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NEXON EV SERVICE MANUAL
1

HV ELECTRICALSYSTEM
6

1. GENERAL INFORMATION
9

1.1 TOOLS
9

1.2 HAND GLOVES
10

1.3 WASHING INSTRUCTIONS
11

1.4 ELECTRICAL COMPONENT INFORMATION
12

1.5 MOTOR COMPARTMENT
13

2. TYPES OF CHARGING
14

A. NORMAL CHARGING (AC CHARGING)
15

B. FAST CHARGING PROCEDURE
20

3. TIGHTENING TORQUES
22

4. SPECIAL TOOLS LIST
28

5. INSTRUCTION FOR WORKING ON HVCOMPONENTS ON VEHICLE
30

6. HV COMPONENT IN UNDER BONNET COMPARTMENT LAYOUT OF HV COMPONENT
31

A. POWER DISTRIBUTION UNIT (PDU) REMOVAL
32

B. VEHICLE CONTROL UNIT REMOVAL
34

C. DC - DC CONVERTOR & ON - BOARDCHARGER REMOVAL
35

D. VACUUM PUMP REMOVAL
37

E. E-DRIVE REMOVAL
38

7. TRACTION COOLING SYSTEM (TCS)
41

A. SYSTEM LAYOUT
41

B. CIRCUIT SCHEMATIC
41

C. TCS COOLANT DRAINING PROCEDURE
42

D. TCS COOLANT FILLING PROCEDURE
42

E. RADIATOR / RADIATOR FAN REMOVAL
43

F. CONDENSER REMOVAL
44

8. HV BATTERY
47

A. SYSTEM LAYOUT
47

B. HV BATTERY REMOVAL
47

9. BATTERY COOLING SYSTEM (BCS)
49

A. SYSTEM LAYOUT
49

B. CIRCUIT SCHEMATIC
49

C. BCS COOLANT DRAINING PROCEDURE
50

D. BCS COOLANT FILLING PROCEDURE
50

E. COMPRESSOR
51

F. BATTERY COOLING PUMP REMOVAL
52

G. AUX TANK RESERVIOR REMOVAL
53

H. CHILLER UNIT (HEAT EXCHANGER)REMOVAL
54

I. HV / LV CHARGER PORT & CABLEREMOVAL
55

10. CRADLE
57

A. CRADLE EXPLODED VIEW
57

B. CRADLE REMOVAL
58

C. CRADLE FITMENT
59

SUPPLEMENTARY RESTRAINT SYSTEM (SRS)
62

1.1. WORKING OF RESTRAINTS
64

1.2. SYSTEM LAYOUT
65

1.3. SAFETY PRECAUTIONS
66

1.4. DISPOSAL OF FAULTY AIR BAG UNIT
68

1.5. SRS POST ACCIDENT PROCEDURE
69

1.6. TIGHTENING TORQUES
70

1.7. COMPONENTS
71

1.7.1. RESTRAINT WITHOUT AIRBAGS
71

1.7.2. RESTRAINT WITH AIRBAGS
71

1.7.2.1. ECU
71

1.7.2.2. SENSORS
74

1.7.2.3. AIR BAGS
76

1.7.2.4. RPLL BELTS
78

1.7.2.5. CLOCK SPRING
80

LV ELECTRICAL SYSTEM
83

1. GENERAL PRECAUTIONS
87

2. BATTERY
90

A. REMOVAL AND REFITMENT OF BATTERY CABLE
91

B. REMOVAL AND REFITMENT OF BATTERY REMOVAL
91

3. LIGHTING SYSTEM
92

3.1 BULB SPECIFICATIONS
92

3.2 FASTENERS TORQUE VALUE TABLE
92

3.3 GENERAL SYMPTOMS AND DIAGNOSTICS
93

3.4 HEAD LAMP
96

A. REMOVAL AND REFITMENT OF HEADLAMP
97

B. HEAD LAMP BULBS REPLACEMENT
98

C. EXPLODED VIEW (HIGH VERSION)
100

D. EXPLODED VIEW (LOW VERSION)
101

E. HEAD LAMP ADJUSTMENT
104

F. HEAD LAMP ADJUSTMENT
105

3.5 SIDE REPEATER LAMP (LH/RH)
106

3.6 ROOF LAMP
106

A. REMOVAL AND REFITMENT OF ROOFLAMP
107

3.7 HIGH MOUNTED STOP LAMP
108

A. REMOVAL AND REFITMENT OF HIGHMOUNTED STOP LAMP
108

3.8 TAIL LAMP
109

A. TAIL LAMP REMOVAL (BODY SIDE)
110

B. TAIL LAMP REMOVAL (TAIL GATE SIDE)
110

