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SAMAND

(XU7JPL3)

Service Manual
Electrical Components

Chapter:

Product:
SAMAND XU7JPL3

Section:

Electrical Components

SAMAND
Service Manual
Foreword:
This Service Manual contains descriptions of the following categories for the
Samand:
Electrical Components

This manual should be used as service manual and s workbook for


training instructors and technicians. We reserve the right to introduce
change without prior notice.

Contents
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
10

Technical data

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Technical description

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge warning lamp, main instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
14
15
16

Checking and charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the voltage regulator and alternator brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
18
19
20

Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Adjustment and replacement

Technical data

Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Technical description

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment and replacement

27
28
29
30

Changing the starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Lighting and Signalling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Technical data

Exterior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical description

System overview, exterior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39


System overview, interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Adjustment and replacement

Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dipped beam bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main beam bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sidelight bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front direction indicator bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light adjustment, headlamps low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light adjustment, headlamps main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light and indicator stalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction indicator, side bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog light adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of rear lamp bulbs, direction indicator and brake light . . . . . . . . . . . . . . . . . . .
Rear lights, trunk lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of reverse and fog lamp bulbs, trunk lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number plate light, boot lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High mounted stop lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy and map reading lamp bulbs, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy lamp bulb, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy lights, front and rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy lights, front and rear door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn switch, light and indicator stalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wash/Wipe system

41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Technical data

Windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67


Washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Technical description

System overview, wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Adjustment and replacement

Windscreen wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Windscreen wiper motor and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen wiper stalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen washer hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71
72
74
75
76
77

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

Technical description

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Adjustment and replacement

Front panel harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Front harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trunk lid harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front roof lamp harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front driver door harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door switch harness, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front passenger door harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear door harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake wear harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main fuse box, engine bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maxi board, engine bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main relay board, fascia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
111

Peykan

Special tools

Special tools
ACTIA

Diagnostic computer

S1251 Pack
Break out box

Peykan

Charging System

Peykan

Peykan

Technical data 11

Technical data
Alternator
Type, Valeo
Class, 8

W711S001

Battery

Type, Atomic
Current, 12 volt
Grounding, Negative

W711S002

Peykan

Peykan

Technical description 13

Technical description
System overview

1
3

W711D001

Role of the charging system

Charging system

The charging circuit must recharge the battery as well


as supplying the electrical equipment of the vehicle.

1 Instrument cluster
2 Battery
3 Alternator

Peykan

14 Technical description

Alternator

5
2

1
7

W711D002

Alternator components
1
2
3
4
5
6
7
8

The alternator is an alternative generator. A diode


bridge located in the rear flange converts the alternating
current to direct current, necessary for charging the
battery. By construction, the alternator automatically
regulates current, but the voltage is controlled by a
regulator incorporated in the alternator.

Rear flange
Front flange
Cooling fan
Drive pulleys
Rectifier
Rotor
Stator
Regulator

Peykan

Technical description 15

Battery

The terminal voltage of the battery is 12V.


The battery located on the left hand side of the engine
with the negative terminal connected to the body.

W711D003

Peykan

16 Technical description

Charge warning lamp, instrument cluster

The charge warning lamp indicates to the driver


whether the generator is charging or not.
It is located in and powered by the instrument cluster
display. If the generator is not rotating or if it is not
charging for some reason, the lamp circuit is grounded
via the regulator field winding and the lamp goes on.

W711D004

Peykan

Adjustment and replacement 17

Adjustment and replacement


Checking and charging the battery
Checking the battery

1 Firstly visually examine the battery to eliminate


the following conditions:
Cracks or breaks in the battery casing.
General condition of the battery terminals.
General cleanness of the battery.
2 Use a voltmetre to check the state of charge
which is only valid when the battery is stabilised,
that is, has not been subject to charge or
discharged for at least one hour.
3 If the battery requires charging, proceed as
follows:
Remove battery from the car (see page 18 for
reference).
Voltage reading of 20% or 12volts
- Minimum Charge 24 hours
Voltage reading of 20% to 60% or
from 12 to 12.3volts
- Minimum Charge 12 hours
Voltage reading 60% or at 12.3volts
- Minimum Charge 6 hours

W711R001

If the battery is completely discharged, due to


auxiliary equipment being left on, a weak starting
charge should be provided to initiate the chemical
process in the battery. Start charging at 1.5amp
current for 24 hours or until the charge current
has dropped to its lowest stable reading.

Safety precautions:

During charging, batteries discharge an explosive gas.It


is therefore imperative to follow these precautions:
Carry out charging in a ventilated location.
Do not smoke.
Avoid naked flames or sparks.
First connect the charger clamps to the battery
terminals, and then connect the charger to the
mains.
When charging is complete, switch of mains
before disconnecting the clamps.
A charger with an Auto-regulating constant voltage
variable current charger should be used.

