Iran Khodro Bardo. Service Manual - part 3

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Mechanical converter gearbox

Gear lever 

It is installed at the protuberances of the 

auto  floor.  The  positions  are  marked  on 

the knob. 

Synchronization tool

This tool is installed for all four front gears 

and gear replacements can be made 

easily and without noise providing that do 

not put the clutch pedal all the way.

Always  use  the  first  gear  to  start  the 

vehicles; otherwise, the clutch will soon 

be abraded .To transfer the gear to the 

reverse gear, put the palm of the hand on 

the top of the gear handle and move it by 

a low pressure to the right side so that the 

spring opens up then press it down and 

clockwise. For the purpose of not mixing 

gears when transferring these gears put 

the spring holder at the end of the right 

side of the gear.

New position of brake lever 

Brake lever position has been transferred 

from side part of the cabin to the middle part 

( between two chairs) .

GERABOX

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ANTI-LOCK BRAKING SYSTEM (ABS)

Anti-lock braking system (ABS)

Anti-lock braking system is one of the car 

control systems preventing the wheels 

from locking on slippery roads, or intense 

braking. Therefore, it reduces the brake 

distance, steer ability, improves stability, 

and increases car safety in general.If the 

wheels slip, when braking, not only the 

brake distance increases but also the car 

control is endangered.Therefore, using the 

anti-lock braking system (ABS) system is 

necessary in this situation. It prevents fully 

locking of the wheels, and lets the driver to 

control the vehicle when making sudden 

and intense brakes. The system has a 

considerable effect on increase safety since 

it controls and adjusts the braking pressure 

electronically, and adapts itself to variations 

in road surface.In the conventional hydraulic 

brakes, a timely constant pressure is 

applied to the brake pedal, and causes to 

lock the wheels on braking.

New navigation and stability system such 

as ABS prevent wheels from locking 

in these situations, which may cause 

critical driving situations. ABS actually 

monitors each of the wheels, and it can 

adjust braking pressures so that each 

wheel gets the maximum possible braking 

force without locking of the wheel while 

functioning. It prevents continual locking 

and slipping of tires, and can provide the 

best braking conditions for the vehicle to 

remain stable and controllable especially 

on slippery roads.

It is possible to summarize the advantages 

of the anti lock braking system (ABS) as 

follows:

1- Ability to maneuver and maintain the 

stability of the vehicle when braking (on 

direct paths and while changing direction)

2- Sustained steerability during braking 

(on direct paths and while changing 

direction)

3- Reducing the burden of responsibility 

regarding the driver

4- Preventing the wearing of tires due to 

impeding repeated locking of the brakes 

and slipping of tires.

Warning

This system shall not be deemed 

as a reason to incite you into 

sudden accelerating and driving 

with high speed. Indeed, nothing 

can be replaced instead of driver’s 

responsibility and precaution while 

driving.This performance is an 

auxiliary system which manages the 

driver’s response according to the 

prompt circumstances during driving 

in critical conditions.

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When using a car equipped with anti 

lock brake system always consider the 

following points:

- Since the anti lock brake system is only 

for balancing the braking force, therefore 

when braking sufficiently press the brake 

pedal and always follow safety guidelines.

-Feeling brake pedal vibrations under the

foot while braking over unstable roads or 

sudden braking is normal and caused by 

the operation of the anti brake system.

- To hear noise when braking over 

unstable roads or sudden braking from 

front and rear wheels is normal and due 

to the operation of the anti brake system.

- The anti brake system is equipped 

with  an  automatic  defect  finding  system 

that will light the anti lock brake system 

warning indicator 

 on the front panel 

display in case of a problem.

- When the car is turned on, the anti- lock

brake system warning indicator 

 on 

the front panel display is on and will turn 

off after a few seconds. If the warning 

indicator does not light when the car 

is turned on or remains lit, is a sign of 

problem in the anti lock brake system. In 

this situation the car should be directed to 

an authorized workshop with precaution.

- If the handbrake is completely released 

the handbrake indicator 

 and anti 

lock brake system warning indicator 

 are both lit on the front panel 

display, stop the car with precaution and 

contact an authorized workshop.

Caution

The brake dragging distance will 

be more  while you’re  driving on 

sloppy surfaces. Make sure of proper 

functioning of the brake after washing 

the vehicle or while you’re passing 

from the puddles.

