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Tool and Measuring Instrument
Basics
Automotive repairs require the use of a variety of
tools and measuring instruments
...


Basic concept for using tools and measuring instruments:
• Learn the correct uses and functions
...
If used for any purpose other than that
specified, the tool or measuring instrument damaged, and parts may be damaged or the quality of the job may be
compromised
...

Each tool and measuring instrument has defined operation procedures
...

• Select correctly
...
Always
choose your tools to fit the shape of the part and the place in which the job is being carried out
...

• Strict adherence to upkeep and management of tools
...
Any necessary repairs should
be carried out immediately, so that tools are always in perfect condition
...

• For removing and replacing bolt / nut or removing
parts
...
If a socket wrench set cannot
be used due to work space restrictions, select a
boxend wrench or an openend wrench in that
order
...

• A socket wrench is useful in that it can be used to
turn bolt / nut without the need for repositioning
...

• A socket wrench can be used in various ways
depending on the type of handle that is fitted
...
The ratchet handle is suitable for use in a
confined space
...

2
...

3
...
However the handle is
long and difficult to use in a confined space
...

NOTICE:
• The amount of strength that can be applied is
dependent on the length of the shaft of the
wrench
...

• If an excessively long shaft is used, there is a
danger of over torque, and the bolt may be
snapped
...
Size and application of the tool
• Make sure the diameter of the tool fits the head of
the bolt / nut
...


-2-

2
...

• If the tool cannot be pulled because of space
restrictions, push it with the palm of your hand
...
Applying strength 2
A bolt / nut, which has been tightened firmly, can be
loosened easily by the application of impact
...


4
...


(4/4)

-3-

Socket (Socket Wrench Set)
Socket wrench set
This tool can be used for the easy removing and
replacing of bolt / nut through the combination of
various handles and sockets, depending on the
operating conditions
...

1
...

The larger part can achieve greater torque than
the smaller one
...
Depth of socket
• There are two types - standard, and deep, which
is 2 or 3 times deeper than standard
...

3
...
The hexagonal part gains a large
contact surface with bolt / nut, making it extremely
difficult to damage the surface of the bolt / nut
...

NOTICE:
Over- large torque places a load on the socket
itself or on small bolts
...

Socket adapter (Large - small)
Socket adapter (Small - large)
Socket with small drive size
Socket with large drive size
(1/1)

Universal Joint (Socket Wrench Set)
Application
The socket square drive can be moved back and
forth, or left and right, and the angle of the handle
in relation to the socket wrench can be changed
freely, making this a useful tool for work in
restricted spaces
...
Do not apply torque with the handle tilted to a
large angle
...
Do not use for an air tool
...

(1/1)

-4-

Extension Bar (Socket Wrench Set)
Application
1
...

2
...


(1/1)

Spinner Handle (Socket Wrench Set)
Application
This handle is used for removing and replacing bolt
/ nut where a large torque is required
...

• The handle slides, allowing the length of the grip
to be changed
...
If it is not in the lock position, the
handle could slide in or out during use
...

(1/1)

Sliding Handle (Socket Wrench Set)
Application
This handle can be used two ways by sliding the
socket drive portion
...
L-shape: For improved torque
2
...
Turn the set lever to the right for tightening a bolt
/ nut and to the left for loosening
...
Bolt / nut can be turned in a single direction
without the need to reattach the socket wrench
...
The socket wrench can be locked with a small
return angle, allowing work in a restricted space
...
This may damage
the construction of the ratchet
...

1
...
It can be refitted in a restricted
space
...
Since the hexagonal surface of the bolt / nut is
surrounded, there is no danger of damage to the
corners of the bolt, and a large torque can be
applied
...
Since the shaft is angled, it can be used to turn
bolt / nut in a recessed space or on a flat
surface
...

1
...
This
means that through turning the openend wrench
(spanner) over, it can be used to rotate further in
a restricted space
...
To prevent the opposite part from turning, such
as when loosening a fuel pipe, use two openend
wrenches (spanners) to loosen a nut
...
Spanners cannot give a large torque, so should
not be used for final tightening *
...

This may cause over- large torque to be applied
and may damage the bolt or the openend wrench
(spanner)
...

(1/1)

-6-

Adjustable Wrench
Application
Used with bolt / nut of irregular sizes, or to hold
down SST
...

One adjustable wrench can therefore be used in
place of multiple openend wrenches (spanners)
...

Instructions
Turn the adjusting screw to fit the bore to the head
of the bolt / nut being used
...
If the wrench is not turned
this way, pressure is applied to the adjusting screw,
which may be damaged
...