Peykan

18 Adjustment and replacement

Battery

It is important to check and look after the battery


regularly, since its ability to start the engine depends on
its state of charge.
The load on the starter motor is greater during the
winter and the capacity of the battery decreases in the
cold weather, which demands a battery in good
condition.
The water level in the battery must be checked at
regular intervals.
Keep the battery clean and dry to prevent dirt from
entering into it while refilling with distilled water or the
build up of oxide on the terminals.
To avoid oxidisation, coat the join between the battery
casing and the terminals with grease.
W711R001

To remove

1
1

The battery is located on the left hand side of the


engine.
1 Disconnect the battery terminals by unscrewing
the wing nut on the negative terminal and clamp
nut and bolt on the positive terminal.
Important
The negative terminal must always be
disconnected first and reconnected last.
2 Remove nuts securing battery clamp and remove
clamp.
3 Remove battery.

W711R003

To fit

Fit in reverse order.


Note
Smear battery terminals with grease,vaseline or
petroleum jelly before reconnecting terminal leads.
Important
The negative terminal must always be reconnected last.

Peykan

Adjustment and replacement 19

Alternator

To remove
2

1 Disconnect the battery negative terminal.


2 Remove 2 rubber grommets and disconnect the
electrical connections at the rear of the alternator.
3 Raise vehicle and support securely.
4 Remove right road wheel.
5 Remove wheel arch liner.

2
W711R004

6 Release auxiliary belt tensioner and secure.


7 Remove auxiliary drive belt.
8 Remove the auxiliary belt tensioner, to gain
access to the alternator lower mounting bolt.
8
8

6
W711R005

9 Loosen the lower mounting bolt.


10 Remove the upper mounting nut and bolt, then
disengage the alternator from the lower mounting
bolt and remove.

10

To fit

Fit in reverse order.

9
W711R061

Peykan

20 Adjustment and replacement

Changing the voltage regulator and alternator brushes


To remove

This method is described with the alternator already


removed.
1 Remove 3 screws and release the alternators
protective end cover.
2 Remove 2 screws securing the regulator.
3 Remove the regulator which is fitted with catches.
The alternator brushes are fixed to the regulator and
the whole unit must be replaced.

To fit

1 Carefully straighten the spring tab so that it is


against the regulator.
Clean and apply a thin layer of grease to prevent
oxidisation.
2 Clean the ground connection on the regulator and
apply grease.
3 Fit the voltage regulator.
4 Fit the protective end cover.

Peykan

21

Peykan

23

Starting System

Peykan

Technical data 25

Technical data
Starter motor
Type
Rotation
Voltage

W711S003

Peykan

Valeo
Right
12 V

Peykan

Technical description 27

Technical description
System overview

Starter motor system


1
2
3
4

Starter motor
Ignition switch
Starter relay
A.C.U.

Peykan

28 Technical description

Starter motor

W711D006

The starter motor is fitted to the engine block. A


solenoid engages a pinion with the ring gear on the
engines flywheel.
When the engine is started and the engine speed
exceeds the starter motor rpm, the pinion is disengaged
from its shaft via a free wheel. This prevents the starter
motor from over reeving.

Peykan

Technical description 29

Ignition switch

Ignition switch

The starter motor operates when the ignition switch is


in the start position.
Releasing the ignition key breaks the starting circuit and
also the operating circuit to the starter solenoid,
whereby a spring returns the pinion to its rest position.

W711D007

Peykan

30 Technical description

Starter relay

Starter relay

The starter relay is located on lower left hand side of


the instrument panel in the relay mounting plate.
11

10

As the ignition is turned to the start position, the starting


relay operates and the operating circuit to the starter
solenoid terminal closes,that is controled by A.C.U.

6
W711D026

Peykan

Adjustment and replacement 31

Adjustment and replacement


Changing the starter motor

To remove

1 Disconnect the battery negative terminal.


2 For easier access to the starter motor remove the
air intake pipes (see page Book.....).
3 Remove 2 nuts and collect 2 washers, then
remove the electrical connections to the starter
motor solenoid. .

W711R008

4 Remove bolts and washers securing the starter


motor to gearbox housing, noting the position of
the bracket.
5 Unclip the crankcase breather pipe from the
bracket and swing the bracket rearward.
6 Manoeuvre the starter motor out from the gearbox
housing.

To fit
Note
5

Before refitting clean the starter motor mounting


surface, electrical contacts, connecting cables and
apply grease.
Fit in reverse order.

