Iran Khodro Samand SE. Service Manual - part 9

136

5

BATTERY CARE & MAINTENANCE

3- Turn off vehicle’s electrical equipments 

(audio system, heater, etc.). Switch off the 

booster vehicle. Make sure both vehicles 

are set at freewheel, with handbrake 

on, otherwise there may be damages 

to electrical equipments which are not 

covered by Guarantee.

4- Open the engine door of both vehicles and 

identify the place of negative and positive 

terminals. If there is not enough light, use 

flashlight or similar safety illumination.

5- Prepare one couple jump lead (proper 

thickness and free from any damages or 

tear). Jump lead is usually made of two 

thick red and black cables. Connect one 

end of first jump lead to the positive (+) 

terminal of the booster battery and the 

other end of it to the positive (+) terminal 

of the flat battery.

6- Connect one end of the second jump lead 

to the negative (-) terminal of the booster 

battery. Connect the other end of  it to an 

unpainted, heavy metal part (i.e. engine 

hook) of the vehicle with the flat battery.

Emergency charge of battery

In case your vehicle is not switched on due 

to weak of flat battery, start your vehicle by 

one of following methods respectively:

A- connecting battery to battery

(by booster vehicle) 

1- Use only a 12 volt battery to jump start 

your vehicle, otherwise the wiring system 

of the vehicle will be damaged which is not 

covered by the Guarantee.

2- When using a battery installed on another 

vehicle, 

DO NOT LET THE VEHICLES 

TOUCH, otherwise short circuit damages 

the wiring system of vehicle which is not 

covered by the Guarantee.

Figure (1)

Figure (2)

Make sure the connection leads are away 

from fuel pipes, brakes and other rotary 

parts of the both engines.

7- Start the engine of the vehicle with 

the booster battery. Run the engine at 

moderate speed.

8- Start the engine of the vehicle with the 

flat  battery.  Wait  a  few  minutes  to  have 

engine run at moderate speed.

9- Remove the jump leads in the exact 

reverse order in which you connected 

them (see. Fig. 2)

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BATTERY CARE & MAINTENANCE

B- Charging battery by charging system

First disconnect the battery from vehicle in 

following steps:

1- disconnect negative (-) terminal of the 

battery

2- disconnect positive (+) terminal of the 

battery

3- Open the holder or fastener of the 

battery and dismantle it.

4- To charge the battery, take it to the 

battery service center. Battery specialists 

will check it and do necessary actions. 

Followings should be considered: 

- The battery terminals and clamps of the 

battery cables should be clean. Disconnect 

them and clean the sediments.

- Never disconnect battery when the 

engine is on.

- Charge the battery only when its cables 

are disconnected.

- If your vehicle is not going to be driven 

for a long term (one month or longer), 

disconnect its cables.

Caution

Make sure the voltage of both 

batteries to be equal (12 V). Leads 

should have insulated clamps which 

are suitable for being used with 12 

Volt batteries.

If your vehicle is not going to be 

driven for a long term, disconnect its 

cables and charge the battery every 

4 weeks.

Since the vehicle’s start is 12 volt, 

using a 24 volt battery or two 12 volt 

batteries will damage the vehicle’s 

electrical systems. So only a 12 volt 

battery should be used as an auxiliary 

battery.

- Final voltage of the 12 volt charged 

battery will be equal to 14.10 – 14.40.

Crimping Tool Battery (red) must 

always be connected to the positive 

pole. To avoid damage to the 

alternator, alternator should never be 

disconnected from the battery.

Caution

In case of disconnecting or changing 

the battery and E.C.U, the vehicle’s 

engine should be adjusted in one of 

the authorized dealer of Iran Khodro 

by pertinent turner.

Never start your machine if the battery 

appears to be frozen.

Make sure the voltage of both batteries 

to be equal (12 V). Leads should have 

insulated clamps which are suitable for 

being used with 12 Volt batteries.

Do not disconnect the cables of the 

flat battery during jump start.

Never connect the positive (+) terminal 

of the battery to the negative (-) terminal. 

Make sure to keep the jump leads away 

from moving parts of the engine.

Do not install non-standard electrical 

accessories to your vehicle. This may 

cause damages to your vehicle’s 

electrical system and battery which 

are not covered by Guarantee. 

Your vehicle should not be started by 

pushing. This starting method could 

result in cam belt and serious damages 

to your vehicles electronic systems 

which are not covered by Guarantee.

