Iran Khodro Pars. Service Manual — part 7

102

4

BRAKES

Brake system

The most important part of safety in your

vehicle, means brake system, is equipped

with disk brakes in forward, bowl brakes at the

back and also a binaural hydraulic system.

When the engine is on, the brake boosting

system, reduces the required force for

pressing the brake pedal.

Brake oil

With continuous using of the car, the

level of the oil may be reduced due to the

erosion of the linings and there is a need

to add brake oil. If in short period of time

you notice a considerable reduction in oil

level, refer to authorized representative. If

the level of oil is less than minimum marked

level on the container, stop driving.

Checking the brake oil:

To avoid entrance of the dusts into the

container, clean the cap of the container

first and then open it and fill the container

up to (MAX) sign with brake oil.

Do not let the level of oil comes down less

than (MIN) sign. Only use fresh oils in a

sealed containers. (old or opened oils or

oils which were leaked from the system

before, absorbs the water and using

them again, creates negative effects on

operation of the system).

Just use the standard brake oils and

approved brands and packages that are

offered by ISACO.

CAUTION

Brake oil damages the paint work. In case, first collect the oil with a piece of clean

cloth and then wash the area with water and especial car shampoo.

WARNING

The Brake oil is strictly Toxic and it

should be kept in a closed container

away from reach of children. In case

of swallowing brake oil, immediately

consult a doctor.

- Avoid contacting with eyes and

hands. In case of contact with skin,

wash the area with lots of water and

in case of contact with eye, after

washing, consult a doctor.

- Due to danger of catching fire, take

care that the brake oil is not purred

on the hot engine.

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4

HYDRAULIC STEERING

CAUTION

Brake oil damages the paint work. In

case, first collect the oil with a piece

of clean cloth and then wash the area

with water and especial car shampoo.

WARNING

The hydraulic oil for steering wheel is

strictly Toxic and it should be kept in a

closed container away from reach of

children. In case of accidental swallowing,

immediately consult a doctor.

In case of contact of hydraulic oil with

skin or eye, wash the area with lots of

water . Due to danger of catching fire,

take care that the hydraulic oil is not

purred on the hot engine.

Hydraulic steering wheel

If the Hydraulic steering wheel, is working

properly, there is no need to add extra

oil in the container and if it is necessary,

it will be very little. In case of sudden or

frequent reduction in oil level, the car

should be investigated by authorized

representative. If the oil level is lower than

the minimum sign on the container, fill

the container before starting the engine,

otherwise, the hydraulic pump for steering

wheel, will get damaged.

In case of reduction of oil below the minimum

sign, or it’s fast and considerable drop, do not

use the vehicle under any circumstances. In

spite of this, if the reduction of oil is gradual,

you can fill the container up to maximum

sign and with making a short distance, take

the car to nearest authorize work shop for

trouble shooting.

Check the oil level weekly. When checking

hydraulic oil level, the engine should be off

and cool and the wheels should be straight.

Checking the Hydraulic oil level for

steering wheel

To avoid entrance of the dusts into the

container, clean the cap of the container

before opening it. Take out the cover and

clean it’s rod with a piece of clean and

coreless cloth. Put it in it’s place again and to

check the level of oil take it out of container.

In case of shortage of oil, add oil until the

level of oil comes somewhere between the

minimum and maximum level.

Do not put extra oils in the container.

(More than required )

To get information regarding recommended

oil specifications, refer to Maintenance and

Service Guide.

104

4

BATTERY

Disconnection of battery

Before disconnecting the battery, switch off the

anti theft system and make sure that the main

switch is closed. First disconnect the negative

cable (-) and then the positive cable (+). For

reconnection, first connect the positive cable and

then the negative cable. Do not let the poles of

the battery come in contact with body and other

metal parts of the car. To take out the battery, first

open the clamps of the battery and take them

out. For repositioning, first place the battery and

it’s clamps precisely in their positions (it’s poles

should be pointing the engine) and then tighten

the nuts in such a way that the battery dose not

move, but not too tight.