C. REMOVAL & REFITMENT OF TAILLAMPBULBS
111

3.9 FRONT FOG LAMP
111

4. HORN
113

5. WIPER & WASHER SYSTEM
115

5.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT
115

5.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY
116

5.3 WIPER AND WIPER CARE
117

6. POWER SOCKETS
119

7. COMBI-SWITCH
120

A. COMBI SWITCH CONNECTION DETAILS
121

B. REMOVAL & REFITMENT OF COMBISWITCH
123

C. COMBI STALK REPLACEMENTPROCEDURE
124

D. PINOUT DETAILS
125

8. FASCIA SWITCHES
126

9. HAZARD SWITCH
129

10. MIRROR SWITCH
131

11. INFOTAINMENT SYSTEM
133

11.1 SPEAKERS
136

11.2 ANTENNA (If Applicable)
137

11.3 MICROPHONE
138

11.4 SILVER BOX (XZ-HIGH VERSION)
139

11.5 TWEETERS
141

12. WINDOW WINDING MODULE
142

13. POWER WINDOW SWITCHES & INHIBIT SWITCH
144

14. STEERING WHEEL SWITCHES
148

15. DOOR HANDLE SWITCH
150

16. TAILGATE HANDLE SWITCH
151

17. IGNITION KEY (If Applicable)
152

18 INSTRUMENT CLUSTER
158

18.1 INSTRUMENT CLUSTER FEATURE MAPPING
159

18.2 TELL TALES INFORMATION
160

18.3 REMINDER FEATURES (Audio Alerts)
163

18.4 CONNECTOR DETAILS
164

18.5 MAIN CONNECTOR PIN-OUTS
165

18.6 REMOVAL OF INSTRUMENT CLUSTER
166

19. IGNITION KEY LEARNING PROCEDURE
167

20. BODY CONTROL MODULE (BCM)
169

20.1 LOCATION
169

20.2 REMOVAL OF BCM
169

20.3 BCM CONNECTION DETAILS
170

20.4 BCM PINOUT DETAILS
170

20.5 BCM SPECIFICATION
173

20.6 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX
174

20.7 BCM FEATURES
178

20.8 BCM REPLACEMENT STRATEGY
179

20.9 BCM FUNCTIONS
180

21 FUSE AND RELAY BOX DETAILS
181

21.1 BATTERY MOUNTED FUSE BOX (BDU)
183

21.2 ENGINE FUSE AND RELAY BOX
184

21.3 CABIN FUSE AND RELAY BOX
188

22. REVERSE PARK ASSIST SYSTEM
190

22.1 REVERSE PARK ASSIST SYSTEMDETAILS
190

22.2 ECU TO SENSOR ELECTRICAL INTERFACE
195

22.3 REVERSE PARK ASSIST WITH CAMERA (IF EQUIPPED)
200

22.4 REAR VIEW CAMERA (if equipped)
201

22.5 TROUBLESHOOTING
203

23 PASSIVE ENTRY PASSIVE START(PEPS)
204

23.1 PEPS ECU
204

23.2 START STOP SWITCH
206

23.3 ELECTRONIC STEERING COLUMN LOCK(ESCL)
207

23.4 DOOR HANDLE SWITCHES WITHHARNESS
209

23.5 LF ANTENNAS
209

DRIVE SHAFT
212

1. INTRODUCTION
214

2. DRIVE SHAFT PARTS
215

3. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE
215

4. TESTING FOR NOISE
216

5. TIGHTENING TORQUES
217

6. SPECIAL TOOLS
217

7. ON VEHICLE REMOVAL OF DRIVE SHAFT(LH & RH SIDE)
218

8. ON VEHICLE ASSEMBLY OF DRIVESHAFT (LH & RH SIDE)
219

9. DISASSEMBLY PROCEDURE FOR DRIVESHAFT
220

10. ASSEMBLY PROCEDURE FOR DRIVESHAFT
222

11. PRECAUTION TO AVOID THE DAMAGE TO DRIVE SHAFT
223

12. DO’S AND DON’T’S FOR DRIVE SHAFT
224

SUSPENSION
225

1. GENERAL INFORMATION
228