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BATTERY CARE & MAINTENANCE

Battery care & maintenance

A) Always keep the battery case clean.
B) To prevent the poles from becoming sulfated, 
cover them in industrial Vaseline or grease. 
C) Electrolyte level in summer, at least every 45 
days, and in other seasons should be checked 
once every three months and if the level drops, to 
recover it by adding only distilled water. Addition 
of other liquids such as industrial water, sulfuric 
acid and... will inflict irrecoverable damage to the 
battery. If in this case, water evaporation volume 
is more than it should be, the vehicle should 
be taken to an authorized representative to be 
checked.
In addition, prevent the battery cells from being left 
without electrolyte. Since its negative plates will 
synthesize with the oxygen in the air in a short time 
and the positive plates will also become sulfated 
and ultimately the battery will become useless.

 

Battery safety tips

- Do not bang on the battery poles. 

-  Prevent short-circuiting of the positive and 

negative poles with each other.

-  Never charge the battery more than the 

permissible level, since it will damage the 

battery panels and reduce battery performance 

and life. 

- Ensure the holes made on the battery cover 

bolt are open otherwise the battery will explode 

due to the accumulation of gases produced. 

- The battery in its place should be tightly 

installed since strong blows and jolts will 

damage it. 

- Do not keep a charged battery under any 

circumstances since the battery plates will 

become sulfated and the battery useless. 

- Since producing sparks or bringing flames near 

the battery will cause battery explosion (due to the 

hydrogen and oxygen produced), producing such 

conditions should seriously be refrained from. 

- It is recommended not to add any chemical stuff 

Warning

- Under normal conditions, batteries emit hydrogen gas that can explode and cause serious injuries. So, the engine compartment keep away from sparks 

or flames directly.

- When you work in the vicinity of the moving parts, be careful.

- When it is dark, use flashlights or other lighting device and never use matches or lighters.

- To start the vehicle using battery to battery, be sure to apply mentioned process. Otherwise, it may result in fire, explosion or other damage to the vehicle .

- Over use of the battery causes fire in the vehicle. So, be careful  the electrolyte level is not lower than the minimum .

- Keep the battery away from children.

such as battery tablets, battery vitamins and... to 

the battery’s electrolyte. 

- To prevent risk of short circuits, when installing 

the battery on the vehicle, first connect the positive 

pole’s cable and then the negative pole’s cable and 

when taking the battery out, do this in reverse order 

(first the negative cable, then the positive cable).

- Ensure that the vehicle alternator and current 

regulator are working properly.

- Do not add additional electrical equipment 

to the vehicle without considering the battery 

capacity. 

- If according to the authorized representative’s 

technical expert’s opinion, the battery has not 

been used properly, or propre service and 

maintenance for it has not been done or battery 

breakdown is due to a long period of inaction 

and non-usage, the vehicle battery will not be 

eligible under the guarantee. 

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TRANSPORTING THE VEHICLE

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.

Warning

- 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.

- Do not remove or close the starting switch when towing on four wheels, since it will block the 

steering wheel. Put the switch in A position.

Towing the car

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.

Front Towing Ring

Use the ring beneath the front bumper 

only to tow the car on 4 wheels.

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)

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5

TOWING 

Shipping by Carrier

This type of carrying is the 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.

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5

FUSES 

Fuse box

The fuse box locates in left rear of the 

engine compartment near to the wiper 

electromotor. Remove the cover to get 

access the fuses.

Fuses

Fuses are simple circuit breakers that protect 

electrical equipment being damaged. 

The supporting fuse may be burnt whenever 

electrical equipment does not operate.

Replacing Fuses

1. Turn off the ignition switch and all 

electrical equipment.

2. Remove the fuse box cover, and then find 

the defected fuse according to the table.

3. Take out the tweezers(located in the 

fuse box), and use it to pull out the defected 

fuse. A blown fuse can be recognized by a 

break in the wire.

4. Replace a blown fuse with another of 

the same or lower rating. Be aware that 

there are a number of spare fuses located 

along the lower side of the fuse box.

Caution

Any  modification  or  change  fuel 

feeding systems ( Electronic Control 

Unit, Wiring, Fuel Circuit, Injectors, 

Protective covers, etc.) due to the 

dangers that may threaten you, is 

strictly prohibited. (Unless by experts 

in After Delivery Service Network).