Changing the battery

Always use batteries that their type and

specifications are like the original battery of the

vehicle. Other types may have different size or

poles. Their connection to electrical system of

the vehicle may have danger of catching fire.

WARNINGS

The acid contained in the battery is Toxic and
corrosive. In case of it’s leakage, note the
followings:
-in case it is in contact with cloth or skin,
immediately take out the infected cloth and wash
the contacted skin areas with lots of water and
consult doctors.
-In case of contact with eyes, immediately wash the
eye with clean water for at least 15 minutes and
quickly consult a doctor.
-If the required medical attentions do not take
place immediately, swallowing acid can be fatal.
-The battery which is being charged, emits
explosive hydrogen gas . take away any sparks
and flames from engine space.
During working on engine space, for your own
safety, take out your bracelets and ornaments .
Never allow the poles of the battery , contact
with tools and metal parts of the car.a

CAUTIONS

-If the car was left unused for more than 6 days ,it
should be switched on at least once and continue
being on for one hour.
-If the car is not going to be used for long time,
you should disconnect the battery cables . In this
situation charge the battery every four weeks.

WARNINGS

-Do not charge a battery which is suspected of
being frozen.
-During battery charging , keep away any spark or
flame from it ( charged battery or the battery being
charged will emit flammable hydrogen ).
- After charging of the battery, and before it’s
connection to the vehicle, wait for an hour so
that flammable gases exit from it and danger of
inflammation is reduced.

CAUTION

-Do not charge the battery when it is connected to the vehicle. This may cause serious damage to electrical
systems of the vehicle.
-It is better to check the level of the water and acid in the battery, in case the caps of the battery can be
opened, up to the maximum level marked on the body of the battery every month and in case of shortage
of water and acid, Distilled water to be added.

105

4

CLEANING & CARING VEHICLE

Recommendations for washing the vehicle

1-Wash vehicle at least once per week if

weather is normal.

2- Wash vehicle away from direct sunlight

3- Start washing at least 30 minutes after

engine has not been running.

4- Do not use cloth and / or hard materials

which can scratch the paint during

washing/wipe off. It is recommended to

wear plastic gloves during washing. Use

warm or lukewarm water for washing.

Never use hot water. Meanwhile it is

recommended to use waxes and polishers

which are not abrasive or erosive.

5- Do not stand on the door step and don

not depress the vehicle’s roof and body

during washing / wipe off. Meanwhile it

is recommended to use leather or cotton

cloth for wiping off and polishing to avoid

scratching the paint.

6- Since the brake’s dust is very corrosive,

first wash the wheels, then change

the cloth and the washing solution and

wash other parts of the vehicle from top

to bottom. Wash Aluminum wheels and

Chrome metal sheets with a water and

mild soap using a soft and clean cloth.

Wheels surfaces are very sensitive such

as the vehicle’s paint. Do not use strong

chemical and/or acid substances and

also abrasive and erosive materials such

as chrome polishers. Chrome polishers

should be used only on the Chrome metal

sheets on the Aluminum wheels.

7- Max. temperature of the water for

washing the vehicle is 60º C, Max 4 to 5

bar pressure, 10 cm distance between

nozzle and washing area and 25 degree

angle for spurting. This angle actually is

the angles between water spurting out the

nozzle in both side of the longitudinal axis

(water exit direction) as following figure.

8- Suitable detergent for washing vehicle:

- Low basic (PH=7-9)

- Proper lubricant to protect the paint from

scratching. Use preferably fluid detergent.

- Free from materials which affect on

vehicle after drying;

- Containing polisher ingredients to

maintain gloss and dry quickly.

- Do not wash the vehicles, having metallic

and two coverage paint, by using automatic

carwashes which use rotary brushes;

- Foreign material such as bird droppings,

tree sap, etc. may damage the finish of

your vehicle. Remove these types of

deposits as quickly as possible.

- If the water permeates to the luggage

compartments and interior parts of the

vehicle, dry it immediately.