6
W711R009

Peykan

Peykan

33

Lighting and Signalling System

Peykan

Technical data 35

Technical data
Exterior lighting

1
2
3
4
5
6

Headlamps (main)
Headlamps (dipped beam)
Position lamp
Front fog lights
Direction indicators
Side repeater lights

55 watts
55 watts
5 watts
55 watts
21 watts
5 watts

Peykan

36 Technical data

Exterior lighting

1
2
3
4
5
6

Rear fog lights


Reversing lights
Rear lights/Brake lights
High mounted brake light
Number plate lights
Door lights

21 watts
21 watts
5.21 watts
LED
5 watts
5 watts

Peykan

Technical data 37

Interior lighting

1 Roof lights
2 Trunk lid
3 Glovebox light
4 Sun visor
5 Map light

5 watts
5 watts
5 watts
5 watts
5 watts

Peykan

38 Technical data

Horn

W711S009

1 Frequency:
420 HZ 35 - low tone
500 HZ 35 - high tone
2 Current consumption, continuous 5.5 0.5

Peykan

Technical description 39

Technical description
System overview, exterior lighting

1 Front fog lights


2 Main/Side/Direction indicator lights
3 Reverse/Rear fog lights
4 Brake/Side/ Direction indicator lights
5 Side repeater
6 Number plate
7 High mounted lamp

Peykan

40 Technical description

System overview, interior lighting

1
2
3
4
5
6
7
8
9

Door switch
Trunk lid lighting Switch
Trunk lid
Glove box light
Front roof light
Rear roof light
Sun visor lighting
Map light
Door lights

Peykan

Adjustment and replacement 41

Adjustment and replacement


Main lighting, headlamps
To remove

1 Remove front bumper assembly (see


page...Book...).

Applies to RH and LH headlamps.


2 Remove 2 bolts from the top and 1 bolt from the
bottom of the headlamp.

3 Carefully pull the headlamp out and unplug the 3


electrical connectors.

To fit

Fit in reverse order.

Note

After fitting, check and adjust the headlamp beam (see


page....).

Peykan

42 Adjustment and replacement

Replacement of headlamp bulbs

There are 4 bulbs incorporated within the headlamp


unit.

To remove, dipped beam bulb

1 Unscrew the centre rear cover.


2 Remove the spring clip by pushing in and lifting
up.
3 Remove bulb and bulb lead.
4 Remove bulb.

To fit

Fit in reverse order


4

Note
W711R012

Peykan

Do not touch the new bulb glass with your fingers.

Adjustment and replacement 43


To remove, main beam bulb

1 Unscrew the rear cover.


2 Unplug the earth lead.
3 Remove the spring clip by pushing in and lifting
up.
3 Remove bulb and bulb lead.
4 Remove bulb.

To fit

Fit in reverse order


4

Note
W711R013

Peykan

Do not touch the new bulb glass with your fingers.

44 Adjustment and replacement


To remove, sidelights

The sidelight bulb connector is situated at the base of


the headlamp unit.
1 Twist to remove connector and bulb.
2 Remove bulb from connector.

To fit

Fit in reverse order.

Note

1
W711R014

Peykan

Do not touch the new bulb glass with your fingers.

Adjustment and replacement 45


To remove, front direction indicators

1 Turn bulb holder and connector anticlockwise and


remove complete from headlamp unit.
2 The bulb has a bayonet fitting, press bulb in and
turn anticlockwise to remove.

2
1

To fit

Fit in reverse order

Note
W711R015

Peykan

Do not touch the new bulb glass with your fingers.

46 Adjustment and replacement

Light adjustment, headlamps


Y

30 Meters

X
Z

SCREEN
H1

h1

H1 DIPPED BEAM CENTER


MARK FOR (X7)

SCREEN
H 1*
h1

15

Y
Z
Y=X-(Z*1.0%)
TOLERANCE: 0.25

LOW BEAM

W711R016

Low beam adjustment

Peykan

Adjustment and replacement 47

30 Meters

X
Z

SCREEN
H1

h1

LEFT

H1 DIPPED BEAM CENTER


MARK FOR (X7)

SCREEN
H2*
h2
L

h
h

Y
Z
Y=X-(Z*1.0%)
TOLERANCE: 0.25

MAIN BEAM

W711R017

Main beam adjustment

Peykan

48 Adjustment and replacement

Light and indicator stalk

To remove

1 Remove top and bottom steering column shroud,


retained with 2 screws (see page ... Book...).
2 Remove 2 screws retaining combination switch
pack.
3 Withdraw switch pack and unplug 2 connectors.

To fit

Fit in reverse order.

Note

Ensure correct routing of wiring on re-connection.


W711R018

Peykan

Adjustment and replacement 49

Direction indicators, side bulb

To remove

1 Push indicator light unit towards the front of the


car and pull outward to remove.
2 Unplug connector.
3 Hold the lens carefully and twist to remove bulb
and holder.
4 Remove bulb.

To fit

Fit in reverse order.


3
W711R019

Peykan

Fog lights

To remove

Access to front fog lights is gained from underneath the


front bumper.
1 Unplug 1 connector.
2 Remove 2 bolts and 1 screw and withdraw the fog
light unit from the rear of the bumper.

To fit

Fit in reverse order.


On fitting, re-adjust fog light (see page... for reference).

2
2
W711R020

Peykan

Replacement of fog lamp bulb

To remove

1 Remove rear cover.


2 Remove spring clip by pushing and lifting to
release.
3 Remove bulb and bulb holder.
4 Remove bulb.

To fit

Fit in reverse order.


