Iran Khodro Dena. Service Manual - part 7

102

4

Brake 

This vehicle is equipped with four-wheel disk 

brakes system. Front wheel are equipped 

with coolant disk brakes and back wheel with 

filled disk brakes. Brake booster is two-circuit 

hydraulic and will adjust pedal force when the 

vehicle is running to increase speed.

Brake oil

The brake oil may decrease due to erosion 

of brakes. In case of considerable brake 

oil shortage, you shall refer to authorized 

workshop.

Brake oils shall be replaced completely 

every two years. 

In moist climates, the brake oil shall be 

replaced every 20000 kilometers.

CAUTION

Brake oil will damage the painted 

surfaces,  if  so,  first  clean  it  with 

a cloth, then wash it with special 

shampoos and water.

WARNING

- The brake oil are highly toxic and 

shall be kept in sealed cans away 

from reach of children. In case 

of easting, immediately refer to a 

clinic. 

- Avoid contacting brake oil with your 

s kin and eyes, if so, immediately 

wash it and refer to a clinic.

- Keep eyes to prevent pouring brake 

oil on the hot engine, it is highly 

flammable. 

- Take care not to power off the engine 

in high slopes.

Checking up brake oil

In order to prevent dust going into the 

tank, first clean the door then open it up, 

then fill the tank up to MAX point.

Never allowed the brake oil to be less 

than MIN point, only make use of fresh 

oils in sealed cans and make sure the 

reliability of its brand because bad oils will 

have severely damaging impacts on the 

brake system.

Never pour oil more than MAX point in 

the tank.

Only make use of standards and reliable 

brake oils and packages approved by 

ISACO.

ENGINE COMPARTMENT

103

4

CAUTION

Hydraulic oil will damage the painted 

surfaces, if so, first clean it with a cloth, 

then wash it with special shampoos 

and water.

WARNING

Hydraulic oil is severely toxic, so keep it in 

sealed cans away from reach of children. 

If so, immediately refer to a clinic.

Hydraulic steering wheel

In case of appropriate functioning, the 

hydraulic steering wheel will not need 

or a bit amount of hydraulic oil. Unusual 

shortage of oil shall be referred to 

workshop. If the oil is less than the pointed 

amount, first fill it then start the engine.

In case of oil shortage, never start the 

engine because the hydraulic equipment 

will be damaged. If you saw the oil 

leakage is very slow, you will be able to fill 

it and go to a workshop. 

Consider the oil level every week in this 

time, power off the engine and allow it 

to get cooled and front wheel shall be in 

straight direction. 

Checking up the hydraulic oil level

Clean  the cap then release it slowly, and 

clean its rode with a clean cloth. Then put 

it and again release it to consider the oil 

level. 

If it is less than pointed amount, fill it and 

close the cap.

Never pour extra oil in the tank.

Use only hydraulic steering wheel oil and 

brands approved by ISACO.

In case of contacting hydraulic oil with 

skin or eyes, immediately wash the 

location but take care because it is highly 

flammable.

ENGINE COMPARTMENT

104

4

LMF Battery

Serviceable starts battery

  

Your vehicle is equipped with LMF, whose  

water level shall be checked up. 

Battery service and maintenance 

- Keep the above side as clean and dry.

- Keep the terminals and connections as 

clean, tight and greased. 

- Clean the water & acid poured location 

with water and soda

Electrolyte level must be checked every 45 days 

in hot seasons and every 3 months in other 

seasons.

If your vehicle is equipped with LMF battery *

if installed on your vehicle *

WARNINGS

- The existing hydrogen in the battery is highly 

flammable.

- Never keep used batteries at home and get it 

to special workshops.

- In case the battery voltage is less than 10.5 

volts, it shall be replaced.

- In case the battery voltage is between 10.5 to 

12.4 volts, it shall be recharged.

- Avoid keeping the electric tools ON, when the 

engine is powered off.

LMF & sealed Battery * 

Sealed Maintenance Free

Your vehicle is equipped with a SMF 

which does not need special cares.

In case of voltage shortage, pay 

attention to the following tips:

1.Check the alternator belt to b tight 

enough and check its erosion issues.

2.Wires, ignition wire failures, with 

appropriate diagonal position. 

3.Avoid unnecessary starts in -18 degree 

centigrade. 