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5

* If equipped

Fuses

Amper

Function

F16

20 A

Cigarette Lighter

F17

10 A

Alarm, Anti-Theft , Audio System Memory

F18

10 A

Rear Fog Tails

F19

5 A

Heater/ Display / Radio/ Switch Lights

F20

30 A

Automatic Backrest of Front Seat *

F21

30 A

Blower Relay

F22

10 A

-

F23

5 A

Rear Window Heater Switch

F24

20 A

Wiper Engine/ Wiper Timer / Washer Pump

F25

5 A

Radio/ Clock Memory, Water Ampere 

(Coolant Temperature  Unit)

F26

15 A

Flashers

F27

30 A

Rear Window Heater, Mirror Heater

F28

10 A

Instrument Panel Screen/Digital Clock/

Brake Warning Light

F29

30 A

Electrical Front Window Regulator

F30

10 A

Map Reading Light/ Glove Box/ Vanity 

Mirror/Electric Mirror*

Fuses

Amper

Function

F1

10 A

Radio & Handsfree*

F2

5 A

Control Unit

F3

5 A

Anti-Lock Brake*

F4

5 A

Beep Sound, Right Indicators & Lamps

F5

5 A

Air Conditioner

F6

10 A

Air Bag / Cruise Contrl*

F7

20 A

Horn

F8

SHUNT

To disconnect all fuses

F9

5 A

Left Indicator Lamps, Number Plate Light

F10

30 A

Electric Rear Window Regulator

F11

30 A

Front Headlights

F12

5 A

Reverse Gear Lights, Rear Sensors*

F13

20 A

Front Fog Tails*

F14

30 A

-

F15

15 A

Door Lights, Courtesy Lights & Electrical 

Aerial* 

FUSES 

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5

FUSES 

Fuse

A / F

Fuse function

F31

30A

Fan 1

F32

30A

Fan 2

---

Reserve

Spare Fuse

---

Reserve 

Spare Fuse

F33

Shunt 

Ignition Switch

F34

Shunt

Main Lamp / Dipped Beam

F35

30A

ABS

F36

30A

ABS

Caution

When transporting or when the car is not used, to remove the F34,F33 shaunts that 

connect the battery to parts consuming electricity, using pliers to avoid discharging 

battery. Obviously to resume the car you must replace the shaunt.

Warning

The electrical system of your vehicle is designed standard or optional equipment. 

Consult an authorized dealer before installing other electrical equipment. Some electrical 

accessorier or  the way in which they are fitted can have damaging effects on the operation 

of your vehicle; the electronic control circuit units, the audio system circuit or the battery 

changing circuit. Installing electrical equipment should be carried out by an expert.

Fuse specification

Owner should not remove or replace fuse connections and all problems should be 

checked by qualified technicians.

Engine Compartment Fuse Box

The fuse box locates in the right of the 

engine compartment. 

Detach clamps and remove the cover to 

access the box. Make sure the cover is 

correctly fitted when replacing the cover.

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5

Warning

The electrical system of your vehicle is designed standard or optional equipment. 

Consult an authorized dealer before installing other electrical equipment. Some electrical 

accessorier or  the way in which they are fitted can have damaging effects on the operation 

of your vehicle; the electronic control circuit units, the audio system circuit or the battery 

changing circuit. Installing electrical equipment should be carried out by an expert.

Fuse box of FN*

The fuse box locates in the right of the 

engine compartment. 

Detach clamps and remove the cover to 

access the box. Make sure the cover is 

correctly fitted when replacing the cover.

Vehicle owner must not manipulate the 

fuses .Any malfunctioning in this part must 

be checked by authorized person.