4

Note

3
1
W711R022

Peykan

Do not touch the new bulb glass with your fingers.

52 Adjustment and replacement

Fog light adjustment

To adjust

Turn to adjust fog light like main beam expect that


Y=X-(Z *2.0%) adjustment.

W711R050

Peykan

Adjustment and replacement 53

Rear lights

To remove

Applies to LH and RH rear light cluster.


1 Remove luggage compartment trim as required
(see page...Book 9 for reference).
2 Unplug electrical connector.
3 Remove 3 nuts and carefully withdraw light
cluster.

To fit

Fit in reverse order.

3
W711R024

Peykan

54 Adjustment and replacement

Replacement of rear lamp bulbs, direction indicator and brake light


To remove

1 Remove luggage compartment trim as required


(see page... Book 9 for reference).
2 Unplug the electrical connector.
3 Press the two plastic clips and remove the bulb
holder.
4 Remove bulbs by pushing in and turning
anticlockwise.

To fit

Fit in reverse order.


W711R025

Peykan

Adjustment and replacement 55

Rear lights, trunk lid

To remove

Applies to LH and RH trunk lid light cluster.


1 Open trunk lid.
2 Unplug electrical connector.
3 Remove 4 nuts and carefully withdraw light
cluster.

To fit

Fit in reverse order.


3
W711R026

Peykan

56 Adjustment and replacement

Replacement of reverse and fog lamp bulbs, trunk lid


To remove

1 Open trunk lid.


2 Unplug electrical connector.
3 Press the two plastic clips and remove the bulb
holder.
4 Remove bulbs by pushing in and turning
anticlockwise.

To fit

3
4

Fit in reverse order.


W711R027

Peykan

Adjustment and replacement 57

Number plate light, boot lid

To remove
1
2
3
4

Push light to the left and lever down to remove.


Unplug connector.
Turn the bulb holder and remove.
Remove bulb from holder.

To fit

Fit in reverse order.

Peykan

58 Adjustment and replacement

High mounted stop lamp

To remove

1 Lift rear of light cover and pull away from parcel


shelf.
2 Unplug electrical connector.

3 Turn light over and remove 4 retaining screws.


4 Remove bulb holder as complete assembly.

Note

This unit is replaced as a complete assembly.

W711R029

To fit

Fit in reverse order.

Note

Ensure the front lugs are secure before pressing rear


clips into place.

Peykan

Adjustment and replacement 59

Front roof and map reading lamp bulbs

Roof light bulb


To remove

1 Insert a screwdriver carefully in the slot at the end


of the light unit and lever away from the front light
console.
2 Unplug the electrical connector.
3 Hold the light unit and unclip the bulb holder.
4 Remove the bulb.

3
4

To fit

Fit in reverse order.

Note

Ensure bulb holder is securely clipped in light fitting on


refit.

W711R030

Map reading light bulb


To remove

The map reading light can only be replaced as a


complete unit, so the bulb cannot be replaced alone.
1 Insert a screwdriver carefully at the top of the light
and lever away from the front light console.
2 Unplug the electrical connector.
3 Remove light unit.

To fit

Fit in reverse order.


3

W711R052

Peykan

60 Adjustment and replacement

Rear roof lamp bulb


2

To remove

1 Insert a screwdriver carefully in the slot at the end


of the light unit and lever away from the
headlining.
2 Unplug the electrical connector.
3 Hold the light unit and unclip the bulb holder.
4 Remove the bulb.

3
4

To fit

Fit in reverse order.

Note

Ensure bulb holder is securely clipped in light fitting on


refit.

W711R032

Peykan

Adjustment and replacement 61

Front and rear doors , roof lights

To remove, front door


1
2
3
4

Carefully lever out light from door.


Unplug the electrical connector.
Turn bulb holder and remove.
Remove bulb.

To fit

Fit in reverse order.

To remove, rear door


1
2
3
4

Carefully lever out light from door.


Unplug the electrical connector.
Turn bulb holder and remove.
Remove bulb.

To fit

Fit in reverse order.

Peykan

62 Adjustment and replacement

Front and rear door switches , roof lights

Front door switch

Located on the bottom rear of the front doors.


1 Remove screw.
2 Unplug electrical connector.
3 Remove switch.

To fit

Fit in reverse order.

W711R034

Rear door switch


2

Located on the bottom of the D-post.


1 Remove screw.
2 Unplug electrical connector.
3 Remove switch.

To fit

Fit in reverse order.


1
W711R035

Peykan

Adjustment and replacement 63

Horn

To remove

There is 1 horn on each side of the vehicle, located


bottom right and bottom left behind the front bumper.

W711R036

1 Disconnect the battery negative terminal.


2 Remove the wheel arch liner(s) (see page...
Book...).
3 Unplug the electrical connector.
4 Remove 1 bolt and withdraw the horn.

2
4

To fit

Fit in reverse order.

