Iran Khodro Bardo. Service Manual - part 4

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Caution

- Never drive the car in slops with neutral 

gear, either with the engine on or off.

- Remove any extra thick cover 

under drivers’ feet. If the cover is not 

standard, the clutch pedal could not 

be pressed while shifting gears. 

-While vehicle is moving, do not 

switch it off or take out the switch, 

otherwise the vehicle steering wheel 

will be locked and you can not steer 

it anymore.

-Avoid starting engine and its working 

idle for a long time in the confined areas.

Warning

Take care to release handbrake when 

driving (brake light is off); otherwise 

brake-band lining gets hot.

Handbrake 

To release handbrake, pull the lever a little 

upward and push the button at the end 

of lever with your thumb, then move the 

lever downward. Make sure that the lever 

is reached to its most possible down limit. 

Operating your vehicle

 

Starting the engine: 

Since exhaust gases contain carbon 

monoxide, a potentially lethal gas, never 

run the engine in a confined space .Before 

starting, place the gear shift lever in neutral 

position and pull the handbrake lever, turn 

ignition key. Be careful that both engine 

oil pressure and battery charge warning 

lights have been turned on before engine 

running. Then start the engine and after, it 

is better drive the car with first gear. Use 

low gears only for a short duration.

Accelerator pedal 

Always depress the accelerator pedal 

smooth and gradually. Rapid depressing 

of accelerator pedal may cause engine 

damage and raising fuel consumption 

Brake pedal

 

1-Two circuit brake, Teklantus in which the 

hydraulic clutch is used at this system and 

the clutch and oil reservoir is shared. 

2- Azin Taneh two circuit brake that uses 

the cable clutch in this system and the 

clutch cable is regulatory.

MAINTENANCE

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Caution

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.

Running-in of engine and gearbox

The running-in of a new engine, gearbox 

and differential are very important, which 

should be taken under care of driver, 

because only under this circumstances 

can be ensured that different components 

of vehicle will worked for long period 

of time, with minimum cost and most 

efficiency.  It  should  be  noted  that  the 

running-in process should be applied not 

only for engine and gearbox, but also it has 

special importance for other components 

of chassis such as wheel ball bearings and 

other moving parts of a car. 

This process should be carried out carefully 

and gradually for the first 3000 km driving. 

It should be considered that within running-in 

period, the engine must not be overloaded. 

In cases such as uphill driving with fourth 

gear in low speed, lower gears should be 

selected. Caring new car in the period of 

running-in, either in driving or engine idling, 

is significantly important.

In first 800Km of driving, the maximum 

speed must be kept in following limits: 

First gear 15 Km/h 

Second gear 30 Km/h 

Third gear 50 Km/h 

Fourth gear 65 Km/h 

Fifth gear 80 Km/h 

Between first 800 to 1600 Km of driving, 

the car speed must not be exceeded from 

the following values and after this duration 

the speed may be increased gradually: 

First gear 20 Km/h 

Second gear 40 Km/h 

Third gear 60 Km/h 

Fourth gear 90 km 

After  completion  of  first  800Km,  the  car 

must be brought to an IRANKHODRO 

authorized service center for free service 

and checking

MAINTENANCE

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Warning

Never travel fast before engine gets 

warm. If the engine does not go off 

by the switch, press brake pedal, 

engage the gear and take your foot 

off the clutch until the engine goes off. 

Brake pedal 

Avoid sudden brake and stoppage of your 

vehicle. Use heavy gears, 1 or 2, while 

running downhill to reduce unnecessary and 

continuous brakes. To increase the brake 

safety a mechanical brake button (STOP) 

has been added. 

After driving through a large puddle of 

water or a car wash, apply your brake pedal 

lightly until your brakes work normally. If the 

brakes are less effective than normal, dry 

them by repeatedly applying the brakes 

while driving slowly until the brakes have 

regained their normal effectiveness 

Do not “ride” the brakes by applying them 

continuously or resting your foot on the 

pedal. This will result in overheating of the 

brakes which could cause unpredictable 

braking action, longer stopping distances, 

or permanent brake damage. In a long-

distance driving or continuous braking, 

have the vehicle checked by an authorized 

dealer. For more security of the automobile 

and passengers, two circuit brakes is used 

so that if any leakage or breakdown is made 

at one the brake circuits, the second circuit 

can stop the vehicle properly.

