NEXON EV SERVICE MANUAL

NEXON EV SERVICE MANUAL	1
HV ELECTRICAL SYSTEM	6
1. GENERAL INFORMATION	9
1.1. TOOLS	9
1.2. HAND GLOVES	9
1.3. PPES FOR HV	10
1.4. MEASURING TOOLS	13
1.5. SAFETY INSTRUCTIONS	14
1.6. DO’S AND DON’TS	15
1.7. SAFETY WHILE SERVICING	18
1.8. WASHING INSTRUCTIONS	22
1.9. ELECTRICAL COMPONENT INFORMATION	23
1.10. MOTOR COMPARTMENT	25
2. TYPES OF CHARGING	26
A. NORMAL CHARGING	27
B. FAST CHARGING	32
3. TIGHTENING TORQUES	34
4. SPECIAL TOOLS	40
5. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE	42
6. HV COMPONENTS UNDER BONNET COMPARTMENT	43
A. POWER DISTRIBUTION UNIT (PDU) REMOVAL	44
B. VEHICLE CONTROL UNIT	46
C. DC – DC CONVERTOR & ON BOARD CHARGER REMOVAL	47
D. VACCUM PUMP REMOVAL	49
E. E - DRIVE REMOVAL	50
F. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS	53
7. TRACTION COOLING SYSTEM (TCS	54
A. SYSTEM LAYOUT	54
B. CIRCUIT SCHEMATICS	54
C. TCS COOLANT DRAINING PROCEDURE	55
D. TCS COOLANT FILLING PROCEDURE	55
E. RADIATOR / RADIATOR FAN REMOVAL	56
F. CONDENSOR REMOVAL	57
G. AUX TANK RESERVIOR REMOVAL	58
8. HV BATTERY	60
A. SYSTEM LAYOUT	60
B. HV BATTERY REMOVAL	60
9. BATTERY COOLING SYSTEM (BCS)	63
A. SYSTEM LAYOUT	63
B. CIRCUIT SCHEMATICS	63
C. BCS COOLANT DRAINING PROCEDURE	64
D. BCS COOLANT FILLING PROCEDURE	64
E. COMPRESSOR	65
F. BATTERY COOLING PUMP REMOVAL	66
G. AUX TANK RESERVIOR REMOVAL	67
H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL	68
I. HV / LV CHARGER PORT & CABLE REMOVAL	69
J. CCS2 INLET ACTUATOR REPLACEMENT PROCEDURE	71
10. CRADLE	73
A. CRADLE EXPLODED VIEW	73
B. CRADLE REMOVAL	74
C. CRADLE FITMENT	75
SUPPLEMENTARY RESTRAINT SYSTEM (SRS)	78
1.1. WORKING OF RESTRAINTS	80
1.2. SYSTEM LAYOUT	81
1.3. SAFETY PRECAUTIONS	82
1.4. DISPOSAL OF FAULTY AIR BAG UNIT	84
1.5. SRS POST ACCIDENT PROCEDURE	85
1.6. TIGHTENING TORQUES	86
1.7. COMPONENTS	87
1.7.1. RESTRAINT WITHOUT AIRBAGS	87
1.7.2. RESTRAINT WITH AIRBAGS	87
1.7.2.1. ECU	87
1.7.2.2. SENSORS	90
1.7.2.3. AIR BAGS	92
1.7.2.4. RPLL BELTS	94
1.7.2.5. CLOCK SPRING	96
LV ELECTRICAL SYSTEM	99
1. GENERAL PRECAUTIONS	103
2. BATTERY	106
A. REMOVAL AND REFITMENT OF BATTERY CABLE	107
B. REMOVAL AND REFITMENT OF BATTERY REMOVAL	107
3. LIGHTING SYSTEM	108
3.1 BULB SPECIFICATIONS	108
3.2 FASTENERS TORQUE VALUE TABLE	108
3.3 GENERAL SYMPTOMS AND DIAGNOSTICS	109
3.4 HEAD LAMP	112
A. REMOVAL AND REFITMENT OF HEADLAMP	113
B. HEAD LAMP BULBS REPLACEMENT	114
C. EXPLODED VIEW (HIGH VERSION)	116
D. EXPLODED VIEW (LOW VERSION)	117
E. HEAD LAMP ADJUSTMENT	120
F. HEAD LAMP ADJUSTMENT	121
3.5 SIDE REPEATER LAMP (LH/RH)	122
3.6 ROOF LAMP	122
A. REMOVAL AND REFITMENT OF ROOFLAMP	123
3.7 HIGH MOUNTED STOP LAMP	124
A. REMOVAL AND REFITMENT OF HIGHMOUNTED STOP LAMP	124
3.8 TAIL LAMP	125
A. TAIL LAMP REMOVAL (BODY SIDE)	126
B. TAIL LAMP REMOVAL (TAIL GATE SIDE)	126
