NEXON EV SERVICE MANUAL
|
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 |
|
B. INFOTAINMENT DISPLAY 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 |
|
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 |
|
HV ECU DTC Troubleshooting Guide |
517 |
|
1.OBC DTC Troubleshooting |
518 |
|
P220017:- KL30 (12V LV supply to OBC) Over Voltage |
523 |
|
P220016:- KL30 (12V LV supply to OBC) under voltage |
526 |
|
P229038:- CP Test point Frequency out is error |
530 |
|
P229003:- CP Test point Duty cycle out of range |
533 |
|
P220301:- OBC can't turn off +12V Power supply |
536 |
|
P226000:- OBC to BMS CAN transceiver error |
539 |
|
P226142:- OBC flash read error |
542 |
|
P226242:- OBC Flash Write error |
545 |
|
P226342:- OBC Flash Erase error |
548 |
|
P226442:- EEprom worn out |
551 |
|
P229104:- Internal SCI communication failure |
554 |
|
P229241:- Internal SCI communication CRC failure |
557 |
|
P22E017:- DC Overvoltage shutdown |
560 |
|
P22E016:- DC undervoltage shutdown |
563 |
|
P224016:- Low input AC voltage shutdown |
566 |
|
P224017:- High input AC voltage shutdown |
569 |
|
P229300:- Low temperature shutdown |
572 |
|
P229398:- High temperature shutdown |
575 |
|
P220416:- Controller internal 3.3V supply Low |
578 |
|
P220516:- Controller internal 12V supply Low |
581 |
|
P229400:- Shutdown diagnostic failure |
584 |
|
P220616:-Low boost voltage |
587 |
|
P229500:- Startup diagnostic failure |
590 |
|
P224119:- Input AC current overload |
593 |
|
P22E119:- DC overload |
596 |
|
P221000:- Sensor diagnostic failure |
599 |
|
P228006:- Self-test failure |
602 |
|
U007388:- OBC external CAN bus Off |
605 |
|
U140088:- OBC internal CAN bus off |
608 |
|
U10C087:- CAN communciation with BMS timeout |
611 |
|
P22E202:- Wakeup output signal error |
614 |
|
CAN Architecture |
617 |
|
2.BMS DTC Troubleshooting |
619 |
|
INTRODUCTION |
625 |
|
IMPORTANT INFORMATION |
625 |
|
PURPOSE OF DOCUMENT |
625 |
|
P1201-17:- BMS cell voltage high first level alarm - circuit voltage above threshold |
626 |
|
P1202-17:- BMS cell voltage high second level alarm - circuit voltage above threshold |
627 |
|
P1203 – 17:-BMS cell voltage high third level alarm - circuit voltage above threshold |
628 |
|
P1204 - 16:- BMS cell voltage low first level alarm - circuit voltage below threshold |
629 |
|
P1205 - 16:- BMS cell voltage low second level alarm - circuit voltage below threshold |
630 |
|
P1206 – 16:- BMS cell voltage low third level alarm - circuit voltage below threshold |
631 |
|
P1208 - 1C:- BMS voltage difference second level alarm - circuit voltage out of range |
632 |
|
P120A - 17:- BMS total voltage high first level alarm - circuit voltage above threshold |
633 |
|
P120B - 17:- BMS total voltage high second level alarm - circuit voltage above threshold |
634 |
|
P120C - 17:- BMS total voltage high third level alarm - circuit voltage above threshold |
635 |
|
P120D - 16:- BMS total voltage low first level alarm - circuit voltage below threshold |
636 |
|
P120E - 16:- BMS total voltage low second level alarm - circuit voltage above threshold |
637 |
|
P120F - 16:- BMS total voltage low third level alarm - circuit voltage below threshold |
638 |
|
P1210 - 21:- BMS SOC low first level alarm - signal amplitude < minimum |
639 |
|
P1214 - 98:- BMS battery charging temperature high first level alarm - component or system over temperature |
640 |
|
P1215 – 98:- BMS battery charging temperature high second level alarm - component or system over temperature |
641 |
|
P1216 - 98:- BMS battery charging temperature high third level alarm - component or system over temperature |
642 |
|
P1217 - 98:- BMS battery discharging temperature high first level alarm - component or system over temperature |
643 |
|
P1218 - 98:- BMS battery discharging temperature high second level alarm - component or system over temperature |
644 |
|