MAINTENANCE

Clutch pedal 

Do not drive with your foot resting on the 

clutch pedal. It could result in excessive 

clutch wear, clutch damage, or unexpected 

loss of engine braking.

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Checks / Adjustments before a journey 

1- Engine Oil 

2- Coolant Level 

3- Clutch & Brake Fluid 

4- Windscreen Washer Fluid 

5- Windscreen washer/ wiper nozzles 

6- Fuel Level 

7- Check Tire pressures. 

8- Check Front / Rear Lamps 

9- Gas pressure level inside the reservoir.

NECESSARY POINTS BEFORE TRAVELING 

Caution 

For critical occasions, take some lamps 

and fuses. 

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* It’s recommended to use the approved brands 

and packages, offered by the Isaco.

Warning

-Should the screen wiper blades are 

stopped or move slowly due to the snow 

or freezing, return the key to the initial 

position immediately and switch off its 

engine to prevent its damage. Then 

clean snow and ice under the blades.

-Make sure the screen wiper blades are 

not frozen (screen wiper engine may get 

hot). Check the blades. Replace them, 

when  their  efficiency  has  decreased 

(approx. each year).

-Clean the windscreen regularly. If you 

switch off the engine before switching 

off the screen wiper (O position) screen 

wiper blades will stop at any position.

Put the screen wiper in position O 

after starting engine, then the blades 

return to stop position.

Make sure the wind screen is in position 

O (stop) when you open the engine 

cover, otherwise you may be injured.

Caution

Anti-freeze is fatal if swallowed. Keep 

it in a closed container and out of 

the reach of children. If swallowed, 

immediately contact a physician. It is 

harmful if it comes in contact with skin 

or eyes. If it gets in eyes, flush eyes with 

plenty of water.

WINTER PRECAUTIONS

Preparation for winter cooling system 

The car is containing of approved anti-

freeze solution. This solution retains the 

system down to -15 ºC (In some countries 

down to- 35ºC). Knowing that antifreeze 

solutions are containing of anti boiling 

and anti corrosion compounds, so it is 

necessary this solution remains in the 

cooling system for all season. Check 

the  amount  of  anti  freeze  and  fill  up  if 

required. The following table indicates the 

anti freeze solution density in relation of 

ambient temperature.

27 %  

anti freeze

25 %  

anti freeze

40 %  

anti freeze

46 %  

anti freeze

50 %  

anti freeze

15

20

25

30

35

Applicable anti-freeze in vehicle is Ethylene 

glycol.

Winter tires 

Two types of winter tires can be used: 

1-Winter tires: Must be used on rear 

wheels 

2-Tires with safety chains: Safety chains 

must be used on rear wheels.

Front windscreen wiper 

Before using wipers: Remove the ices on 

the windscreen by heater defroster. 

To use the windshield wiper, press its key 

and  note  while  the  finger  is  on  the  key, 

the water pump function is automatically 

done. To balance the windshield wiper 

pump which is set on the air conditioning 

network at the bottom of the windshield, 

put some sharp metal like needle inside 

the windshield wiper eyes and turn it to the 

concerning direction. It is better wash out 

the washing liquid reservoir in each refilling 

due to avoid clogging its port by dust and 

particles accumulation. To prevent the 

rusting of dimmer head you must always 

use the windscreen washing liquids.

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WINTER PRECAUTIONS

Door locks and door rubber seal 

- Smear the door locks with graphite lubricants. 

-Smear the door rubber seals with paraffin. 

Passenger air intake 

Look for opening of external air spoiler (At 

the bottom of front windshield), which is not 

clogged in any way by snow, ice or leaves. 

Handbrake 

Avoid from prolonged using of handbrake 

for parking of the car in freezing weather. 

In such cases block off the wheels front 

with a chock or put the gear change lever 

in first or reverse gear. 

Battery 

Check regularly the battery situation. 

Lights and Turn Signal 

Check all the external lights for cleanness 

and proper operation. 

Car body 

At the end of winter wash the vehicle 

thoroughly and pay attention for washing of 

under body parts and fe

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Warning

Damaged tires are dangerous! Avoid 

driving with damaged, worn and bald 

or overinflated tires.

Caution

Do not drive with worn, cracked, 

damaged, 

underinflated 

or 

overinflated tires.

Underinflated  tires  are  worn  rapidly 

and have severe adverse effects on 

safety and control of the vehicle.

TIRES

The role of tires at protecting the safety 

and improving the driving is vital and 

important. 