Fuses function

 Fuses

Ampere

Fuses

Fuses function

 Fuses

 Ampere

Fuses

Horn

30A

F11

Wiper motor

30 A

F1

Door feeding node

10A

F12

AC compressor

15A

F2

Alarm feeding

Wiper  washer

ECU

10A

F14

Double relay 2

30A

F3

Right front fog lamp

15A

F16

Double relay 1

30A

F4

Left front fog lamp

ABS brake 2

30A

F6

Left front indicator

20A

F17

ABS brake 1

30A

F7

Left main beam lamps

Fan 1

30A

F8

 Left Night warning lamp

Right mirror heater

20A

F9

Right dipped head lamps

Right front mirror indicator

Right front indicator

20A

F18

Right front window regulator

Right main beam lamps

Right front door functioning motor

Right Night warning lamp

Right mirror motor

Left dipped head lamps

Right folding mirror

Central node feeding  2

40A

F19

Right front door light

   Start feeding

50A

F20

Map reading light key

Central node feeding  1

60A

F21

Door feeding node

Fan 2

40A

F22

 Left mirror heater

20A

F10

Left front mirror indicator
Left front window regulator

Left front door functioning motor

Left mirror motor
Left folding mirror
Left front door light
Door feeding node

* If equipped

FUSES 

145

5

FUSES 

Fuses function

Fuses Ampere

Fuses

Front seat electricity 

20 A

F1

Ignition switch 1, 2

10A

F2

Cruise control electricity 

Brake switch electricity

Raining sensor electricity

Radio electricity

Lighter electricity

20 A

F3

-----------

10A

F4

Ventilation fan 

30A

F5

Starter

20 A

F6

-----------

10A

F7

-----------

5A

F8

CCN electricity

Immobilizer electricity

Right rear indicator

15A

F9

Left rear fog lamp

Right rear gear lamp

Left brake lamp

Plate lamp

Fuses function

Fuses Ampere

Fuses

Right rear night warning lamp

15A

F9

Rear window key regulator lamp

RN electricity

Left rear indicator

15A

F10

Right rear fog lamp

Left rear gear lamp

Right brake lamp

Rear & front roof lamp controlled by doors 

Left rear night warning lamp

RN electricity

Electrical motivator of boot

30A

F11

Electrical motivator of rear doors

Electrical motivator of petrol tank

Rear door & boot lamp 

Rear & front roof lamp in permanent position

-----------

-----------

20 A

F12

Rear window & mirror heater 

30A

F13

Left rear electrical window regulator

Right rear electrical window regulator

Radio & memory of radio

15A

F14

Diagnostic connector electricity

-----------

5A

F15

Raining sensor

Instrument panel light & central consul

Map reading lamp, Glove box lamp vanity mirror & electrical mirror

CCN electricity 

Rear window heater &mirror heater key lamp

Flasher key lamp 

Central lock key lamp

Electrical motivator of boot key lamp

FN electricity 

ICN electricity 

ICN memory

Diagnostic connector electricity after switch

5A

F16

Ignition switch 2,3 

ABS electricity 

Air bag

10A

F17

NODE CCN*

The location of this node is under the steering wheel.

* If equipped

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5

FUSES

Fuses function

Rating

Fuse No.

Electric Seat Supply

20 A

F21

Main switch supply (position 2) air bag unit and air conditioning system

10A

F22

Main switch supply (position 1) lighter

10A

F23

Main switch supply - position 1(motivation of heater relay ، Radio, brake, light, front node, 

central node and instrument panel), Motivation of Glass Heater Relay

10A

F24

Radio permanent supply

10A

F25

Central node supply

20A

F26

Central node supply

20A

F27

Central node supply and motivation of rear door motive relay

30A

F28

Rear Lifting Window

30A

F29

Central node supply (Front lifting window)

30A

F30

Rear window heater

30A

F31

Heater fan supply

30A

F32

Engine ignition

30A

F33

Main switch supply (position 2) immobilizer, diagnostic connector, instrument panel, 

cooler gas pressure sensor, engine unit

10A

F34

Main switch supply (position 2), Anti-brake system (ABS)

5A

F35

Immobilizer permanent supply, diagnostic connector, instrument panel

10A

F36

Rating - type

Relay Function

Relay 

No.

----

----

RLY1

Contact 1 - 30A

Trunk Lid Electric Actuator

RLY2

Contact 1 - 30A

Mirrors and rear window

heater

RLY3

Contact 1 - 30A

Ventilation Fan Relay

RLY4

Contact 2 - 30A

Rear Lifting Window

(Left)

RLY5

Contact 2 - 30A

Rear Lifting Window

(Left)

RLY6

Contact 2 - 30A

Rear Lifting Window

(Right)

RLY7

Contact 2 - 30A

Rear Lifting Window

(Right)

RLY8

Fuses guide table (cabin)

FUSE BOX AND DASHBOARD RELAY*

The fuse box is located under the dashboardon 

the left. To open, pull the fuse box cover to the 

front.

* If equipped

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5

Fuses function

Rating

Fuse 

No.

Electric supply for ignition switch

40 A

1

Relay switch for fog lamp/horn

30A

2

BCM Inside systems electric 

connection supply

40A

3

BCM Inside systems electric 

connection supply

30A

4

Fan (High speed)

40A

5

Fan (Low speed)

30A

6

Brake (ABS)

30A

7

Brake (ABS)

40A

8

Reserve

----

9

Front node supply

20A

10

Front node supply

15A

11

Front node supply windshield 

wiper and relay for windshield 

washer pump

30A

12

Spare

----

13

Double relay supply

30A

14

Fuel pump supply

10A

15

Engine unit supply

10A

16

Reserve

----

17

Reserve

----

18

Reserve

----

19

Reserve

----

20

Rating - type

Relay Function

Relay 

No.