Battery's common issues:

- Electrolytes shortage which consists 

50% of errors due to heat and over 

charge. (in case of SMF battery)

- Keeping the lamps turned on which may 

cause discharge

- Incompatibility of replaced battery with 

the initial one.

- Alternator belt failures

- Battery terminals loosing 

- Making use of urban water instead of 

distilled water. 

- Corrosion 

- Freezing

ENGINE COMPARTMENT

105

4

Dismantling battery 

First turn off the alarm system and make 

sure than the switch is off, then release 

negative terminal (-) and then positive 

terminal (+), if you wanted to install it 

again,  first  positive  and  then  negative 

terminals shall be installed. 

Avoid contacting battery terminals with 

metal body of the vehicle. To dismantle 

the  battery,  first  open  up  its  hook  then 

release the battery, to install it again, first 

close the hooks and clamps, then fix the 

battery. 

CAUTIONS

In case of resting for more than 6 days, the 
vehicle shall be started and  kept powered on for 
one hour.

CAUTIONS

- Never charge the battery when it is installed on 

your vehicle because of electric failures.

- The level of battery water and acid shall be 

checked up each month and filled if necessary.

WARNINGS

The battery acid is highly toxic and corrosive, 
pay attention to the following tips in case of its 
leakage:
In case of pouring on clothes, immediately take off 
clothes and wash it, then refer to a clinic.
In case of its contact with eyes, immediately wash 
it then refer to the physician. 
Negligence in medical actions may be result in 
death. 
The battery under charges will release hydrogen 
explosive gas, hence, put away ignition and fire 
from around it. 
Put out all our jewelry when working in the hood 
in order to avoid firing and blazing. Never allow 
contact of battery terminals with metal tools.

WARNINGS

Never charge the batteries which may be frozen.
Put away fire and ignition from around the battery 
when it is charging, because of hydrogen gas.
After charging the battery and before its installing, 
wait for one hour so as to allow flammable gases 
to be released.

Battery replacing

Always make use of original batteries 

whose type and size are appropriate. 

Other types may have other details which 

may not be compatible with your vehicle 

and cause firing.

ENGINE COMPARTMENT

106

4

Filling glass washer tank

Check up the level of glass washer 

tank level weekly. Fill the tank with a 

combination of water and a reliable 

washer to ensure its cleaning factor. First 

mix the water and a washer then pour 

it into the tank. Always observe the tips 

inserted on the washer. 

CAUTION

- Never make use of a combination of 

water and anti-freezing liquid because 

it will damage the color of vehicle.

- Never contact high-pressure water 

tools in car wash workshops with 

the locks because of erosion 

considerations. 

- Make sure that the wipers are not 

frozen in cold climate due to danger 

of motor warm up.

- When you feel the wipers function 

decreased, please replace them with 

new ones. Approximately every year. 

ENGINE COMPARTMENT

107

4

Releasing the snow wipers

Pull up the snow arms and rotate it up to 

90 degree. 

1. Press down its hook to release the 

wiper.

2. press the snow wipers inside in order to 

release it from the arm them easily open 

it.

Installing the snow wipers

Replace the snow wipers one by one, so 

you can see the other one and make a 

pattern for its installation

Grease, silicon adhesives and 

oil combinations will damage the 

performance of snow wipers. Wash the 

snow wipers with warm water and soap 

and always check them up.

ENGINE COMPARTMENT

108

4

WASHING AND CAR CARE

Cleaning the vehicle's body

Pay attention to the following tips in order 

to keep the color's quality:

- Never use of hot water to wash your car

- Make use of damp cloth to clean the 

dust and fogs from the body.

- Never use cloth washing powder or dish 

washing liquid to clean your car.

- Never wash the car on direct sunlight in 

hot climates.

- Never pour direct water to door locks, 

rubbers and brakes equipment when 

washing your car.

- Never put footrests on the vehicle's body 

to wash or dry it.

- Drying footrests on the vehicle's body 

will damage the color of vehicle.

- Make use of water to clean all dust first, 

then try to clean it with special washers 

is order to avoid crashing the color of 

your vehicles, after cleaning clearly, try 

to dry the body with a special cloth.

Cleaning beneath the vehicle's body

Try to periodically clean the beneath of 

vehicle's body especially in winters and 

specially beneath the tires.