106

4

CLEANING & CARING VEHICLE

Cleaning the Bodywork

In order to preserve the car painting finish,

please consider the following advices.

-

Do not use hot water to wash the car.

- Use wet linen cloth to clean dirt and

dust from the car metallic paint to prevent

scratching.

- Do not use detergent powder or washing

liquids.

- In hot weather, do not wash the car in

direct sunlight.

- Do not flush the water directly to the windows,

door liners or the brake components.

Avoid putting the the foot pad

on the vehicle body .Otherwise it will

change the color of the body by the

course of time.

- Use a water hose to flush dust and dirt

front the bodywork before washing, and

when the car is too dirty. Then wash the

car with cold water or lukewarm water

and a good quality shampoo.

Use plenty of water to make sure that the

bodywork has become free of dust. Rinse

the car with clear water and soak up using

a chamois leather cloth.

Cleaning The Underneath

Occasionally and especially in winter,

flush away mud from underneath of the

car such as the wheel compartment and

frame gaps (seams), which can easily

collect debris.

Do not flush water directly to susceptible

areas.

Use the following materials to wash the

exterior of the vehicle:

- Car shampoo

- Wax polish

- Tar remover

- Glass cleaner

- Rubber protector

- Cleaner of rings and aluminum

CAUTION

-In some high pressure, water

penetrates in doors and windows

liners, and cause damages to the

locks. Do not use high pressure water

on sensitive parts

- Blue straps on the trim, side mirrors,

windows, fenders & ... should be

detached. otherwise it may cause

problem.

107

4

CLEANING & CARING VEHICLE

Cleaning of Tar stains

To clean the tar and grease stains ,use

white alcohol. Then wash the area with

water and soap till the residues of alcohol

disappears.

Plastic parts:

First clean these parts with diluted

washing liquids. Then clean the area with

wet cloth. Do not shine front dashboard

areas. This place should not shine , so

that it’s reflection in front glass , dose not

obstruct the driver’s vision.

Floor mat (Carpet)

Use diluted home cleaners, like carpet

shampoo and to avoid change of color,

dry them up in the shades.

Paint polishing of the body

Sometimes use good quality polish

containing following materials to finish up

the paint works:

- Eroding soft particles to remove surface

stains without damaging the paint.

-Filling materials for removing or covering

the scratches on the body paint work.

-Wax for creating protection shield

between the paint and foreign objects.

Blades of the wipers

Wash the blades with warm water and

soap. Do not use alcohol or petrol cleaners.

Glasses and Mirrors

Regularly Clean the glasses from inside and

outside with a high quality glass cleaner.

Front glass

Wash the front glass with glass liquid

cleaner, specially after polishing and

cleaning of body and before installing

new wipers.

Rear glass

Clean the interior side by soft cloth with

left and right movements so that there is

no damage to the heaters . Do not clean

the glass with eroding cleaners. This will

damage the heaters of the rear glass.

Mirrors

Wash the mirrors with water and soap. To

remove the ice patches from the mirror

surface, use plastic pallet knife.

NOTE: Never use metal pallet knife or

eroding cleaners.

Interior parts of the vehicle

Seats: To clean the dirt from the surface

of the seats, use standard cleaning

materials.

Dashboard: To protect the dashboard,

there is no need to use covers, because

it is very resistible against sun light, heat

and coldness.

To remove grease stains and other

dirt from dashboard, only use cleaning

materials…

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4

*If equipped

CLEANING & CARING VEHICLE

Maintenance of the Vehicle's Natural

Leather*

Natural leather requires care to keep its

beauty and durability. Clean any spots,

whether made by foodstuff, alcohol or

liquids, using an absorbent cloth. In case

of water being spilt on the leather, do not

use hair dryer or brush to dry it, just let it

dry naturally. Never use tableware polish,

solvents and soap or frictional polishes

and cleaners on the leather. Just use

special leather cleaners. These cleaners

will completely clean all spots and grease

marks without leaving any marks.

To ensure the cleaning agent does not

have any undesirable effects on the

leather's color and appearance, first test

it on a parts not in view.