Warning

This system shall not be deemed as 

a reason to incite you into sudden 

accelerating and driving with high 

speed. Indeed, nothing can be replaced 

instead of driver’s responsibility and 

precaution while driving.

This performance is an auxiliary 

system which manages the driver’s 

response according to the prompt 

circumstances during driving in critical 

conditions.

ANTI-LOCK BRAKING SYSTEM (ABS)

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* If equipped

Starting on CNG mode (1) 

Changing the type of fuel is done by the 

fuel conversion key located on the front 

console .The vehicle will be operated on 

CNG fuel at the following situations. 

A) Before driving (at first the vehicle starts 

on the gasoline then it switches on gas).

B) While driving

C) Starting the vehicle on gas mode (**).

Warning

- ** This mode shall only be used in emergency situation such as lack of gasoline. 

This mode is not recommended in normal conditions because it may damage the gas-

powered parts.

- Do not park your vehicle, which is on, in places that there may be any contact of 

hot exhaust with flammable things such as grass or leaves.

Caution

There should be always at least 5 litters gasoline in fuel tank because the gasoline 

pump is on, even when engine is working with CNG and also  gasoline is necessary 

for cooling the gasoline injectors.

- Use unleaded  super gasoline; otherwise vehicle catalyst will be damaged.

Avoid combination of any fluid with standard fuels.

SWITCHING ON AND DRIVING WHILE USING CNG

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A) Operating on CNG mode before 

starting 

Start the engine then put the fuel 

conversion key on gas. In this mode, in 

addition to the light on the right side of the 

conversion key (yellow) being turned on, 

the green light on the left and the red light 

for saving gas on the left of the conversion 

key are blipping fast. 

The blinking of the lights on the conversion 

switches show that fuel consumption 

has not turned yet from gasoline to gas. 

Therefore the fuel conversion is done and 

lights are frequently on and gas saving red 

lights and yellow ones on the right side are 

turned off. When the engine is turned on, 

the 4 green lights of the conversion key 

are turned on in compliance with the gas 

pressure inside the gas pump.

B) Selecting CNG fuel while moving 

Put the fuel conversion key on gas mode 

(on the left) and the fuel converted to gas 

instantly.

C) Turning the engine on CNG 

mode directly 

This method is used only for special 

situations like gasoline shortage and 

it’s not recommended at the ordinary 

conditions. Fist turn on the switch and 

put the fuel conversion key on the gas 

mode. Then start the engine. If there is no 

technical malfunction in the gas system, 

the engine will start on CNG. 

D) Fuel conversion from gas to gasoline

Switching to gasoline is easily done in any 

case just by pushing the fuel conversion 

key on the gas mode. When the engine 

is started on the gasoline mode, the right 

light of the conversion key (yellow) is on.

SWITCHING ON AND DRIVING WHILE USING CNG

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LIGHTS POSITION OF FUEL SELECTION KEY

Fuel conversion keys positions of 

lamps 

Considering the consumptive fuel type 

and the amount of CNG fuel in the pump, 

the position is as follows:

Fuel conversion key

 

This fuel type selection key is located on 

the front console instead of panel key. 

Conversion key positions 

(Gasoline to gas)*

 

The yellow light at the right side is on and 

the left green light as well as red gas saving 

light is set on blinking mode (the blinking at 

the above lights show that the conversion 

of gasoline to gas is not yet done). Then 

after fuel conversion, the light of the fuel 

conversion key on the left side is still on 

and the red and yellow lights are turned 

off. The 4 green lights over the conversion 

key are turned in accordance with the gas 

pressure level inside the pump.

The vehicle is on gasoline, mode The yellow 

light shows

* If equipped

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Fuel conversion keys in gas running 

out position* 

When the gas inside the container is near 

termination, the four lights above the fuel 

conversion key (green) turn off. Then the 

red light above the fuel conversion key 

turns on. With the complete termination of 

gas inside the tank, the light on the left side 

of the fuel conversion key (green) starts to 

blink. The slow glimmering of green light 

at the left side of the conversion key does 

not mean depletion of fuel but it shows 

some errors at the gas system which 

causes rotor not to start on the CNG fuel 

and must return to the gasoline mode.