W711R037

Peykan

64 Adjustment and replacement

Horn switch, light and indicator stalk

To remove

1 Remove top and bottom steering column shroud,


retained with 2 screws (see page ... Book...).
2 Remove 2 screws retaining combination switch
pack.
3 Withdraw switch pack and unplug 2 connectors.

To fit

Fit in reverse order.

Note

Ensure correct routing of wiring on re-connection.


W711R018

Interior light rheostat


To remove

1 Insert a screwdriver carefully in the end of the unit


and lever away from the steering shroud.
2 Unplug the electrical connector and remove
rheostat.

2
1

To fit

Fit in reverse order.


W711R055

Peykan

65

Wash/Wipe System

Peykan

Peykan

Technical data 67

Technical data
Windscreen wiper motor

Stroke (stroke/min) and current consumption at


13.5V on wet windscreen
-low speed
45 +/- 6rpm
-high speed
71 +/- 8rpm
Rated current consumption
-low speed
-high speed
Current consumption at 13.5V, jammed motor (e.g.
frozen wiper blades)
-low speed
-high speed

W711S010

Maximum torque
-low speed
-high speed

Washer pump
Location
Type

W711S011

Peykan

On washer fluid reservoir


Centrifugal pump

Peykan

Technical description 69

Technical description
System overview
2

3
2

1
4

W711D010

Wiper system
1
2
3
4
5

motor. The wiper motor incorporates an automatic


parking function which always returns the wipers to the
same position when they are switched off. The
wipers/washers are operated by means of a stalk on
the steering column.

Windscreen wiper stalk switch


Windscreen wiper motor
Washer fluid motor
Windscreen wipper control unit
Washer fluid reservoir

Washer assembly
The washer system consists of a fluid reservoir with a
pump and fluid level monitor (situated in the lower part
of the reservoir) hoses and nozzles for the windscreen.

The system consists of:

Windscreen wipers
The windscreen wipers are driven by a two-speed
Peykan

Peykan

Adjustments and replacements 71

Adjustments and replacements


Windscreen wiper arm
To remove
3

1 Disconnect the washer fluid hose from the end of


the connector on the scuttle grille panel.
2 Lift up the wiper arm spindle nut cover, remove
the spindle nut.
3 Lift the wiper blade off the windscreen, remove
the wiper arm off the spindle.

Note

Mark the position of the wiper arm on the spindle before


removal.
1

W711R038

To fit

Fit in reverse order

Note

Make sure the wiper arm is replaced in the same


position on the spindle.

Peykan

72 Adjustments and replacements

Windscreen wiper motor and linkage

To remove

The assembly is located in the scuttle at the rear of the


engine compartment.
1 Disconnect the battery negative terminal.
2 Remove the wiper arms (see page... for
reference).
3 Remove 4 screws and lift up scuttle grill.
4 Disconnect the washer fluid hose from the end of
the connector on the left hand side in the scuttle.

5 Remove 2 screws and release plastic cover over


heater intake and washer fluid reservoir.
5

W711RO40

6 Remove the expandable plastic cover on the


wiper motor and unplug the electrical connector to
the motor.

6
W711R041

Peykan

Adjustments and replacements 73


7 Remove 3 bolts and washers securing the motor
and linkage to scuttle, then remove complete
assembly.
7

W711R042

8 Remove 1 nut securing linkage to the wiper motor


spindle.
9 Remove 3 bolts securing wiper motor to the
mounting bracket, then remove motor.

To fit

Fit in reverse order

9
9

8
W711R043

Peykan

74 Adjustments and replacements

Washer fluid reservoir

To remove

The reservoir is located in the left hand corner of the


scuttle at the rear of the engine.
1 Disconnect the battery negative terminal.
2 Remove scuttle grill and cover for heater intake
(see page... for reference).
3 Unplug electrical connector from the fluid pump.

3
W711R044

4 Remove 2 nuts securing reservoir to scuttle, then


lift reservoir from the scuttle.
5 If the reservoir contains any fluid, empty contents
and then disconnect fluid hose from the pump.
6 Remove reservoir.

To fit

Fit in reverse order

Peykan

Adjustments and replacements 75

Washer pump

To remove

1 Disconnect the battery negative terminal.


2 Remove washer reservoir (see page... for
reference).

3
W711R046

3 After disconnecting the electrical connector and


fluid hose, carefully ease the pump out of its
sealing grommet in the reservoir.

To fit

Fit in reverse order.

W711R047

Peykan

76 Adjustments and replacements

Wiper switch

To remove

1 Remove top and bottom steering column shroud

Peykan

Adjustments and replacements 77

Windscreen washer hoses

To remove

1 Remove 3 screws and lift down the windscreen


washer hoses

Peykan

Peykan

79

Wiring Harness

Peykan

Technical description 81

Technical description
System overview

W711D027

Wiring harness

Fuse box/branch box/relayes set

The Peykan has 14 harnesses:


Front panel harnes
Front harness
Instrument panel harness
Rear harness
Trunk lid harness
Front roof lamp harness
Engine harness
Front left hand door harness
Door switches harness
Front right hand door harness
Rear door harness
Heater harness
Brake pad wear harness

The fuse box is located in the engine bay just below the
windscreen.
The branch box is located on the left hand wing just up
from the headlamp.
The relayes set is located under the left hand side of
the Instrument Panel.

