Measuring tools

Automotive repairs require precision measurement. You need to fully understand the function and use of such specialize
measuring tools as Vernier caliper, inside and outside micrometers, dial and vacuum gauges, circuit tester, dwell angles
tester and timing advance testers.
Length and mass may be expressed in various units. For sake and simplicity, however, meters and kilograms are used
throughout this manual.

1. TORQUE WRENCH
- The torque wrench is used to measure the twisting force of the bolts and nuts so that the specified tension
can be achieve. A socket can be attached to the wrench to accommodate various sizes of bolts, etc.

click type torque wrench

Dial type torque wrench

Note;
- Used an ordinary wrench to pre retighten the bolt. Use a torque wrench for final tightening only.
- Used a torque wrench having an appropriate torque range (maximum torque).
- To prevent the socket wrench from slipping, hold it down with your left hand, as shown, as you pull the
pivoted handle towards you.
VERNIER CALIPERS
- A Vernier caliper has two measuring scales-the main scale and the Vernier scale – and used to measure
outside diameters, inside diameters, and depths.

Principle of measurement
The main scale and the more accurately graduated Vernier scale are used in combination to measure small distances by
finding the difference between the two graduations, this method is called the principle of Vernier measurement.

Reading measured value

main scale + conversion scale x Vernier scale = total scale

2 + (0.1x 6) = 2.6 mm

1/10 conversion ratio for Vernier

scale

53 + (0.1 x 7) = 53.7 mm

1/10 conversion ratio for

Vernier scale
Handling Vernier caliper
- Before measurement, wipe both the item to be measured and the caliper with a clean rag.
- Before use, check that the Vernier scale moves freely, and that the “0” points on the two scales line up
accurately. When measuring, hold the item to be measured as close as possible to the standard surface of
the main scale. If it is placed in the thin end of the jaw, the reading will be less accurate.
- When measuring, place the caliper at right angles.
- The reduce error when reading the scale, read the measurement from directly above the appropriate
graduation line.
- To prevent rust, wipe with an oiled cloth after used and before storing away.

MICROMETERS
- Outside and inside micrometers are precision tools used to measure outer and inner diameters respectively.
The micrometer, which is more precise than Vernier caliper, is capable of measuring accurately to one one-
hundredth of millimeters.
Principle of measurement
When the bolt makes one turn with nut fixed, the bolt moves one pitch of its threads. Assuming that one pitch
of the threads is 1mm, the bolts moves 1mm when it makes one turns. Therefore, two turns move the bolt 2mm, three
turns move the bolt 3mm and so on. And the turn of the bolt changes in proportion to the amount of the bolts
movement. This is the principle of measurement with micrometers.

The micro meter is calibrated correctly if the “0” point on the thimble is lined up with the index line on the outer sleeve.
Otherwise, the micro meter must be calibrated.

Reading measured value;

The outer sleeve has graduations mark above and below. Markings above the line are separated 1mm from each
other and those below the line ae separated 0.5 mm from each compared with intervals of the lines shown above line.
The thimble has 0.01 mm graduation along its conference. the measured value is equal to the sum of readings at these
three graduations.

= 5.76 mm

Note;
- Check the “0” point before use. If necessary, calibrate the micrometer.
- Clean the area of the work to be measured with a clean cloth before measurement.
- Hold the micrometer by the frame, turn the spindle toward the item to be measured and turn the ratchet
stopper until the spindle touches it. Turn the ratchet stopper two or three notches to apply some pressure
to the item to be measured, and read the scale.
- Note never turn the thimble to apply pressure
- Repeat measurement several times to minimize measurement error.
DIAL GAUGE (DIAL INDICATOR)
The dial gauge is used to measure bends shafts, runout, parallelism, flatness, etc. it has a special mechanism
inside that enlarges small movements. Its spindle is moved along the surface of the work being inspected and any
movement of the spindle relative to the stem is enlarged by the enlarging mechanism. The enlarged movement of
spindle is indicated by pointer.

Note;
- Position of the dial gauge spindle perpendicular to the surface of the work being inspected.
- The imaginary line connecting your eye and the pointer of the dial gauge must be perpendicular to the dial
face when you read the measurement.
- The dial gauge must be fitted accurately to the supporting tools.
- Turn the outer ring and adjust the “0” point. The n touches the spindle with your finger and move it up and
down lightly. Check that the pointer always returns to “0” point of the scale when you are not touching the
spindle.
- The dial gauge contains a watch-like precision mechanism inside. Never drop or otherwise apply shock to
the gauge.
- Never apply oil or grease between the spindle and stem. If the spindle movement becomes hard due to oil
or dirt adhering between the spindle and the stem, hold the dial gauge vertically and lower the stem into
high – quality gasoline. Move the spindle in the gasoline several times until the oil or dirk is removed.