CAUTION

High  pressure  of  water  will  inflict 

damages on rubber tools, hence; never 

pour water with a high pressure on 

sensitive places.

Try to make use of following materials 

to clean the vehicle's body

- Automobile shampoo

- Shining wax

- Tar spot cleaner

- Glass washer

- Rubber sealing protective

- Rings and aluminum rings cleaner

109

4

WASHING AND CAR CARE

CAUTION

- Installation of extra equipment

Only make use of standard and determined equipment which are compatible with your 

vehicle in order to avoid decreasing the safety of vehicle.

- Electric and electrical equipment

Any  modification  on  vehicle's  electric  circuit  shall  be  performed  only  by  authorized 

workshops because only one false connection may result in sever electrical failures or it 

tools attached to it. When you are trying to install different electric equipment, make sure 

that it is protected by a fuse, then make sure appropriate place of fuse and its voltage. 

Vehicle equipment maintenance 

Clean the dusts before cleaning inside of 

the vehicle. 

Plastics parts:

First clean these parts with special 

cleaners then wash them with a damp 

cloth. Never shine the dashboard 

because of safety considerations due to 

light reflection. 

Floor mat

You can make use of home cleaners 

like carpet shampoo. Try to dry them in 

shadow to avoid damaging their color.

Hands-free mobile microphone and 

lever of cruise control *

It is enough to clean it with a dry cloth. 

Never use hard materials to clean them.

*if installed on your vehicle

110

4

Cleaning tar spots 

Make use of alcohol to clear the tar spots 

on the body. Then wash the place clearly 

with water and soap in order to eliminate 

the alcohol material. 

Protection of vehicle's body

Always analyze the body's color after 

washing

Try to repair the crashed parts of the color 

with a special paint color. Try to paint the 

vehicle in two steps, and this action shall 

be done before waxing and polishing 

the body. Repairing big areas of color 

damage shall be done according to the 

manufacturer's manual, Or, the guarantee 

of the vehicle will be canceled, you can 

also call authorized workshops to make 

sure of it.

Polishing the body color 

Sometimes, the following polishes are to 

be used for the vehicle's body:

- Corrosive smooth spots to clear the 

spots on the body without any damage 

to the color

- Filler materials to eliminate or restore the 

crashes on the body

- A wax to create protective cover between 

the color and external materials.

Snow wipers

Try to wash the wipers with warm water 

and soap. Never use white alcohol or 

gasoline cleaners.

Windows and mirrors 

Try to clean the windows and glasses with 

washers.

Windshield:

Always clean the windshield especially 

after car wash and before installing new 

snow wipers.

Back windows:

Try to clean its internal parts with cloths 

smoothly so as not damage heater 

elements.

Making use of corrosive washers will 

damage the heater elements. 

Mirrors:

Wash the mirrors with water and soap. 

Make use of plastic tools to eliminate ice.

Notice:

Never make use of corrosive washers 

and/or metal tools.

Cleaning Internal set of the vehicle

Seats:

Make use of standard materials to clean 

the seats.

Dashboard:

Dashboard is resistant against sunlight, 

heat and cold, so try not to use covers on 

it.

Make use of standards washers to clean 

the dashboard.

WASHING AND CAR CARE

111

4

Qualitative recommendations in car 

wash process

1.It is advised that you wash your car 

every week in normal climate conditions.

2.Try to wash your vehicle in shadow.

3.Pay attention to take action for car 

wash thirty minutes after powering off the 

engine.

4.Never make use of hard or blading 

objects or tools in car wash because 

these will damage on the body and the 

color. Also never make use of hot water 

for washing the vehicle. Just warm water 

is enough. Then after drying the vehicle, 

try to make use of standards polishes and 

shiners for your vehicle. 

5.Never force on the foot place or the car 

body when washing or drying the vehicle. 

You can also make use of cotton clothes 

for drying the body.

6.Try  to  wash  first  the  tires,  because 

the brake dusts are so corrosive and 

their remaining on the washing cloth 

will damage the vehicle's color. Also in 

case of using aluminum rings and metal 

plates, You shall make use of a soft and 

clean cloth soaked in a mix of water and 

soap. This is to be mentioned  that the 

rings surfaces are so sensitive just like 

the vehicle body, so sever chemical will 

damage on them. Also making use of 

detergent and corrosive materials will 

crash them; shiners are also used to 

shine them not washing them.