Peykan

82 Adjustment and replacement

Adjustment and replacement


Front panel harness

W711D012

Peykan

Adjustment and replacement 83

Front panel harness, associated components


Description

Component
Number

Battery VE Control Unit


Earth Point
Earth Point
Fan
Fan
Fan Relay
Fan Relay
Fan relay
Horn
Horn
Interco FRP-FR
LH Front Fog lamp
LH Frt Direction In. Lamp
LH Head Lamp
LH Side lamp
RH Front Fog lamp
RH FRT Direction Lamp
RH Head Lamp
RH Side Lamp

BB10
E001
E002
1510A
1510B
1500A
1500B
1500C
2520A
2520B
IC01
2670
2320
2610
2620
2675
2325
2615
2625

Peykan

84 Adjustment and replacement

Front harness

Peykan

Adjustment and replacement 85

Front harness, associated components


Description

Component
Number

Description

Component
Number

ACU
ACU
Air Cond. Compressor Relay
Blower Relay
Bonnet Switch
Brake Fluid Level Switch
Branch Box
Branch Box
Central Locking Control Unit
Cooler Relay
Earth Point
Earth Point
Earth Point
Earth Point
Electronic Box temp. Unit
Flasher Relay
Flasher Unit
Front Fog Lamp Relay
Front Window Lift Relay
Fuse Box
Fuse Box
Fuse Box
Fuse Box
Fuse Box
Fuse Box
Fuse Box
Fuse Box
Fuse Box
Fuse Box
Ignition Switch
Ignition Switch
Ignition Switch
Instrument Cluster
Instrument Cluster
Instrument Cluster
Instrument Cluster
Instrument Cluster
Instrument Cluster

8618B
8618A
8005
8048
8611
4410
BB10B
BB10A
6235
8005B
E020A
E005
E006
E020
8010
2350
2305
2665
6020
BF00A
BF00B
BF00C
BF00D
BF00E
BF00F
BF00G
BF00H
BF00I
BF00J
CA00A
CA00B
CA00C
0004A
0004B
0004C
0004D
0004E
0004F

Interco FA-FR
Interco FA-FR
Interco FR-FR/LH/D
Interco FR-FR/LH/D
Interco FR-FR/RH/D
Interco FR-FR/RH/D
Interco FR-HE
Interco FR-R/L
Interco FA-RR
Interco FA-RR
Interco FA-RR
Interco FR-EN
Interco FR-EN
Interco FR-EN
Interco FRP-FR
Interco FR-PW
Interco FR-PW
Lamps on Buzzer Relay
Left Hand Side Repeater Flasher
Light Switch
Light Switch
Lighting Rheostat
Pressostat
Radio Cassette
Radio Cassette
Rear Screen Heater
Timer Switch Relay
Rear Window Lift Relay
Right Hand Side Repeater Flasher
Screen Wiper Switch
Security Alarm Siren
Starter Relay
Stop Lamp Switch
Windscreen Wash Pump
Windscreen Wiper Control Unit
Windscreen Wiper Motor

IC20A
IC20B
IC22A
IC22B
IC24A
IC24B
IC26A
IC21
IC23A
IC23B
IC23C
IC02A
IC02B
IC02C
IC01
IC03A
IC03B
4720
2340
2600B
2600A
3050
8007
8410A
8410B

Peykan

8116
6126
2345
0005
8605
1086
2100
5100
5010
5015

86 Adjustment and replacement

Instrument panel harness

W711D013

Peykan

Adjustment and replacement 87

Instrument panel harness, associated components


Description

Component
Number

Cigar Lighter Lamp


Clock
Front Cigar Lighter
Glove Box Lamp
Glove Box Lamp Switch
Hazard Warning Switch
Interco FA-FR
Interco FA-FR
Roof Lamp Timer
RR Screen Heater Switch

3053
7220
8100
3115
3110
2300
IC20A
IC20B
3005
8110

Peykan

88 Adjustment and replacement

Rear harness

Peykan

Adjustment and replacement 89

Rear harness, associated components


Description

Component
Number

Door Contact Switch


Door Contact Switch
Door Contact Switch
Door Contact Switch
Earth Point
Earth Point
Earth Point
Electric Aerial
Fuel Filler Flap Lock Motor
Fuel Gauge
Hand Brake Switch
Heated Rear Screen
High Mounting Stop Lamp
Interco FA-RR
Interco FA-RR
Interco FR-RR
Interco RR-REL
Interco RR-RR/D
Interco RR-RR/D
Interco RR-TL
Loud Speaker (LH)
Loud Speaker (RH)
Rear Cigar Lighter
Rear Roof Lamp
Tail Light (LH)
Tail Light (RH)
Trunk Lamp
Trunk Lamp
Trunk Lamp Switch
Rear cigar lighter lamp
Reverse sensor buzzer
Reverse sensor unit