C. REMOVAL & REFITMENT OF TAILLAMPBULBS	127
3.9 FRONT FOG LAMP	127
4. HORN	129
5. WIPER & WASHER SYSTEM	131
5.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT	131
5.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY	132
5.3 WIPER AND WIPER CARE	133
6. POWER SOCKETS	135
7. COMBI-SWITCH	136
A. COMBI SWITCH CONNECTION DETAILS	137
B. REMOVAL & REFITMENT OF COMBISWITCH	139
C. COMBI STALK REPLACEMENTPROCEDURE	140
D. PINOUT DETAILS	141
8. FASCIA SWITCHES	142
9. HAZARD SWITCH	145
10. MIRROR SWITCH	147
11. INFOTAINMENT SYSTEM	149
11.1 SPEAKERS	152
11.2 ANTENNA (If Applicable)	153
11.3 MICROPHONE	154
11.4 SILVER BOX (XZ-HIGH VERSION)	155
11.5 TWEETERS	157
12. WINDOW WINDING MODULE	158
13. POWER WINDOW SWITCHES & INHIBIT SWITCH	160
14. STEERING WHEEL SWITCHES	164
15. DOOR HANDLE SWITCH	166
16. TAILGATE HANDLE SWITCH	167
17. IGNITION KEY (If Applicable)	168
18 INSTRUMENT CLUSTER	174
18.1 INSTRUMENT CLUSTER FEATURE MAPPING	175
18.2 TELL TALES INFORMATION	176
18.3 REMINDER FEATURES (Audio Alerts)	179
18.4 CONNECTOR DETAILS	180
18.5 MAIN CONNECTOR PIN-OUTS	181
18.6 REMOVAL OF INSTRUMENT CLUSTER	182
19. IGNITION KEY LEARNING PROCEDURE	183
19.1. PAIRING OF EMS-ECU & IMMOBILIZERCONTROL UNIT	183
19.2. SMART KEY OR WEARABLE LEARNINGPROCEDURE	184
20. BODY CONTROL MODULE (BCM)	185
20.1 LOCATION	185
20.2 REMOVAL OF BCM	185
20.3 BCM CONNECTION DETAILS	186
20.4 BCM PINOUT DETAILS	186
20.5 BCM SPECIFICATION	189
20.6 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX	190
20.7 BCM FEATURES	194
20.8 BCM REPLACEMENT STRATEGY	195
20.9 BCM FUNCTIONS	196
21 FUSE AND RELAY BOX DETAILS	197
21.1 BATTERY MOUNTED FUSE BOX (BDU)	199
21.2 ENGINE FUSE AND RELAY BOX	200
21.3 CABIN FUSE AND RELAY BOX	204
22. REVERSE PARK ASSIST SYSTEM	206
22.1 REVERSE PARK ASSIST SYSTEMDETAILS	206
22.2 ECU TO SENSOR ELECTRICAL INTERFACE	211
22.3 REVERSE PARK ASSIST WITH CAMERA (IF EQUIPPED)	216
22.4 REAR VIEW CAMERA (if equipped)	217
22.5 TROUBLESHOOTING	219
23 PASSIVE ENTRY PASSIVE START(PEPS)	220
23.1 PEPS ECU	220
23.2 START STOP SWITCH	222
23.3 ELECTRONIC STEERING COLUMN LOCK(ESCL)	223
23.4 DOOR HANDLE SWITCHES WITHHARNESS	225
23.5 LF ANTENNAS	225
DRIVE SHAFT	228
1. INTRODUCTION	230
2. DRIVE SHAFT PARTS	231
3. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE	231
4. TESTING FOR NOISE	232
5. TIGHTENING TORQUES	233
6. SPECIAL TOOLS	233
7. ON VEHICLE REMOVAL OF DRIVE SHAFT(LH & RH SIDE)	234
8. ON VEHICLE ASSEMBLY OF DRIVESHAFT (LH & RH SIDE)	235
9. DISASSEMBLY PROCEDURE FOR DRIVESHAFT	236
10. ASSEMBLY PROCEDURE FOR DRIVESHAFT	238
11. PRECAUTION TO AVOID THE DAMAGE TO DRIVE SHAFT	239
12. DO’S AND DON’T’S FOR DRIVE SHAFT	240
SUSPENSION	241
1. GENERAL INFORMATION	244
2. TECHNICAL SPECIFICATIONS	248
3. TIGHTENING TORQUES	249
4. SPECIAL TOOLS	253
4.1. FRONT SUSPENSION	253
4.2. REAR SUSPENSION	259