2. TECHNICAL SPECIFICATIONS
232

3. TIGHTENING TORQUES
233

4. SPECIAL TOOLS
237

4.1. FRONT SUSPENSION
237

4.2. REAR SUSPENSION
243

5. DIAGNOSIS
244

6. PRECAUTIONS
245

7. EXPLODED VIEWS FRONT SUSPENSION
246

A. ASSEMBLY FRONT STRUT
246

B. ANTI ROLL BAR MOUNTING
247

C. LOWER LINK
248

D . FRONT AXLE ASSEMBLY
249

8. EXPLODED VIEWS REAR SUSPENSION
250

A. REAR SHOCK ABSORBER AND SPRING
250

B. REAR HUB ASSEMBLY
251

C. PIVOT MOUNTING BRACKET AND BUSH
252

9. ON VEHICLE PROCEDURE
253

A. FRONT STRUT ASSEMBLY
253

B. FRONT STRUT ON BENCH
254

C. WHEEL HUB
255

D. SUBFRAME ASSEMBLY
258

i. REMOVAL OF SUBFRAME ASSEMBLY
258

ii. REMOVAL OF ANTI ROLL BAR
259

iii. REMOVAL OF LOWER ARM BALL JOINT
261

iv. REMOVAL OF LOWER ARM RUBBERBUSHES
262

v. INSTALLATION OF SUBFRAME ASSEMBLY
263

E. REAR SHOCK ABSORBER AND COILSPRINGS
264

I. REMOVAL OF REAR SHOCK ABSORBERAND COIL SPRINGS
264

II. INSTALLATION OF REAR SHOCKABSORBER AND COIL SPRINGS
266

F. TORSION BEAM
267

10. SUSPENSION PRE-LOADING CONDITION
271

WHEELS AND TYRES
272

1. GENERAL INFORMATION
274

A. SPECIFICATIONS
274

B. TYRE PRESURE DETAILS
274

C. CONSTRUCTION
275

D. TIGHTENING TORQUES
277

2 GENERAL SYMPTOMS DIAGNOSIS
278

A. DIAGNOSIS CHART
278

B. TYRE WEAR PATTERN
280

C. WEAR CAUSES
281

D. TYRE VIBRATION DIAGNOSIS
282

3 MAINTENANCE, INSPECTION AND TESTS
283

A PRELIMINARY INSPECTION
283

I. VISUAL INSPECTION
283

II. PRECAUTIONS
283

B REGULAR MAINTENANCE
284

I. INFLATION
284

II. WHEEL BALANCING
284

III. TYRE ROTATION
285

IV. WHEEL RUN OUT
286

V. DO'S AND DON’TS
286

4. WHEEL AND TYRE REPLACEMENT
287

A. PRECAUTIONS DURING TYREREPLACEMENT
287

B. TYRE REPLACEMENT
288

C. WHEEL ASSEMBLY REPLACEMENT
288

D. WHEEL REMOVAL
289

STEERING (ELECTRICAL POWER ASSIST SYSTEM - EPAS)
290

1.1. GENERAL INFORMATION
292

1.1.1 SPECIFICATIONS
292

1.1.2 . SYSTEM LAYOUT
292

1.1.3. GENERAL DESCRIPTION
293

1.1.4. TIGHTENING TORQUES
294

1.1.5. SPECIAL TOOLS
296

1.2. MAINTENANCE, INSPECTION AND TEST
297

1.2.1. PRELIMINARY INSPECTION
297

1.2.2. REGULAR MAINTENANCE
298

1.2.3. ON VEHICLE REPAIRS
300

1.2.3.1. STEERING WHEEL REMOVAL
300

1.2.3.2. STEERING COLUMN REMOVAL
301

1.2.3.3. INTERMEADIATE SHAFT REMOVAL
302

1.2.3.4. RACK & PINION ASSEMBLY REMOVAL
302

1.3. OVERHAULING
304

1.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY
304

1.3.2. PRECAUTIONS
305

1.3.3. DISMANTLING, INSPECTION AND ASSEMBLY
305

1.3.3.1. DISASSEMBLY OF RACK & PINON
305

1.3.3.2. INSPECTION OF DISMANTLED PARTS
306

1.3.3.3. ASSEMBLY OF RACK & PINON
306

1.3.3.4. OBJ ON-VEHICLE REMOVAL
308

1.3.3.5. DO’S & DON’TS
308

1.3.3.6. WHEEL ALIGNMENT
309

1.4. TROUBLESHOOTING AND DIAGNOSIS