3003A
3003
3002
3002A
E027
E026D
E026G
8405
6265
4310
4400
8120A
2110
IC23A
IC23B
IC23C
IC35
IC33
IC32
IC60
8430
8435
8105
3020
2630
2635
3105A
3105B
3100
3053B
2225
2220

Peykan

90 Adjustment and replacement

Trunk lid harness

W711D016

Peykan

Adjustment and replacement 91

Trunk lid harness, associated components


Description

Component
Number

Interco TL-RR
License Plate Lamp
License Plate Lamp
Tail Lamp Trunk Lid (LH)
Tail Lamp Trunk Lid (RH)
Trunk Lid lock Actuator

IC60
2636
2633
2632
2637
6260

Peykan

92 Adjustment and replacement

Front roof lamp harness

W711D017

Peykan

Adjustment and replacement 93

Front roof lamp harness, associated components


Description

Component
Number

Interco FA-RFL
Infra Red Receiver
Map Reading lamp
Roof Lamp
Sunvisor Lamp (RH)
Sunvisor Lamp (LH)

IC21
6230
3065
3010
3060
3061

Peykan

94 Adjustment and replacement

Engine harness

Peykan

Adjustment and replacement 95

Engine harness, associated components


Description
Number

Component

Air Cond. En. Cool. Tem. Ter


Air Conditioning Compressor
Alternator
Battery VE Control Unit
Canister Purge Solenoid Valve
Coolant Thermis. Thermal SW.
Coolant Thermistor
Distributor Capacitor
Earth Point
Engine Oil Level Sensor
Engine Speed Sensor
Idling Regulation Stepper Motor
Ignition Coil
Ignition Injection Control Unit
Inertial Switch
INJ. Multi-Function Double Rel.
Injection Ignition Test Con.
Injection Potentiometer
Injector Cylinder No. 1
Injector Cylinder No. 2
Injector Cylinder No. 3
Injector Cylinder No. 4
Inlet Air Thermistor
Inlet Manifold Pressure Sens.
Interco FR-EN
Interco FR-EN
Interco FR-EN
Knock Detector
Oil Pressure Switch
Oil Vapour Heater Element
Reverse Lamp Switch
Starter
Supply Pump Fuse Holder Con.
Throttle Housing Fuse Con.
Throttle Housing Heater Resist.
Vehicle Speed Sensor

8008
8020
1020
BB10
1215
4025
1220
1136
E040
4120
1313
1225
1135
1320
1203
1304
C1300
1317
1331
1332
1333
1334
1240
1312
IC02A
IC02B
IC02C
1120 (not used)
4110
1273
2200
1010
C1260
C1265
1270
1620

Peykan

96 Adjustment and replacement

Front driver door harness

Peykan

Adjustment and replacement 97

Front driver door harness, associated components


Description

Component
Number

Door Contact Switch


Door Contact Switch
Door Lamp
Door Lock Motor
Door Lock Switch
Interco FA-FR/LH/D
Interco FA-FR/LH/D
Mirror Motors
Interco FR/LH/D -D/S
Interco FR/LH/D -D/S
Window winder motor

3000A
3000
3040
6240
6200
IC24A
IC24B
6415
Ic25A
Ic25B
6040

98 Adjustment and replacement

Front driver door switch harness

Peykan

Adjustment and replacement 99

Front driver door switch harness, associated components


Description

Component
Number

Auto Window Winder Switch


Electronic Box
Interco FR/LH/D-D/S
Interco FR/LH/D-D/S
Isolator Switch
Loud Speaker
Window Winder Switch FRT RH
Window Winder Switch Rear LH
Window Winder Switch Rear RH
Mirror switch

6000
6030
IC25A
IC25B
6120
8420
6015
6110
6115
6400

Peykan

100 Adjustment and replacement

Front passenger door harness

Peykan

Adjustment and replacement 101

Front passenger door harness, associated components


Description

Component
Number

Door Contact Switch


Door Contact Switch
Door Lamp
Door Lock Motor
Door Lock Switch
Interco FA-FR/RH/D
Interco FA-FR/RH/D
Loud Speaker
Mirror Motors
Window Winder Motor
Window Winder Switch

3001A
3001
3045
6245
6205
IC24A
IC24B
8425
6415
6045
6005

Peykan

102 Adjustment and replacement

Rear door harness (LH/RH)

W711D022

Peykan

Adjustment and replacement 103

Rear door harness, associated components


Description

Rear door(LH)
Door Lamp
Interco RR/D/LH-RR
Rear Door Lock Motor
Window Winder Motor
Window Winder Switch
door(RH)
Door Lamp
Interco RR/D/RH-RR
Rear Door Lock Motor
Window Winder Motor
Window Winder Switch