• Two sizes, large and small, to fit the size of spark
plugs
...

NOTICE:
1
...

2
...

(Reference: specified torque 180~200 kg•cm)
(1/1)

Screwdriver
Application
Used for removing and replacing screws
...

Instructions
1
...

2
...

NOTICE:
Do not use slip joint pliers or other tools to overapply torque
...


(1/1)

-7-

REFERENCE:
Choosing a screwdriver according to use
• While ordinary screwdrivers are most frequently
used, the following types of screwdrivers are also
available for different uses:
Penetration screwdriver
Can be used to apply impact to a fixed screw
...

Square- shank screwdriver
Can be used where the application of a large
torque is required
...

Shank completely penetrates handle
...

(1/1)

Needle-Nose Pliers
Application
Used to operate in tight spaces or to grip small
parts
...

• Includes a blade towards the neck, which can cut
fine wire, or remove insulation from electrical
wires
...

They may be bent open, rendering them useless
for detailed work
...

• Changing the position of the hole at the fulcrum
allows the extent to which the jaws open to be
adjusted
...

• Fine wire can be cut at the neck
...

(1/1)

-8-

Cutting Pliers (Nipper)
Application
Used for cutting fine wire
...

NOTICE:
• Cannot be used to cut hard or thick wire
...


(1/1)

Hammer
Application
Used to remove and replace parts by hitting them,
and to test the tightness of a bolt by sound
...

Plastic hammer
Has a plastic head, and is used where damage
must be avoided to the item being struck
...

Instructions
Drive by striking directly
...
g
...

Removal by striking directly
...
g
...

Removal by striking indirectly
...

E
...
) Used for checking bolts for looseness
...
)
(1/1)

Brass Bar
Application
A support tool that prevents hammer damage
• Made of brass, so does not damage parts ( as it
will deform before the part does)
NOTICE:
If the tip deforms, repair it with a grinder
...

Instructions
1
...
However, the surface is scraped
easily
...
However, the surface being scraped is
not damaged
...
When using on an easily damaged surface, the
scraper should be covered in plastic tape
(except for the blade)
...
You
may injure yourself on the blade
...
Always
sharpen the blade on an oilstone
...

• The blade tip has been hardened, with tempering
...
Do not strike too hard when marking
...
The tip of the blade should be maintained using
an oilstone
...

• The punch tip has been hardened, with
tempering
...

• Incorporates a rubber cushion, which ensures
that the part is not damaged when stuck
...

• The rubber cushion can also be set to cover both
the punch and the pin, and the pin held while
force is applied
...
They enable
work to be completed quickly
...
Always use at the correct air pressure(Correct
value : 686kPa ( 7kg / cm2))
2
...

3
...

4
...
If the
air tool is used right from the start, the screw
thread may be damaged
...
Use a lower power range to tighten
...
At the end, use a torque wrench to check the
(1/1)

Air Impact Wrench
Application
Used with bolt / nut requiring relatively large torque
...
Torque can be adjusted to 4-6 stages
...
Rotation direction can be changed
...
Used in combination with a dedicated socket
wrench
...

Socket wrenches other than dedicated ones
should not be used
...
Simply operating the buttons releases
a large torque, and may cause shaking
...

1
...

2
...

3
...

CAUTION:
• Make sure that the air exhaust opening is not
turned towards bolts, nuts, small parts, oil or
waste products
...


-11-

(1/1)

Measuring Instruments
To Obtain Accurate Measured Values
Measuring instruments are used for diagnosing the
condition of a vehicle by checking whether parts
dimensions and adjustment conditions match
standard values, and whether the parts of a vehicle
or engine are functioning properly
...
Clean the part to be measured and the
measuring instrument
Waste products or oil can lead to errors in
measurement values
...

2
...
Bad example:
Using a vernier caliper to measure the outer
diameter of a piston
...
05mm
Required precision:0
...
Calibrate zero
Check that zero is aligned to its correct position
...

4
...
Do not use if broken
...
Fit the measuring Instrument to the part to be
measured at a right angle
...
(For details, refer to individual
instructions for measuring Instruments
...
Use an appropriate range
...
The
measurement value should be read from a dial
that is suitable for the range
...
When reading the measurement value
Make sure your eye level is at a right angle to
the dial and pointer
...
Do not drop or strike, otherwise apply impact
...

2
...
Errors in measurement values
may occur from use at high temperature or
humidity
...

3
...
Put the tool away only after it
has been cleaned of oil or waste products
...
Measuring
tools must be stored in a defined place
...

(3/3)

-12-

Torque Wrench
Application
Used to tighten bolt / nut to a specified torque
...
Preset type
The required torque can be preset by turning the
sleeve
...