Method of measurement;
PLASTICGAGE
Plastic gage is commonly used to measured oil clearance between the crankshaft journal, pin and bearing. It is a
thread like, plastic material having a uniform thickness, and comes in a paper envelope.

Method of measurement;
The following describes a plastic gage check oil clearance between crankshaft pin and a connecting rod
bearing.

1. Wipe your hands, the crankshaft pin and the bearing clean.
2. Tear ad appropriate length off the end of the plastic gage envelope according to the width of the bearing.
3. Carefully drop the plastic gage piece out of the wrapper and lay it across the crankpin.
4. Keeping the piece in place, put the bearing cap onto the crank pin and tighten the nuts or bolts to the specifies
torque. Be sure not to turn the crank shaft.
5. Remove the bearing cap and measure the width of the flattened plastic gage using the scale printed on the
plastic gage envelope. If the width is not uniform along the flat plastic gage, measure the widest part.
Note; a range of measurable clearance is indicated on the plastic gage envelope. Select plastic gage of a
appropriate size accordingly
THICKNESS GAUGE
Thickness gauge are also known as feeler gauges and are used to measured clearance between two parts
They are thin steel blades having precision of 1/100 mm (0.01 mm). the blade thickness ranges widely, but an ordinary
blade thickness ranges widely, but as ordinary blade set ranges 0.03mm to 1.00 mm in thickness. The thickness is
indicated on each blade.

Note;
- Wipe your hands, blades and parts being measured carefully before starting measurement. Adhesion of dirt,
oil, etc., will result in an incorrect measurement.
- Thickness gauge blade thickness does not increase in increments of 0.01mm. if one blade is not sufficient for
measurement, combine two or more blades as needed. However, keep the number of blades as low as
possible to minimize error.
- Insert a thickness gauge very carefully between parts. Never bend or otherwise damage the blade edge,
damage blades must be thrown away.

Method of measurement
Insert thickness gauge carefully between parts being measured. If the gauge can go in and out easily, use a
thicker gauge (or combination of gauges) until you feel some resistance as you pull the gauge out. The thickness of the
thickness gauge (or gauges) is equal to the clearance between two parts.
CIRCUIT TESTER (VOLT AND OHM METER)

A circuit is an electric testing tool. It is used very widely for measuring the volt of alternating and direct current,
the current of direct current and the resistances, and for checking the electrical continuity of parts.
There are different type of circuit tester. Digital testers indicate the measured value directly by numbers, while
analog tester have a pointer to indicate the value.
Method of measurement,

1. Zero – scale check and adjustment

Before using and analog tester, you must make sure that the pointer is at the left end line on the scale. If not,
turn the pointer calibration screw with a screw driver until the pointer read on the left – end line.

2. Measuring DC volts
The range of measurable voltage is from 0 -500V. connect the red test lead to the positive terminal, and the
black test lead to the negative terminal of the tester. Set the range selector at one of the range value indicates
the maximum value that can be measured.

3. Measuring Volts AC
The range of measurable volts is from 0 – 1000V. connect the test lead to the tester. And set the range selector
to one of the V AC (ACV) ranges. The range value indicates the maximum value that can be measured. The n
connect the test lead in parallel to the appliance being checked, and reads the V AC (ACV) scale indicated by
pointer.

4. Measuring DC Current
Measuring DC current from 0 to 250Ma
Connect test leads to the appropriate tester terminals (the red test lead to the positive and the black test lead to
the negative terminal) and set the range selector to 250Ma A DC (DC A).
Then, break the electrical circuit at the point where you wish to measure the electric current. Connect the red
test lead (from the positive terminal of the tester) to the positive terminal of the power source, and the black
test lead (from the positive terminal of the tester) to the negative terminal of the power source. In order words,
connect the tester in series to the power source and the load, and read the DC (A DC) scale indicated by pointer.

Measuring DC current from 0 to 20A

The electric current is measured in basically the same way as in measuring DC current from 0 to 250MA except
for following changes; the red test lead is connected to the positive terminal which is used only for measuring
20A DC the range selector is set to DC A 20A the pointer reading is red on the 20A DC scale.

5. Measuring Resistance
Calibration
Before you measure resistance, you must first turn the OHM calibration knob, with the test leads shorted, until
the pointer reads 0 ohms on the ohm’s scale. The calibration is necessary every time you change the range,

Measuring
Set the range selector to one of the ohm’s positon. There are several scales for measuring resistance “K” stands
for thousand so 10 k means ten thousand, etc.

X1 = 1k
X10 = 10k
X100 = 100k
X1k
Once you set the range, you must calibrate the pointer. Disconnect the load to be measured, and then connect
the test lead both ends of the load. Either terminal of the tester may by connect to either end of the load,