Component
Number

3042
IC32
6250
6130
6100
Rear
3047
IC33
6255
6135
6105

Peykan

104 Adjustment and replacement

Heater harness

W711D023

Peykan

Adjustment and replacement 105

Heater harness, associated components


Description

Component
Number
Passenger compartment
8035
Blower control module/ Heater blower motor 8045/8050
Heater panel
8025
Evaporator thermostat
8006
Air inlet flap reduction motor
8070
Interco FR-HE
IC26A

Peykan

106 Adjustment and replacement

Brake wear harness

W711R058

Peykan

Adjustment and replacement 107

Brake wear harness, associated components


Description

Interco FR-PW
Earth point
Brake pad

Component
Number
Ico3
E009
4432

Peykan

108 Adjustment and replacement

Fuse box, engine bay


1A

17

18

19

20

21

22

23

24

25

10

26

11

27

12

28

13

29

14

30

15

16A

16

W711D025

No.

F1
F1A
F2

Rating
10A
10A
5A

F3
F4

5A
5A

F5

5A

F6
F7
F8
F9

30A
20A
----5A

F10
F11

30A
30A

F12

5A

F13
F14

20A
30A

F15

10A

Function

Radio (Switch)
Radio (Battery)
Coolant temperature
unit, Air conditioning Swith,
Compressor Cut-Off Really
Pressostate air Conditioning,
Roof LampTimer Control
A.B.S
Right hand tail lamp.Lights
on Buzzer
Heater Control Relay,Heater
Control Switch
A.B.S
Horns
Shunt
License plate lamp,
Left hand Tail lamp
Electrical rear windows
Main beem,Dipped
beem,Side lamps
Instrument panel warning
lamp,Reversing lamp,
Tachometer automatic
transmission starter inhibitor
Front fog lamps
A.B.S
Roof lamp
Central Locking Control Unit
Electric aerial
Roof lamp timer
Unit door lamps

No.

Rating

F18

10A

F19

5A

F16 20A
F16A 10A
F17 10A

Function

Cigar lighter(Battery)
Cigar lighter(Switch)
Alarm control unit
Back of siren
Rear fog lamps,Front fog
relay

Heater panel illumination


Instrument panel illumination
Radio illumination
Lighting rheostat
F20 30A
(non active)
F21 30A
Blower relay
F22 20A
(non active)
F23 5A
Heated rear screen control
F24 20A
Windscreen wiper motor
Wiper timer,Wash pump
F25 5A
Clock,Radio (memory+),
Coolant temperature unit
F26 15A
Hazard warning,Flasher relay
F27 30A
Heated rear screen,Heatedmirrors
F28 10A
Instrument panel, Stop lamp
Load warning lamp,Front
window loft relay,digital clock
F29 30A
Electric front windows
F30 10A
Direction indicator,one touch
window lift,Electric window control relay,Map reading
lamp,Vanity mirror,Electrically controlled mirrors light on buzzer
glove box illumination
Peykan

Adjustment and replacement 109


No.

Rating

F25
F26

5A
30A

F27

30A

F28

15A

F29

15A

F30

15A

F31
F32
F33
F34
F35
F36
F37
F38

30A
30A
Shaunt
Shaunt
Shaunt
30A
20A
30A

F24

30A

Function

Radio memory
Clock
Coolant temperature unit
Hazard warning
Heated rear screen
Heated mirrors
Instrument panel
Digital clock
Stop lamps
Electrical front window
regulator
Sunroof (if fitted)
Map light
Glove box illumination
Lights on buzzer
Electrically controlled mirrors
Fan
Fan
Ignition switch

Anti-lock brakes (not used)


Anti-lock brakes (not used)
to be specified
to be specified

Peykan

110 Adjustment and replacement


No.

Rating

Function

F31
F32
F33
F34

30A
30A
Shunt
Shunt

Fan
Fan
Ignition switch
Front foglamps
relay

F13
Spare fuse
F33

F32
Spare fuse
F34

Branch box, engine bay

Brown

Gray
Black
Black
W712D044

Peykan

Adjustment and replacement 111

Relays set, Instrument panel

W711RO48

Pos. No.

Relay No.

1
2
3

1086
2350
4720

8116

5
6

6020
5010

7
8
9
10

2665
8045
6126
8005

11

8005B

Relay

Starter
Flasher
Lamps on
buzzer
Rear heated
screen switch
Front window lift
Windscreen wiper
control unit
Front fog lamp
Blower
Rear window lift
Air condition
compressor
Cooler

Color
Black
Black
White

Orange
Black
Blue
Black
Yellow
Black
Black
Black

Peykan

SAMAND

Service Manuals

The intellectual property rights pertaining to the technical information in


this document are the sole property of the manufacturer. No parts of this
information mar be reproduced of distributed in any from or by any
means, without the prior written consent of the manufacturer.
This document is strictly confidential and reserved for the in-house use
of the IKCO company network.
IKCO after Sales Services Department
SAMAND building (No. 5)
14KM Karaj highway - Tehran - Iran
Tel: +98 21 48909353
Fax: +98 21 48909360

Http://Iksa.ikco.com/Export