1- Underinflated Tires 

Driving with low-pressure tires causes high 

fuel consumption may damage the tires.

Consequences: The risks of tread 

throwing or separation of the casing which 

could give rise to rapid deflation or even 

a blow out.

2- Kerb contact

There is a risk of deformation, cuts or blisters 

of the casing, which is overstretched. This 

can lead to rapid deflation or blow-out. 

- Hitting made by falling down the vehicle 

into a hollow space which produces dents 

on the ring and make damages to the tires 

(Pot-holes). There is a risk of deformation 

of the rim and/or damage to the tyre, which 

often takes the form of an internal, therefore 

often undetectable, cut; this in turn will 

trigger off a tear in the casing ply, causing 

abnormal wear concentrated on one part of 

the tread, which can lead to rapid deflation 

or a blow-out. 

Consequences: If abrasion appeared 

on some part of spokes of the tire is not 

discovered on time, the tire, which is 

exposed to these hitting falling into the 

hollow space, must be visited.

The advantages of the tire pressure adjustment.

Controlling the 

vehicle on the roads 

Longer life of your tire 

Total checks: 

- Inspect the air pressure of the tires 

properly especially before long travels, 

when the tires are cold. 

- Wheels and tires must be precisely 

inspected to identify the status of spokes 

and sidewalls of tires and wheel rings. 

- Never lower the warm tire air; since it can 

be 0.3 bar or 4pounds power per squared 

inch (4) more than cold tires. 

- While the air pressure at the spare tires is 

not specified, then drive using the low speed. 

- Under no circumstances, do not use tires 

without inner tubes.

Abrasion Index 

In some tires the corruption of tires is 

located under the spokes which appears 

after abrasion; in this mode we should 

replace the tire.

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Warning

Batteries contain sulfuric acid which is 

very corrosive. If it is poured on the 

skin, wash with water. Charged or 

being charged battery emit Hydrogen 

which is very flammable.

Never leave the batteries near the 

fire (risk of explosion)

- Make sure the cables are connected 

correctly to avoid damage to the 

vehicle charging system.

Spare battery 

Consumption battery in this automobile is 

of 12 volt and 60-ampere and in case of 

de-charging battery; it can be charged by 

another vehicle of an auxiliary battery (12 

volts) and begins to start. For this purpose 

use the following instruction: 

1- Turn the ignition switch containing low 

battery off and use high power cables and 

clamps to make the connections. 

2- It’s better to leave the auxiliary vehicle 

running. 

3- Connect the positive (+) terminals and 

negative (-) terminal of the two batteries. 

4- Disconnect the low battery of the 

ignition switch and start.

ACCESSORY BATTERY

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BATTERY SERVICE AND MAINTENANCE

Caution

-Batteries emit Hydrogen which 

may cause serious injuries. So keep 

flame  or  spark  away  from  engine 

compartment.

-Do not start engine when your vehicle 

battery seems to be frozen.

-Make sure the voltage of the both 

battery to be same (12 volt) and 

connection cable have insulated clamps 

and are suitable for 12 volt batteries.

- Do not detach the discharged 

battery’s cable when connecting 

another battery to it.

- Never attach the battery’s positive 

terminal to the negative terminal and 

make sure the connection cable to be 

away from moving parts of the engine.

Be careful when working near moving 

parts of the engine. 

Warning

Connecting the battery to an auxiliary 

battery or another vehicle’s battery by 

the cable is the only approved method 

for starting a vehicle with discharged 

battery.

Maintenance of the battery 

1-Check the battery terminals (poles) to be 

clean of the sulfated residue. Clean them 

with solution of the clean water and baking 

soda. Then clean terminals by clean water.

2-Cover the terminal by mineral (oil) 

grease to prevent further sulfating. 

3-Use special tool to disconnect the cable 

from battery. First disconnect negative cable 

(negative connection). When connecting the 

cables, connect positive cables first.

Clean terminals by brush, if necessary.

Best maintenance for batteries

-Fasten battery firmly in its place.

-Keep top of the battery clean and dry.

-Keep terminals and their connection 

clean, firm and covered by grease.

-Should battery electrolyte (acid) is poured 

out; clean there by solution of water and 

baking soda.

-If the vehicle is going not to be used for a 

long time, disconnect the battery cables. 

Charge the battery every 6 weeks.