30A-1Contact

Relayt switch for engine 

control

RLYa

30A-1Contact

Relay switch for fuel pump

RLYb

30A-1Contact

Relay switch for fog lamp

RLY1

30A-1Contact

Relay switch for horn

RLY2

30A-2Contact

Relay switch for 

windshield wiper

RLY3

30A-2Contact

Relay switch for 

windshield wiper

RLY4

40A-2Contact

Relay switch for fan (high 

speed)

RLY5

30A-1Contac

Relay switch for fan (low 

speed)

RLY6

30A - Contact 2

Relay for fan

RLY7

30A - Contact 1

Relay for windshield 

washer pump

RLY8

Fuses Guide Table *

Relays Guide Table *

Engine Compartment Fuse box *

Fuse box is in the right part of the engine

compartment. To access the fuse located in the

engine compartment, unclip the fuse box cover.

Close the fuse box cover carefully when you

have finished.

Vehicle owner shall not tamper fuse connection.

Any problem in this part should be checked by

authorized experts.

FUSES

* If installed in your car

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5

* If equipped

CHANGING LAMPS

Lamp

Watt

1- Headlamp-Main Beam 

55

2- Headlamp-Dipped Beam 

55

3- Side Lamp 

5

4- Front Direction Indicator 

21

5- Front Fog Lamp* 

55

6- Rear Lamp/Brake Lamps 

21/5

7- Rear Direction Indicator 

21

8- Reversing Lamps 

21

9- Rear Fog Lamp

21

10- High Mounted Brake Lamp (Third 

Stop Brake Lamp)

21/5

11- Side Repeater Lamp 

5

12- Trunk Lid Lamp 

5

13- Dashboard Lamp* 

5

14- Vanity Mirror Lamp* 

5

15- Study Lamp* 

5

16- Door Lamp* 

5

17- Plate Lamp

5

Warning

Check the performance of all external lights before driving. To replace the faulty 

lamps, switch off the relevant lamp for preventing short circuit.

149

5

Front Lamp / High beam 

1- Unsrew the cover

2- Press the spring clamps inward, and lift 

it up to release.

3- Remove the bulb. 

4- Disconnect the connector. 

5- Fit the connector, and place the new 

bulb 

without touching the bulb glass. 

Align the bulb by the sign on the reflector 

and place the spring clamps. 

6- Refit the cover 

Front Lamp / Dipped beam

 

1- Unsrew the cover

2- Disconnect the connector  

3- Release the spring clamps. 

4- Fit the connector, and place the new 

bulb 

without touching the bulb glass. 

Align the bulb by the sign on the reflector 

and place the spring clamps.

5- Fit the connector at the back of the bulb.

6-Refit the cover 

CHANGING LAMPS

Warning

All the bulbs are vacuumed and maybe broken at the time of changing them and 

subsequently cause the wound.

Small bulbs 

Connector of the small bulbs is located 

beneath the high beam lamp, inside the 

lamp body.

1- pull out the lamp and its base.

2- Disconnect the base from the bulb.

3- Press the new bulb in the base then 

insert the combination of bulb and base in 

its own location.

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5

Reverse Gear and Rear Fog Lamps

Unlock the trunk lid, push the two plastic 

jag towards inside and remove the holder.

Lamps have bayonet fittings. Push towards 

inside and turn counter clockwise to remove. 

Replace the lamp and refit the holder.

Side Repeater Lamps

Push the light assembly frontward, and 

pull it out to remove. Hold the light cover 

carefully and turn the lamp holder. Remove 

the lamp from the holder and replace it. Put 

back the holder and turn it to fit. Replace the 

light assembly.

Front Direction Indicators

 

Turn the holder counter clockwise to 

become released, and remove it. The holder 

is of a bayonet type. Press it inward then 

turn counter-clockwise to remove. Replace 

the bulb.

CHANGING LAMPS

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CHANGING LAMPS

Reverse Gear & Rear Fog Lamps*

Unlock the trunk lid, turn the holder counter- 

clockwise to release and remove it. Lamps 

have bayonets. Push towards inside and 

turn counter clockwise to remove. Replace 

the lamp and refit the assembly.

Rear Direction Indicator & Rear 

Brake Lamps*

From the trunk turn the holder counter- 

clockwise to release, and then remove. 

Lamps have bayonets. Push towards inside 

and turn counter- clockwise to remove. 

Replace the lamp and refit the assembly.

Trunk Lid Lamp (Loadspace Light)

Insert a screwdriver carefully into the light 

rear slot. You can access the bulb by 

removing the transparent lid. Detach the 

bulb from two connection points. Replace 

the bulb, and refit the lamp.

Warning

All the bulbs are vacuumed and maybe 

broken at the time of changing them 

and subsequently cause the wound.