2
...
The
force applied can be read using the pointer and
scale to allow the specified torque to be
achieved
...
0
...
Used for
preload measurement
...
If the torque wrench
is used to tighten from the beginning, the
operation efficiency becomes worse
...

(1/2)

NOTICE:
1
...

2
...

3
...

(2) Apply forces so that the grip does not touch the
shaft
...

(2/2)

-13-

REFERENCE:
Torque calculation
Tightening torque with an extension tool attached
to a torque wrench:

T' = Torque wrench reading with extension tool [N•m {kgf•cm}]
T = Specified tightening torque [N•m {kgf•cm}]
L1 = Length of extension tool [cm]
L2 = Length of torque wrench [cm]

1
...
If this
combination is used to tighten a bolt / nut until
the specified torque is read on the torque
wrench, the actual torque will exceed the
specified tightening torque
...
In addition to the specified tightening torque,
repair manuals list the T' readings of typical
torque wrenches
...

3
...

Standard values:
T= 80N•m [816kgf•cm]
(specified tightening torque)
T'= 65N•m [663kgf•cm]
(reading when using torque wrench 1300F with
extension tool )
4
...

Measurement range
0~150, 200, 300mm
Measuring precision
0
...
Close the jaws completely before measuring,
and check that there is enough of a gap
between the calipers for light to be seen
2
...

3
...

Stopper screw
Vernier

(2/3)

-14-

REFERENCE:
Examples of use
1
...
Inside diameter measurement
3
...
Depth measurement

(1/1)

Reading measurement
1
...
0mm
Read the main measuring scale, positioned to
the left of the vernier 'zero'
...
g
...
The value to 0
...
0mm
Read the point, which the scale on the vernier
and main measuring scale become aligned
...
g
...
25(mm)
3
...
g
...
25=45
...

Measurement range
0~25mm
25~50mm
50~75mm
75~100mm
Measuring precision: 0
...
Zero calibration
Before using a micrometer, check to make sure
that the zero graduation aligns correctly
...
Then, check that the base line on the
sleeve and the zero graduation line on the thimble
are aligned
...
02mm
Engage the lock clamp to secure the spindle
...

• If the error is more than 0
...
Use the adjustment wrench to loosen the
ratcher stopper in the direction of the arrow as
shown in the diagram
...

(2/4)

2
...

(2) Once the spindle touches gently the item to be
measured, turn the ratcher stopper a few times
and read the measurement
...

NOTICE:
1
...

2
...


(3/4)

3
...
5mm
Read the largest value, which is visible on the
scale of sleeve
...
g
...
5(mm)
(2) Reading the value to 0
...
5mm
Read the point, which the scale on the thimble
and the scale on the sleeve become aligned
...
g
...
45(mm)
(3) How to calculate the measuring value
+
e
...
) 55
...
45=55
...
5mm increments
(4/4)

-16-

Dial Gauge
Application
The up- down movement of the suspended
measuring tip is converted into revolutions of long
and short pointers
...

Types of suspended measuring tip
Long type: used to measure parts in a confined
space
Roller type: used to measure convex / concave
patterns of tires etc
...

Measuring precision: 0
...
01mm / dial increment)
Short pointer (1mm / dial increment)
Dial face (Rotate to set indication to zero)
Spindle
Suspended measuring tip
(1/2)

Instructions
1
...

Adjust the dial gauge position and the item
being measured, and set the pendulum so that it
is at the center of its range of movement
...

2
...

Deviation range: 0
...
With the type shown in the diagram on
the left, the long pointer rotates once as the
moveable lug moves 2mm
...
01mm
(Gauge reading: 20 graduations =0
...
Adjusting to zero
(1) Set the micrometer to the standard measure,
and immobilize the spindle with a clamp
...

(3) Set the gauge to zero at the closest possible
point (the point at which the gauge pointer goes
over to indicate the moving lug is in a closing
side)
...
Measuring
(1) Use the movement button to close the
moveable lug and insert the lugs into the part to
be measured
...

Left and right: at the position with the longest
distance
Up and down: at the position with the shortest
distance

Micrometer
Spindle
Locking clamp
Stand
Fulcrum
Closing direction
Open direction

3
...
g
...
00mm+0
...
20mm
12
...
2: Gauge reading (open direction)
12
...
Using the fixed lug as the fulcrum, move the
gauge left and right, and find the point at which
the distance is largest
...
At that point, move the gauge up and down and
take a reading at the point at which the distance
is shortest
...

Measuring precision: 0
...

• A micrometer is also used to obtain the cylinder
bore

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