-Never  have  flame,  cigarette  or  match 

near the battery, since Hydrogen, which 

is  very  flammable  is  always  available  in 

the cells. Never let the electrolyte contacts 

with your skin, eye or vehicle finishing.

Never keep the old batteries, especially 

those which have sulfuric acid and lead, 

together with the home appliances. They 

should be kept out of the reach.

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Jump starting

- Do as follows:

1- Connect a cable from auxiliary battery’s 

positive terminal to the positive terminal of 

the flat battery.

2- Connect a cable from auxiliary battery’s 

negative terminal to a heavy metal part 

of  the  vehicle  with  the  flat  battery  (such 

as engine handle of any un-painted 

part) which is away from the battery and 

gasoline hoses and brake. 

Make sure the connection cables are 

away from moving parts of the both 

engines, then start auxiliary vehicle and 

leave it work for some minutes.

BATTERY SERVICE AND MAINTENANCE

Warning

Should you use auxiliary battery 

improperly, it causes dame to the 

vehicle and battery. So observe 

followings strictly:

Vehicle start is 12 volt, so if you use a 

24 volt battery or two 12 volts batteries, 

electrical systems of the vehicle 

damage. Therefore use only a 12 volt 

battery as auxiliary battery

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Warning

In order to be able to use more electric 

equipments, we have installed 65A 

alternator on your vehicle. Make sure 

to replace it only with 65A type.

ALTERNATOR AND FAN BELT 

Alternator / fan belt

The alternator charges the battery through 

a completely closed circuit transistorized 

voltage regulator which no maintenance is 

required or possible. 

As the alternator bearings are packed 

permanently with grease during assembly, 

future lubricating is not needed.

Fan belts tensioning adjustment

The drive belt is correctly tensioned, when 

a total movement of 16mm can be obtained 

on the largest deflection of the belt. 

To adjust the tensioning of belt, first loosen 

the alternator mounting bolts as shown in 

figure and move the alternator for reaching 

to correct tensioning amount. Then tighten 

the bolts. Run the engine for few minutes 

due to working of belt, then shut down the 

engine and recheck the belt tensioning.

This function must be done in every 

8000 km.

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Ignition system of pickup engine

Bardo engine ignition is of electronic 

double ignition coil type. 

Due to higher voltage in electronic 

ignition systems, compared with common 

mechanical systems, always before working 

with the systems, always make sure of 

turning the ignition off or disconnecting the 

battery cables while: 

The switch is off or battery cable is 

disconnected.The systems must be tested 

exclusively by the relative experts. 

Bardo engine ignition is of electronic double 

ignition coil type. 

Due to higher voltage in electronic ignition 

systems, compared with common 

mechanical systems, always before working 

with the systems, always make sure of 

turning the ignition off or disconnecting the 

battery cables while: 

The switch is off or battery cable is disconnected. 

The systems must be tested exclusively by the 

relative experts. 

Inertia / safety switch: 

In Bardo fuel injection cars, due to shutting 

down the fuel flow in the event of a sever 

shock or car rolling over, a safety switch 

is provided in this switch. There is a globe 

which in case of applying a shock to a 

switch or rolling over, make the electric 

current of fuel pump cuts - off. 

If, by any reasons, the switch is deactivated, 

it should be activated again by pushing the 

top of switch to return to the initial position 

(activated mode); otherwise the engine 

may not be start.

SAFETY CARES

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Warning

Cooling system fan is electrical and 

may continue working a few minutes 

after the engine is switched off. To 

help preventing personal injury, keep 

away from working fan while engine 

compartment cover is open. 

Warning

If you need to check the water cooling 

after a long driving, keep in mind 

never open the radiator at once; 

but firstly turn it 1/4 round to the left 

and wait a moment till the system 

inside the compartment at the top 

of radiator is gradually depleted and 

lose the pressure. Turn the overhead 

completely to the left side and open it. 

Engine coolant system (Radiator) 

When water temperature at the radiator 

raise up and its pressure passes over 

the relief valve of the radiator head. 

The above mentioned valve opens and 

the steam goes out of the upper pipe 

of this valve. Obviously some water is 

gradually lost in this order, which must be 

compensated, in proper inspections. The 

radiator mustn’t overpass the bottom line 

of the radiator glottis. Keep in mind that 

radiator overhead must be completely 

closed at all seasons and the packing 

rubber at overhead must be intact. 

Flowing out radiator water 

At  first  we  must  remove  the  radiator 

overhead (according to figure).