* If equipped

Notice 

If you have trouble starting the car 

in gas mode, set the fuel conversion 

keys to gasoline position and start 

the vehicle. If the engine does 

not start again, consult with an 

authorized dealer.

LIGHTS POSITION OF FUEL SELECTION KEY

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Ignition key 

There are 4 positions 

O. The steering wheel lock and ignition off. 

I. Supply to electrical accessories and 

steering wheel unlock. 

II. The electrical devices on, Engine on 

and diagnostic lamplight up. 

III. Running. Ignition on. 

Please note that the key is getting in and 

out only in 0 position

Unlocking the steering wheel 

Put the key at I position.

Move the steering wheel gently while 

turning the key. 

Starting 

By turning the key to III position, release 

the key till located in the II position.

Caution

Never turn off the engine while going 

down the hill (the brake booster will be 

damaged). Never remove the switch 

while driving (the steering wheel is 

locked).

Notice

To start the vehicle, put it on gasoline 

position.

MAIN SWITCH

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Caution

We strictly recommend all the owners 

of CNG vehicles to avoid fuel injection 

at  CNG  fuel  filling  stations  related 

to buses and other heavy vehicles 

because of its probable damage of 

reservoir valve and its belongings.

* If equipped

CNG Fueling steps*

1) During fueling at gas stations, avoid 

smoking or using your cell phone. 

2) After going to filling station (2), the driver 

should turn off the vehicle and make sure 

the automobile has stopped completely 

(pull the brake lever up). Never move the 

vehicle while the nozzle is connected. 

3) The station operator does the fuel 

injection operation after controlling the fuel 

certificate label of automobile. 

4) Make sure of closing the gas filler valve 

overhead after each fuel injection. (It’s 

essential to prevent entering dust and 

accordingly defects into the gas system). 

5) The cylinder is used to store CNG at the 

working pressure of 200 bars.

CNG REFUELING STAGES

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Caution

Each 8000 km, have your vehicle 

serviced.

Factors determine the fuel 

consumption: 

The condition of the engine: 

A badly tuned engine adds fuel consumption. 

Ignition system: 

Check the spark plugs electrode gap and 

adjust them if required.

Fuel feeding system:

To prevent oil leakage, check the fuel 

injection feeding system for fuel rail, fuel 

filler pipes, fuel pump and fuel filter.

Fuel quality: 

Fuel quality does affect not only on the 

fuel consumption rate, but also on the 

mechanical condition and performance of 

engine in long period.

SAVING FUEL CONSUMPTION

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SAVING FUEL CONSUMPTION

Notice

Clogged  air  filter  reduces  the  engine 

power. If the car is used on dusty roads, 

the period of services must be shorten

Heat shield of exhaust manifold

For the purpose of elimination the exhaust 

manifold heat radiation effect on throttle 

valve and intake manifold assembly, a 

shield plate is mounted between intake 

and exhaust manifolds. 

Fuel consumption 

The fuel consumption is depended not 

only on the car design, but also on driving 

style and maintenance. 

Considering the following points could reduce 

fuel consumption down to a reasonable limit. 

A- Vehicle maintenance 

Maintenance & services of car should be 

performed according to the recommended 

intervals by replacing on time oil, and 

regular checking of the related parts in fuel 

consumption. 

- Engine tuning up according to manufacturer’s 

instruction 

- Removing carbon deposits of spark plugs 

- Air filter changing as determined in service 

section

- Keeping tire pressure corrects

(Underinflation of the tires can waste fuel due 

to increased running resistance of the tires. 

Keep your tires inflated to the correct pressure) 

- Using standard tires.

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B-Driving style 

- Keep a steady cruising speed: Keep 

as  constant  a  speed  as  road  and  traffic 

conditions permit. 

- Slowly move the shift lever into the gear 

you wish, till the tachometer indicates 

appropriate engine speed in revolution per 

minute (rmp). 

- Don’t drive with high speeds. The 

optimum fuel consumption can be gained 

with speed of 80Km/h in fifth gear. 

- By increasing the speed, the fuel 

consumption will be increased accordingly. 

(Fuel consumption rate in a distance of 

100Km with speed of 90Km/h is about 8.3 

litters). 