P121B – 98:- BMS battery discharging temperature high third level alarm - component or system over temperature |
645 |
|
P121C - 21:- BMS battery charging temperature low third level alarm - signal amplitude < minimum |
646 |
|
P121D - 21:- BMS battery discharging temperature low first level alarm - signal amplitude < minimum |
647 |
|
P121E - 21:- BMS battery discharging temperature low second level alarm - signal amplitude < minimum |
648 |
|
P121F - 21:- BMS battery discharging temperature low third level alarm - signal amplitude < minimum |
649 |
|
P1220 - 22:- BMS temperature difference high first level alarm - signal amplitude > maximum |
650 |
|
P1223 - 19:- BMS discharging current overload first level alarm - circuit current above threshold |
652 |
|
P1224 - 19:- BMS discharging current overload second level alarm - circuit current above threshold |
653 |
|
P1225 - 19:- BMS discharging current overload third level alarm - circuit current above threshold |
654 |
|
P1226 - 19:- BMS feedback current overload first level alarm - circuit current above threshold |
655 |
|
P1227 - 19:- BMS feedback current overload second level alarm - circuit current above threshold |
656 |
|
P1228 - 19:- BMS feedback current overload third level alarm - circuit current above threshold |
657 |
|
P1229 - 1A:- BMS insulation fault first level alarm - circuit resistance below threshold |
658 |
|
P122A - 1A:- BMS insulation fault second level alarm - circuit resistance below threshold |
659 |
|
P1231 - 1A:- BMS insulation fault third level alarm - circuit resistance below threshold |
660 |
|
P1232 - 27:- BMS SOC jump fault - signal rate of change above threshold |
661 |
|
P1233 - 17:- BMS power supply high fault - circuit voltage above threshold |
662 |
|
P1234 - 16:- BMS power supply low fault - circuit voltage below threshold |
663 |
|
P1235 - 13:- BMS_NegMainRlyConglut - circuit open |
664 |
|
P1236 - 13:- BMS_PosMainRlyConglut - circuit open |
665 |
|
P1237 - 13:- BMS_HVILAlarm - circuit open |
666 |
|
P1238 - 16:- BMS_PrechargeFaultAlarm - circuit voltage below threshold |
667 |
|
P1239 - 09:- BMS_BMUFault - Component Failures |
668 |
|
U1301 - 87:- BMS lost communication with VCU - missing message |
669 |
|
U1302 - 87:- BMS host lost communication with slave –missing message |
670 |
|
APPENDIX-A: COMPONENT DETAILS AND INFORMATION |
672 |
|
Place images of LV and HV connector. Show MSD location. Explain functionalities |
672 |
|
APPENDIX-B: MSD DISCONNECTION PROCEDURE |
672 |
|
4- step procedure for removing MSD |
672 |
|
Additional Instructions |
673 |
|
APPENDIX-C: TOOL CONNECTION AND COMMUNICATION |
673 |
|
3.DCDC_DTC_TroubleshootingV3.0 |
674 |
|
P130016:- KL30 (12V LV Supply to DC-DC) severely over voltage |
679 |
|
P130017:- KL30 (12V LV supply to DC-DC) over voltage |
684 |
|
P130018:- KL30 (12V LV Supply to DC-DC) under voltage |
689 |
|
P130019:- KL30 (12V LV Supply to DC-DC) severely under voltage |
694 |
|
P130020:- High temperature derating (Rated) |
699 |
|
P130021:- High temperature derating (Peak) |
704 |
|
P130022:- Low temperature warning |
709 |
|
P130023:- Low temperature shutdown |
714 |
|
P130024:- Output Voltage High |
719 |
|
P130025:- Output Over Voltage |
724 |
|
P130026:- Output Voltage Low |
729 |
|
P130027:- Output Under Voltage |
734 |
|
P130028:-Input Under Voltage |
739 |
|
P130029:- Input over voltage |
744 |
|
P130030:- Output Over Current |
749 |
|
P130031:- Input Over Current |
754 |
|
P130032:- Fatal fault |
759 |
|
CAN Architecture |
763 |
|
4.DTC_Troubleshooting_E-Drive |
765 |
|
P130000:- Hardware Fault |
769 |
|
P130100:- HV under / Over voltage fault |
773 |
|
P130200:- Over Temperature Fault |
779 |
|
P130300:- Motor Discharge Fault |
783 |
|
P130400:- Motor Over Speed Fault |
787 |
|
P130500:- LV under/over voltage fault |
791 |
|
P130600:- CAN Communication Fault |
796 |
|
CAN Architecture |
800 |