Put the control lever of heater on warm 

after removing the overhead then open 

the evacuation valve under the radiator 

as well as engine nearside the evacuation 

valve to deplete (evacuate) water (the 

figure on the next page).

COOLING SYSTEM

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Re-filling the radiator 

1- Put the controlling lever of heater on warm 
2- Close the evacuation valve under the radiator 
and close to engine. (Figure 1 and 2) 
3- Spill the solvent into radiator till it is full. Note 
that water is always clean and lacks any settled 
minerals if possible. 
4- after filling up radiators, start the engine and let 
it work a few moments then visit those parts of the 
radiator which are not dropping or leaking water. 
5- To open thermostat valve the engine must 
be functioning fixed and its temperature must 
reach 80 degrees centigrade then the confined 
air is released and you can control the water 
level again so that you can spill water again. 

Clean the radiator once in two years. 

This is highly required when you use water 
including settled solvents, which contain lime 
materials. 

To clean the radiator and its rotor please do 

as following: 

At  first  evacuate  the  radiator  water  then  if  the 
radiator is cool put the water pipe inside the 
edges of radiator and cleanse the residues by 
pressing it softly then close the evacuation valves 
and fill up the radiator with the cleaning solvent 
(these types of solvents must be reliable and 
without materials which make damages to metal) 
and follow the instructions which is ordered by 
producers of how to use the solvents. 
You must keep in mind that these types of 
material may make damages to the automobile 

paint so while using them we can give precise 
attention, then evacuate the cleansing solvent 
and wash it by tubes again and close the 
evacuation  pumps  finally  and  fill  them  up 
whole gear of cooling solvent (defrost and non-
mineral water, according to the indices and 
table of page 

Cleansing the outer parts of the radiator 

At regions and conditions in which the dust and 
several insects exist, the we must swipe out the 
radiators by pumping compressed air through 
the inner part of engine and every while we visit 
it properly and try out the plastic pipes and the 
related connections (settings) to prevent the 
corruption and dysfunction.

COOLING SYSTEM

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Recommendations for washing the 

vehicle

1- Wash vehicle at least once per week 

when weather is normal. 

2- Wash vehicle away from direct sunlight

3- Start washing at least 30 minutes after 

engine has been stopped.

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 do 

not depress the vehicle’s roof and body 

during washing/wiping. 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 60

º

C, Max 65 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.

9- Do not wash the vehicles, having metallic 

and two coverage paint, by  automatic 

carwashes which use rotary brushes;

10- 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.

11- If the water permeates to the luggage 

compartments and interior parts of the 

vehicle, dry it immediately.

WASHING AND MAINTAINING THE VEHICLE

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Caution

Blue straps on the lacing of the side 

mirror, windows, and vehicle bumper 

should be detached. Otherwise they 

may cause problem.

Warning

-Never  use detergents, abrasive or 

chemical products

-Do not wash seat belt by whitening 

substance.

Clean any stain on the upholstery by 

carpet shampoo and sponge

Caution

Use only vacuum cleaner for vehicle 

whose  floor  are  entirely  covered  by 

carpet. Application of the detergents 

may result to corrosion of the body 

and carpet.

General washing upholstery:

Dry clean 

Plastic parts:

(Glove box, doors internal cover and internal 

part of the roof)

Use only lukewarm soap water or industrial 

alcohol. Consult with Iran Khodro authorized 

dealer if there is any problem.

Special washing

Seat belt:

Use only lukewarm soap water and avoid 

using any metal objects

Type of stain

Leather and plastic parts

Fabric upholstery 

Mud

Lukewarm soap water

Commercial detergents

Commercial detergents

Acetic acid

Chocolate (cacao)

Lukewarm soap water

Commercial detergent

Ammonia solvent 25% borax 

solvent then soap and water

Sugary substances,

 fruit juice

Lukewarm soap water

Commercial detergent

Lukewarm soap water

Commercial detergent

Pen ink

Industrial alcohol 

90 alcohol

Industrial alcohol

90 alcohol

Blood

Lukewarm soap water

Commercial detergent

Ammonia solvent 25%

Lukewarm soap water

Grease or bitumen

Turpentine / gasoline

Turpentine

Engine oil

Gasoline/industrial alcohol

Gasoline/ industrial alcohol

WASHING AND MAINTAINING THE VEHICLE

General hints for washing various part of the vehicle