311

1.5. STEERING ANGLE CALIBRATION
315

1.6. TUNING DATA SELECTION
318

BRAKES
320

1. PRECAUTIONS
323

2. TECHNICAL SPECIFICATIONS
324

3. TIGHTENING TORQUES
326

4. DIAGNOSIS
330

5. NESSECITY OF ABS with EBD
333

6. BRAKE HYDRAULIC LINES
334

7. VACUUM BRAKE BOOSTER
335

8. WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS)
336

9. ABS COMPONENTS
340

9.1. ABS 9.3 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU)
341

9.2. HYDRAULIC CONTROL UNIT
342

9.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED
343

9.4. ABS SYSTEM FAILURE WARNING LIGHT
344

10. MAINTENANCE, ADJUSTMENTS & TEST
345

10.1. FRONT BRAKE MAINTENANCE
345

10.2. REAR BRAKE MAINTENANCE
347

10.3 BRAKE TROUBLE SHOOTING
352

10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO
353

10.5 STOP LIGHT SWITCH ADJUSTMENT
354

11. BRAKE PEDAL ASSEMBLY
355

12. REGENERATION SENSOR REMOVAL
356

13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE
357

14. REPAIRS
358

14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT
359

14.2. REMOVAL OF FRONT BRAKE DISC
364

14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY
365

14.4. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY
368

14.5 REMOVAL & REFITMENT OF WHEELCYLINDER
371

14.6. REMOVAL OF PARKING BRAKELEVER
374

14.7. REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE
375

14.8. PARKING BRAKE CABLE ADJUSTMENT
376

14.9. REMOVAL AND REFITMENT OF ABSECU / HCU
377

14.10. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR
378

14.11. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR
379

15. TROUBLE SHOOTING & DIAGNOSIS
380

16. ABS ECU CONNECTOR (K2)
382

FATC
384

1. TECHNICAL SPECIFICATIONS
388

2. TIGHTENING TORQUES
390

3. PRECAUTIONS
394

4. FATC SYSTEM LAYOUT AND BATTERY COOLING SYSTEM WORKING
395

5. COMPONENTS OF FULLY AUTOMATICCONTROL PANEL (FATC
398

i. AC COMPRESSOR ON / OFF BUTTON
398

ii. BLOWER SPEED CONTROL KNOB (Roundknob)
399

iii. ECON Button
399

iv. MAX DEFROST BUTTON
399

v. REAR WINDOW DEMISTER BUTTON
399

vi. FRESH AIR / RECIRCULATION BUTTON
399

vii. AIR DISTRIBUTION (MODE) BUTTON
399

viii. “OFF” BUTTON
400

ix. AUTO ON SELECTION BUTTON
400

x. TEMPERATURE CONTROL KNOB
400

xi. REMOTE AC MODE
401

6. CONTROL PANEL CONNECTOR DETAILS
402

7. FATC UNIT
404

i. BLOWER
404

ii. LINEAR POWER MODULE (LPM)
405

iii. EVAPORATOR COIL AND TXV (THERMALEXPANSION VALVE)
405

iv. HEATER COIL
405

8. COMPRESSOR
406

9. CONDENSER AND RECEIVER DRIER
407

10. CHILLER UNIT
407

11. COOLANT PUMP
407

12. FATC SENSORS AND ACTUATORS
408

A. EVAPORATER SENSOR
408

B. ON VEHICLE INSPECTION (WITHOUT DISMANTLINGHVAC UNIT)
408