7. Maximum standard water temperature 

is advised as 60 degrees centigrade, 

maximum pressure 4 to 5 bars and 

distance of nozzle and washing place 

about 10 cm and angle of pouring water 

about 25 degree.

You can take a look at the following picture 

for more information on the angle of water 

pouring or spraying in a car wash process

8. Characteristics of appropriate washers 

to wash the vehicle:

Its PH shall be 7 to 9. 

Try to make use of high quality lubricants 

to protect the shiny surfaces from 

crashes. It is advised to make use of 

liquid cleaners. 

Try not to make use of cleaners which 

remain some sports on the vehicle after 

its drying.

Try to make use of shiners in order to 

protect the shininess and rapid dryness. 

9. Rotating brushes used in some car 

wash workshops are not advised for 

washing the vehicle with metallic colors.

10. In case of seeing any spot including 

birds wastes and trees gums, it is advised 

to wash them immediately due to their 

penetration potential to the vehicle's color.

11. Dry the leaked water to the boot and 

internal parts of the vehicle after doing the 

car wash.

WASHING AND CAR CARE

112

4

Natural leather maintenance *

Natural leathers need a special care for 

the maintenance of beauties and stability. 

Try to dry them in case of pouring any 

spot of food or liquids. Never make use of 

blowers to dry the leathers. Never make 

use of dish washing liquids, detergents, 

and soap, solvents, polish and corrosive 

cleaners to wash the vehicle's leather. 

You shall only make use of special leather 

cleaners; these materials will clean the 

spots without remaining any spot on the 

leather.

You can test the performance of cleaners 

in small areas out of vision, and then use 

them for other leather parts.

Cleaning the leather surface shall be 

done every several months. First clean 

the dusts from the surface e of leather. 

Then use cleaners from the surface in a 

rotating move of hands.

Smelling the leathers surface is natural in 

first months of buying the vehicle. In case 

of parking the vehicle in a private and safe 

parking, you can put one of the windows 

a bit open.

Avoid direct sunlight on leather parts.

Never make use of any wax for leather 

parts, because they will result in absorbing 

dust on the surface.

The leather cover shall be cleaned by a 

damp cloth and a cotton cloth soaked in 

shampoo is very effective.

You can refer to IRAN KHODRO 

authorized workshops in order to restore 

the leather surfaces with small corrosions.

Maintenance of clothes used in 

internal decorations 

These kinds of clothes just like the other 

ones need special care for maintenance 

and stability; so, you shall clean any spots 

including those of foods, drinks, alcohols 

with a sponge and shampoo from the 

clothes. Never make use of dish washing 

liquids or polishes especially corrosive 

ones on the clothes.

CAUTION

Try to clean any kind of spot(s) from 

the clothes by carpet shampoo and 

sponge.

WASHING AND CAR CARE

113

TECHNICAL SERVICES

5

*If equipped

WHEELS REPLACING  .......................................... 114-117

AUTO TOWING  ...................................................... 118-119

BATTERY SERVICE AND MAINTENANCE  ....... 120-122

FUSES  .................................................................... 123-128

LAMPS REPLACING  ............................................ 129-136

114

5

Spare tire and its tools

Pull  up  the  floor  mat  of  hood  and  push 

the related clamp in order to tight to the 

special hole on the edge of mirror.

WARNING

- The jack shall be used for replacing 

the spare tire, never make use of 

it for repairs and accessing some 

parts. 

- In case of taking too long, refer 

to IRAN KHODRO authorized 

workshops in order for inspecting 

the spare tire, then to be sure of its 

performance.

Spare tire

Open up the fastening belt of spare tire 

and warning triangle, put up the tools box, 

and release the spare tire.

Warning triangle 

When stopping due to failure or any 

emergency, the warning triangle shall 

be installed at 50 to 100 meters behind 

the vehicle. If an embossed area or a hill 

prevents behind driver's vision, put it in 

another appropriate place.

Tools:

1. Wheel wrench  

2. Jack wrench 

3. Jack

The tools box prevents the boot mat to 

sink. Fix the sealing belt tightly in order to 

prevent tools from moving.

For some models, there designed special 

other tools herein tools box.

CHANGING WHEELS

115

5

WARNING

Always select a far place to replace 

the wheel in order for safety 

consideration, far the passengers 

away from vehicle and start repairing.