You need to clean the leather surface once

every few months. First dust the leather,

then to clean and protect leather surface,

use leather cleaners and protectors using

a circular motion.

A smell of leather is natural in the first few

months.

If possible, when the vehicle is parked,

leave one of the windows slightly down.

Prevent direct sunlight on the leather

surface for long periods, as much as

possible.

Do not use any types of wax on the

leather surface since this will attract dust.

The leather covers may be cleaned

using a damp clean cloth. If the leather

surface is very dirty, you can use a cotton

cloth with the suds made by a shampoo

solution to clean it and then dry it.

If as time passes, any signs of attrition or

discoloration appears, apply to your Iran

Khodro authorized representative to rectify it.

Care Of the Fabric Used in Inside

Furnishings of the Vehicle*

This type of fabric, like any other, requires

care to keep its beauty and durability. For

this reason, any type of stain, whether

from foodstuff, alcohol or liquids should

be cleaned using a sponge and carpet

shampoo. Never use tableware cleaners,

solvents, soap or polish and especially

abrasive cleaners on the fabric.

CAUTION

Clean any type of stain on the fabric,

using only carpet shampoo and sponge.

109

TECHNICAL EMERGENCIES

5

*If equipped

TOWING . . . . . . . . . . . . . . . . . . ...110

CHANGING WHEELS . . . . . . . . . . . . . 112

CHANGING LAMPS . . . . . . . . . . . . . ...115

FUSES* . . . . . . . . . . . . . . . . . . ...119

MAINTENANCE & SERVICING OF BATTERY . . ...133

HANDLING METHOD IN A CASE OF LEAKAGE* . ..137

110

5

VEHICLE TRANSPORT

Front Towing Ring

Use the ring beneath the front bumper

only to tow the car on 4 wheels.

Towing the car with a manual gear box

(non-automatic)

Neutralize the gear and turn on the flashers.

Drive carefully and never exceed the

speed limit of 50km/hr when being towed

Always keep the tow rope stretched by

gently applying the brake as necessary. It

avoids impact on the rope and its rupture.

- Get help from experienced persons to

carry the car.

Rear Towing Ring

The rear ring should be used only to tow

cars lighter or with the same weight.

Do not use the rings for suspending tows

(on two wheels)

WARNING

- If the engine is off, the hydraulic

Steering wheel and brake system, do

not operate.

- The vehicle on tow should be always

lighter than the towing vehicle.

- The towed vehicle should never

have any passengers.

- Remember that the brake servo

does not operate when the engine

is off, and you need much generator

force to operate on the brake pedal.

- Do not take out the start switch or

turn it off when the vehicle is being

towed on four wheels since this will

cause the steering wheel to lock. It is

recommended to place the switch in

the A position.

- We recommend use of a sturdy and

fixed bar when towing the vehicle. If

using rope or cable (where it is legal),

the towed vehicle should be able to

brake (the engine could be turned on).

- Do not tow a vehicle that can not be

moved and driven.

- To prevent damage to the vehicle,

do not brake violently or speed up

suddenly.

- At any rate it is recommended not to

let the speed go over 25 km an hour.

111

5

VEHICLE TRANSPORT

Transport by truck

This type of carrying is recommended to

prevent any accident or damage.

Rear Towing

Avoid

suspension towing on front wheels

if possible. If it is necessary, tow it at least

speed and short distances.

The steering should be locked when

the wheels are completely ahead. Use

supporting clamps or catches in addition

to the steering lock.

Front Towing

The steering should be locked when

the wheels are completely ahead. Use

supporting clamps or catches in addition

to the steering lock.

CAUTION

When the car is being towed from

the front and moves on back wheels,

make sure the handbrake operating

on the rear wheels is released.

112

5

CHANGING WHEELS

Changing the wheels

Stop the car on a hard and smooth

surface, put the hand brake and shift the

Gear lever to Gear one or reverse Gear

and then intend to change the wheel.

