tool name :Hose blocking clamp (26mmdiameter)
Usage :For temporary blocking of fuel supply hose when fuel output is being measured.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuelUsage location: Engine
Mechanical
Remarks :
96
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Special code :266 01 002
Tool name :Hose blocking clamp (70 mmdiameter)
Usage :For temporary blocking of coolant hoses during replacement of cooling system partssuch as radiator, etc.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuelUsage location: Engine
Mechanical
Remarks :
97
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Special code :268 01 001
Tool name :A/C compressor pressureplate extractor
Usage :For removing compressor drive pulley from its shaft.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: A/C system
Mechanical
Remarks :
98
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Special code :268 02 001
Tool name :Overhauling kit for Sandencompressor
Usage :This tools set is used for repairing Sanden A/C compressors of model SD508/510/709.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: A/C system
Mechanical
Remarks :
99
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Special code :268 03 001
Tool name :Adjustable lug wrench
Usage :This tool is used for holding the A/C compressor clutch to facilitate clutch bolt removal.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuel.Usage location: A/C system
Mechanical
Remarks :
100
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Special code :268 04 001
Tool name :Pipe disconnector (1/2 bluepipe)
Usage :This adaptor is used for disconnecting pump pipes from inside the evaporator pipe.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 405-GLX-XU92C /Peugeot Pars XU7JP/K/Peugeot 405 GLX-XU7JP/K /Peugeot ParsXU7JP4/L4 /Peugeot 405 GLI /PeugeotPars XU7JP/L3 /Peugeot Pars ELX/Peugeot 405 GLX-XU7JP/L3 /Peugeot 405bi-fuel CNG /Samand XU7JP/K /SamandXU7JP/L3 /Samand CNG /Samand LX/Samand EL /Samand Sarir /Samand EL bi-fuelUsage location: A/C system
Mechanical
Remarks :
101
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Special code :268 04 002
Tool name :Pipe disconnector (5/18 blackpipe)
Usage :This adopter is used for disconnecting pump pipe from inside evaporator pipe.
Tool drawing :
Vehicle model & usage location Workshop section
Peugeot 405 GL-XU52C /Peugeot 206TU3JP+MA5Usage location: A/C system
Mechanical
Remarks :
102
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SAMAND Service Manuals