C. LINEAR PRESSURE SENSOR (LPS
409

D. SOLAR LOAD SENSOR
410

E. OAT SENSOR
411

F. IN-CAR SENSOR
412

G. AIR INLET ACTUATOR
412

H. BLOWER CONTROL MODULE
413

13. TROUBLESHOOTING
414

14. MAINTENANCE
424

A. PRELIMINARY INSPECTION
424

i. AC SYSTEM PERFORMANCE TEST
424

iv. LEAK DETECTION
426

B. REGULAR MAINTENANCE
426

i. REFRIGERANT RECOVERY, RECYCLINGAND RECHARGING
426

ii. RECOVERY AND RECYCLING
427

iii. EVACUATION AND RECHARGING
427

iv. FLUSHING OF AC SYSTEM
427

v. REPLENISHING COMPRESSOR OIL
428

15. ON VEHICLE REPAIRS
430

A. CONTROL PANEL ASSEMBLY REMOVAL
430

C. COMPRESSOR
431

D. BLOWER
432

E. LPM
432

F. AIR FILTER
433

G. PTC HEATER
435

H. REAR DUCT
435

I. TXV
436

J. HVAC UNIT
436

K. CONDENSER SEALING DUCT
437

M. CHILLER UNIT
437

N. SOLENOID VALVE
438

B. INFOTAINMENT DISPLAY REMOVAL
430

16. REFRIGERANT HOSES/PIPES
439

17. DO’s & DONT’s
440

BODY
441

1. GENERAL LAYOUT
445

2. TIGHTENING TORQUES
446

3. SPECIAL TOOL
449

4. ON VEHICLE PROCEDURES
450

4.1 BONNET
450

4.2. FLOOR CONSOLE
452

4.3. DASHBOARD SKIN
455

4.4. GLOVE BOX
460

4.5. SIDE AIR VENTS
462

4.6. FRONT BUMPER
463

4.7 REAR BUMPER
464

4.8. FRONT DOOR
465

4.9. FRONT DOOR TRIMS
466

4.10. DOOR INNER LOCK HANDLE
467

4.11. FRONT OUTER DOOR LOCK
468

4.12. FRONT DOOR LATCH
469

4.13. FRONT DOOR GLASS AND WINDOWWINDING MECHANISM
470

4.14. REAR DOOR
471

4.15. REAR DOOR TRIM
472

4.16. REAR OUTER DOOR LOCK
473

4.17. DOOR LATCH REAR
474

4.18. TAIL GATE
475

4.19. TAIL GATE LATCH CABLE
478

4.20. TAIL GATE TRIM
478

4.21. ORVM
479

4.22. INNER REAR VIEW MIRROR
480

4.23. FRONT ROW SEAT
480

4.24. REAR ROW SEAT
481

4.25. FRONT SEAT BELT
483

4.26. REAR SEAT BELT
484

4.27. “A” PILLAR TRIM
485

4.28. FRONT SCUFF PLATE
486

4.29. “B” PILLAR TRIMS
487

4.30. “C” PILLAR TRIMS
488

4.31. GRAB HANDLE
488

4.32. SUNVISOR
489

4.33. ROOF LINEAR
489

4.34. PLENUM COVER
490

4.35. BONNET INSULATION
490

4.36. GLASS
491

4.37. FRONT WHEEL ARCH LINER
492

4.38. REAR WHEEL ARCH LINER
493

4.39. FRONT FENDER
494

4.40. REAR WIPER MOTOR
497

4.41. FRONT WIPER
498

4.42 SUNROOF
499

A. SUNROOF DO’S AND DON’TS
499

B. EXPLODED VIEW
500

C. SUNROOF REMOVAL
501

D. SUNROOF FITMENT
502

E. SUNROOF CHILDPARTS SERVICIABLITY
503

1. WIND DEFLECTOR
503

2. GLASS PANEL
503

3. SUNSHADE
504

4. ELECTRIC DRIVE ASSEMBLY
505

5. REAR WATER CHANNEL ASSEMBLY
506

6. CORNER COVER PIECE
506

7. CONNECTING PART
508

8. COLISSA GUIDE ASSEMBLY
508

9. RETAINING HOOK GUIDE AC
509

10. GUIDE RR AC
510

11. GUIDE FR ASSY
511

12. MECHANISM MAINTENANCE
511

13. WATER CHANNEL MAINTENANCE
513

14. GUIDE RAIL MAINTENANCE
513

15. RE-INITIALIZING THE POWER SUNROOF
513