Changing the reserve wheel

1- First, bring up the carpet covering

the reserve wheel in the rear trunk and

according to the sketch, hang it to the edge

of the rear trunk. Then open the belt.

2- Removing the reserve whee:

-Removing wheel spanner, jack and

hubcap spanner from the foam cover of

the reserve wheel.

-Removing reserve wheel from rear trunk.

3-Removing the wheel.

Removing the wheel

- Put the peak of the wheel spanner into

the groove of the hubcap, against the tire

air manifold and remove the hubcap.

- loosen the nuts of the wheel.

- locate the head of the jack in special

position for use of jack, in the required

side and raise the jack up. Then unscrew

the nuts of the wheel completely and take

out the wheel.

WARNINGS

-Park your car on a smooth and hard

surface which is not slippery (for

example, do not park on ceramics) and

if necessary use a barrier underneath

the base of the jack and switch on the

flashers (Emergency lights)

Put the hand brake and remove the

gear from neutral. Disembark the

passengers and lead them to a place

away from traffics.

-

Never work under the vehicle when

the only resting point is jack. It is only

for the purpose of changing wheels.

- Always in order to change the

wheels, choose a safe place away

from traffics.

Disembark the passengers and lead

them to a place away from the vehicle.

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5

CHANGING WHEELS

Putting the reserve wheel

-Put the reserve wheel in to it’s place

properly and tighten the nuts with hands

as much as possible.

-Lower down the jack and remove it from

the place underneath of the car.

-Tighten the wheel nuts with wheel

spanner completely.

-Fix the hubcap on the ring in such a way

that air manifold of the tire comes out of

the related groove. To fix tightly, hit the

fringes of the hubcap strongly with palms

of the hand.

- Put the flat tire (Punctured tire) in place

of reserve tire in rear trunk.

-Put the Jack, wheel spanner and hubcap

spanner on the foam cover and secure

the wheel with belt.

Attention

On vehicles equipped with aluminium wheels:

-There are four screws in the Jack Box for installation of spare steel wheels.

- Fifth wheel is a temporary wheel (to change in urgent situation and when one of

the tires are punctured).

So, due to the mismatch of tires and spare tire, there is no problem if the tire or the

tire crown is different from the other aluminium ring tires.*

WARNINGS

-Jack is only used for changing the

wheels only. Under no circumstances

it should be used for other operations

such as repairs or reaching underneath

of the vehicle.

- If the life time of the reserve tire is

over, take it to the one of the authorized

repair shops, so that you can make

sure about it’s good conditions and

safe usage.

-May be the air pressure in the reserve

tire is not adequate. Therefore drive

calmly and precautionary and as soon

as possible check it’s air pressure.

Also check whether the nuts of the

wheels are correctly secured and

they are absolutely tight.

-Repair the punctured tire quickly so

that in case of any requirements , you

can fix it on your vehicle again.

114

5

CHANGING WHEELS

Tread wear indicator

The tires have molded-in tread wear

indicators in the grooves. When the

indicators appear on the tread surface, the

remaining depth of the tread is 1.6 mm and

the tire should be replaced.

Air pressure of the tires

Inspect your vehicle’s tires at least once

a months when the tires are cold. Under-

inflation can cause heat which decreases

the tires life. Over-inflation can cause

negative effects on convenient driving.

Tire size:

Your vehicle’s tire size is molded on its

body such as following:

185/65 R 15, in which 185 is the width of

the tire in mm, 65 is the ration of the height

to width of tire, R means Radial structure

and 15 is the wheel diameter in inch.

Tire rotation

Front tires wear more than rear tires in front

differential vehicles due to braking, driving

and steering forces. To avoid uneven wear

of your tires and to prolong their life, rotate

the tires as follows every 10000 km driving:

Taking care of the tires

Inspect the treads and side wall of the tires

to find out damages (especially cracks

and node).

Puncture

Change the punctured tire and have it

inspected before patching.

To avoid more possible damages to the tire,

it should be repaired by an expert technician.

Repair should be performed by expert

technicians who accept full responsibility for

the quality of the repair.