Place of jack beneath the vehicle 

Install the jack in one of the four points 

showed in the image near to the wheel to 

be replaced. 

- Make sure that the jack is placed in a flat 

horizontal manner.

- Never make use of jack when any 

passenger is seat on the vehicle.

- Make sure that the front wheels are 

straight, then pull up the handbrake and 

put the gear into 1.

WARNING

Never repair the beneath the vehicle 

when it is pulled up ONLY by the jack. 

The jack is designed just for replacing 

a flat tire.

Putting the jack beneath the vehicle

1.Loose four tire screws with 

abovementioned wrench.

2.Install the wheel wrench to the jack 

wrench and put its tail hook on the jack 

hole, rotate the wrench clockwise to pull 

up the vehicle.

3.Pull up the vehicle from earth until it 

goes up enough.

4.Loose four other screws and put out the 

wheel.

Insert the spare wheel.

- Fasten all four screws.

- Tight the screws in a cross manner.

- Put the tools into their box and into their 

appropriate place in the boot. Then 

fasten its belt.

- Repair the flat tire as soon as possible 

and put it into its appropriate place.

CHANGING WHEELS

116

5

CHANGING WHEELS

Releasing aluminum sport ring 

The steps of replacing aluminum sport 

ring is just like metal ring, just the step of 

releasing hubcap shall be omitted.

WARNINGS

After replacing the wheel, always 

check up the air pressure and make 

sure the good fastening of screws. 

-  Replace  the  flat  tire  as  soon  as 

possible, the flat tire shall be surely 

analyzed by an expert.

-  Always  park  your  vehicle  is  a  flat 

surface not in slippery surfaces, and 

make use of a jack holder. Turn on 

the flashers. Pull up the handbrake 

and never put the gear in N mode. 

Try to far other passengers away 

from the vehicle then do your 

operation.

CAUTION

- Low air pressure will cause in early 

erosion and unusual warming of tires, 

and also lots of safety issues. 

- Bad performance in the roads

- Risk of exploding or erosion of tires 

rubber

- The air pressure depends on the 

weight and speed of vehicle. Adjust 

the air pressure according to the 

conditions. 

- Pay attention that inappropriate 

fastening of air valve will cause in air 

release.

- Always make use of an air valve just 

like the initial one and fasten it tightly.

CAUTION 

In the vehicles equipped with aluminum rings:

- Four screws are provided in tools box which shall be used for replacing the steel spare 

tire.

- The fifth tire is deemed as a spare tire which shall be used in replace of flat tires.

117

5

CHANGING WHEELS

Tires erosion indicator 

The tires prepared for the vehicle are 

equipped with some erosion indicators. 

When the tires are worn way, these indicator 

crowns will remain only in 1.6 mm and this 

shows that the tires may be replaced. 

Tires air pressure

Tires air shall be adjusted every month 

when the tires are cool. Tires low air 

pressure will make it hot and reduce the 

useful life of tires. High air pressure will 

also have negative impacts on the vehicle's 

convenience. 

WARNINGS

- Flat or worn out tires are so 

dangerous so avoid driving with 

such tires. 

- Always make use of radial tires with 

the same design, and avoid using 

cross designed tires.

-  Never  drive  your  vehicle  with  flat 

or work out tires which air is not 

adjusted. Flat tires will have erosion 

soon, which will cause fuel increase 

and reduction of steering wheel 

functioning.

Tires size

The size of tires are inserted in a phrase 

on the wall of tire like this 185/65 R15, 

185 is the width of tire in mm, 65 is the 

ratio of heights to width in mm, R shows 

the design of radial and 15 shows the ring 

diagonal characteristic. 

Tires rotating in the vehicle

In front differential vehicles, the erosion 

of front tires is more than back tires due 

to existence of brake force, running force, 

and steering wheel forces. Hence, the 

tires shall be replacing every 10000 km 

based on above plan.

Tires maintenance 

Always drive your vehicle based on 

details of your tires.

And always analyze their crown and side 

walls in order to check up any possible 

failure. 

Getting flat

The  flat  tire  shall  be  immediately 

released from the vehicle and put under 

consideration, in order to prevent more 

possible damages to the tires, its repair 

shall be done by skilled experts. The 

repairs shall be done only by experts who 

are responsible for its quality.