After raising the engine coolant temperature 

up to normal range, drive the car quietly 

and avoid from extra acceleration. 

Warm up the engine by slow driving in the 

first few kilometers 

- Driving with high speed will increase fuel 

consumption. Drive with a slow speed. 

- Avoid high acceleration in low gears (First 

and second) select the highest possible 

gear without to prevent excessive load on 

the engine. By keeping suitable distance 

from frontal vehicle minimize unnecessary 

stops and breaks. 

- By making realistic guess about the traffic- 

allowing proper distances, eliminating a lot 

of unnecessary breakings and avoiding 

hard accelerations- keep pace with the 

traffic flow. 

- Turn off the electrical equipments when 

they are not really in use. 

- Avoid driving with open windows; it is 

preferable to use ventilators. 

- Disassemble the roof rack after usage. 

- Make an arrangement before travelling 

- Don’t use the car in city short trips. 

- be Driving in heavy city traffic makes the 

highest fuel consumption rate. 

- Use ring road as well as possible to 

avoid traffic encounters and entering into 

the city zones.

SAVING FUEL CONSUMPTION

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* If equipped

SAVING FUEL CONSUMPTION

Improving fuel economy

Periodic maintenance schedule is 

included in the Service and Guarantee 

book. To be able to enjoy common 

guarantee of the Iran Khodro, which is 

described in said book, you should  do 

necessary periodic maintenance up to 

first 10000 km function, otherwise in case 

of any fault, it is considered as fault of the 

owner and manufacturer undertakings are 

excluded.

Intervals of the periodic maintenance are 

specified in the schedule. Remuneration 

depends on the quantity of the performed, 

material and the parts are excluded. 

Should you use your vehicle in the harsh 

situation and also drive in the polluted 

environment, intervals of the replacing 

engine oil, oil filter, air filter, oil pump and 

other parts affected by the unfavorable 

environment should be less than those 

predicted in the maintenance schedule. 

It is recommended to consult with one 

of the Iran Khodro authorized dealer to 

determine the new intervals.

Periodic maintenance should be done 

only in one of the Iran Khodro authorized 

shops. Special place considered in the 

service book for each service should be 

sealed by that authorized shop’s stamp.

Vehicle gas consumption*

Vehicle gas consumption for every 100 

km. based on the ECER83/03 standard 

shall be as below table:

Driving condition

fuel consumption

200 bar pressure

Urban

45 lit. 

Suburban

28.3 lit.

Urban and suburban 

(combined cycle)

34.14 lit.

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Warning

Never use anti-freeze and water mixture 

in windshield washer reservoir. It can 

severely damage your vehicle paint.

SCREEN WASHER AND SCREEN WIPER

Wind screen washer

Pull the stalk towards steering wheel and  

keep it for a while to spray the liquid in the 

water reservoir.

Wind screen wiper

Wiper can start moving with different  speeds; 

by turning of stalk in a multiple steps.

(c) Windscreen washer fluid reservoir 

Regularly check windscreen washer fluid 

reservoir (inside engine). Always use liquid 

glass cleaner specified for windscreen in 

the reservoir.

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Caution 

Before starting driving at night:

Make sure electrical equipments function properly and adjust vehicle lights (in case 

of over loading). In general, make sure the lights are not covered (by dirt, mud, snow 

or any other object.

Warning

Should the vehicle is going not to be used for more than 6 days, it should be started  

at least once and work one hour idle.

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VEHICLE MAINTENANCE

4

MAINTENANCE ..............................................................54-56

NECESSARY POINTS BEFORE  TRAVELING ................….57

WINTER PRECAUTIONS................................................58-59

TIRES……..............................................…......….....………. 60

ACCESSORY BATTERY.......................................................61

BATTERY SERVICE AND MAINTENANCE.................…62-63

ALTERNATOR AND FAN BELT………........................……..64

SAFETY CARES...................................................................65

COOLING SYSTEM ........................................................66-67

WASHING AND MAINTAINING THE VEHICLE................68-70

BODY STAIN REMOVING ....................................................71

CHANGING OIL ...................................................................72

OIL TYPE…...........................................................………73-74

INSPECTION AND REPLACING OIL……..................….75-77

INSPECTION AND REPLACING FILTERS .........................78