WARNINGS

-Damaged tires are very dangerous!

Avoid driving with damages, worn

and/or over-inflated tires.

-Use always same type and size

radial tires for front and rear tires.

Do not use tires with crisscross form.

Your vehicle’s wheel are not tubed,

do not use tubed tires.

-Never drive with worn, punctured

and not adjusted air pressure. Under-

inflated tires are worn quickly and

increase the fuel consumption and

decrease the control on vehicle.

115

5

Changing the lamps

Front lights

In order to dismantle the front lights , it

is necessary to dismantle the forward

bumper and forward vent channel window

first . Then by opening the light installation

screws to the light socket frame, separate

the light combination from the socket

frame.

6-Side lights on the mud guards

- By separating the plastic pins on the

bottom and screws available (within the

limits of the tires), remove the mud shield.

- Pull-out brushed metal of the traffic lights

which is sliding. (1)

- By rotating the traffic lights, remove it from

its place. Rotate the lights counterclockwise

to remove the bulb base. (2)

- change the bulb.

-side light lamp on the mud guard T8.4 = 4

watts, 12 volts.

7-Anti fog lights on the bumper

Remove the blue socket of the anti fog

light. Change the bulb.

The front anti fog light H1= 55 watts, 12

volts.

8-Adjusting screws for front lights

CHANGING LAMPS

1-Front light bulbs

Turn the plastic covers behind the light,

anticlockwise, until it gets separated. Then

change the bulb.

2- Small lights of 5 watts

3- Main lights (Big), lower beam H7= 55

watts.

4- Main lights (Big), upper beam H7= 55

watts.

5-Front side lights

By releasing the Brushed Metal, open the

lamp and then replace it.

Side light lamp of 21watts

WARNING

For replacing the turn signal lamps، needed

to open a large number of components. So,

for this reason it is recommended refer to one

of the dealers authorized for do that.

The bulbs are under vacuumed and, at the

time of replacing may be broken and cause

injuries.

116

5

CHANGING LAMPS

Changing the combination of lights at

the back

-Remove the decorative frame of the rear

light sockets from the rear trunk.

-Unscrew the holding nut of the frame for

rear side light and change the combination

of light.

Changing the bulbs for rear lights

- Unscrew the holding nut of the rear light

from the rear trunk and take out the rear light

frame, then change the side light bulbs.

Change of lamp

Rear side lights

1-Side light lamp=

21 watts.

2-Reverse gear light lamp=

21 watts.

3-Light reflector-Small light lamp=

5 watts.

4-Rear anti fog light lamp=

21watts.

5-The brake light lamp=

21watts.

6-Small light lamp=

5watts.

All rear light lamps are changed trough

the rear trunk. To dismantle the frame

of the lamp, first unscrew the nut of the

frame and then change the fused bulb.

7-Vehicle number light lamp =

5 watts.

Unscrew the plastic cap of the lamp and

change the fused bulb.

WARNING

The bulbs are vacuumed and may break

during changing and cause injuries.

It is recommended that always keep

one set of required lamps, bulbs

and fuses with you in the vehicle.

Front/Rear Ceiling Lights

Enter a screwdriver into the slot, at the end

of the lamp, and lever off the lamp, detach

the lamp assembly from the console.

Keep the lights assembly, and open the

lamp base. Remove and replace the bulb

ensure that solid foundation is in place.

Then install lamp assembly in place.

117

5

High brake lights (rear shelf) *

- Pull the side clamp downwards and, open

the lamp assembly.(1)

CHANGING LAMPS

If equipped*

- Then detach the jack. (2)

- By opening the holding screws,

replace the lamp assembly.(3)

LED map reader (middle)

For replacing LED map reader lamps, first,

open the screws Decorative cantilever

roof, remove the frame and then release

sockets of LED map reader and rotate the

bulb inside it in the opposite direction of

clockwise and remove, then replace. After

that, re-instal.

WARNING

The bulbs are under vacuumed and, at

the time of replacing may be broken and

cause injuries.