5. DIAGNOSIS	260
6. PRECAUTIONS	261
7. EXPLODED VIEWS FRONT SUSPENSION	262
A. ASSEMBLY FRONT STRUT	262
B. ANTI ROLL BAR MOUNTING	263
C. LOWER LINK	264
D . FRONT AXLE ASSEMBLY	265
8. EXPLODED VIEWS REAR SUSPENSION	266
A. REAR SHOCK ABSORBER AND SPRING	266
B. REAR HUB ASSEMBLY	267
C. PIVOT MOUNTING BRACKET AND BUSH	268
9. ON VEHICLE PROCEDURE	269
A. FRONT STRUT ASSEMBLY	269
B. FRONT STRUT ON BENCH	270
C. WHEEL HUB	271
D. SUBFRAME ASSEMBLY	274
i. REMOVAL OF SUBFRAME ASSEMBLY	274
ii. REMOVAL OF ANTI ROLL BAR	275
iii. REMOVAL OF LOWER ARM BALL JOINT	277
iv. REMOVAL OF LOWER ARM RUBBERBUSHES	278
v. INSTALLATION OF SUBFRAME ASSEMBLY	279
E. REAR SHOCK ABSORBER AND COILSPRINGS	280
I. REMOVAL OF REAR SHOCK ABSORBERAND COIL SPRINGS	280
II. INSTALLATION OF REAR SHOCKABSORBER AND COIL SPRINGS	282
F. TORSION BEAM	283
10. SUSPENSION PRE-LOADING CONDITION	287
WHEELS AND TYRES	288
1. GENERAL INFORMATION	290
A. SPECIFICATIONS	290
B. TYRE PRESURE DETAILS	290
C. CONSTRUCTION	291
D. TIGHTENING TORQUES	293
2 GENERAL SYMPTOMS DIAGNOSIS	294
A. DIAGNOSIS CHART	294
B. TYRE WEAR PATTERN	296
C. WEAR CAUSES	297
D. TYRE VIBRATION DIAGNOSIS	298
3 MAINTENANCE, INSPECTION AND TESTS	299
A PRELIMINARY INSPECTION	299
I. VISUAL INSPECTION	299
II. PRECAUTIONS	299
B REGULAR MAINTENANCE	300
I. INFLATION	300
II. WHEEL BALANCING	300
III. TYRE ROTATION	301
IV. WHEEL RUN OUT	302
V. DO'S AND DON’TS	302
4. WHEEL AND TYRE REPLACEMENT	303
A. PRECAUTIONS DURING TYREREPLACEMENT	303
B. TYRE REPLACEMENT	304
C. WHEEL ASSEMBLY REPLACEMENT	304
D. WHEEL REMOVAL	305
STEERING (ELECTRICAL POWER ASSIST SYSTEM - EPAS)	306
1.1. GENERAL INFORMATION	308
1.1.1 SPECIFICATIONS	308
1.1.2 . SYSTEM LAYOUT	308
1.1.3. GENERAL DESCRIPTION	309
1.1.4. TIGHTENING TORQUES	310
1.1.5. SPECIAL TOOLS	312
1.2. MAINTENANCE, INSPECTION AND TEST	313
1.2.1. PRELIMINARY INSPECTION	313
1.2.2. REGULAR MAINTENANCE	314
1.2.3. ON VEHICLE REPAIRS	316
1.2.3.1. STEERING WHEEL REMOVAL	316
1.2.3.2. STEERING COLUMN REMOVAL	317
1.2.3.3. INTERMEADIATE SHAFT REMOVAL	318
1.2.3.4. RACK & PINION ASSEMBLY REMOVAL	318
1.3. OVERHAULING	320
1.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY	320
1.3.2. PRECAUTIONS	321
1.3.3. DISMANTLING, INSPECTION AND ASSEMBLY	321
1.3.3.1. DISASSEMBLY OF RACK & PINON	321
1.3.3.2. INSPECTION OF DISMANTLED PARTS	322
1.3.3.3. ASSEMBLY OF RACK & PINON	322
1.3.3.4. OBJ ON-VEHICLE REMOVAL	324
1.3.3.5. DO’S & DON’TS	324
1.3.3.6. WHEEL ALIGNMENT	325
1.4. TROUBLESHOOTING AND DIAGNOSIS	327
1.5. STEERING ANGLE CALIBRATION	331
1.6. TUNING DATA SELECTION	334
BRAKES	336
1. PRECAUTIONS	339
2. TECHNICAL SPECIFICATIONS	340
3. TIGHTENING TORQUES	342
4. DIAGNOSIS	346
5. NESSECITY OF ABS with EBD	349
6. BRAKE HYDRAULIC LINES	350
7. VACUUM BRAKE BOOSTER	351
8. WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS)	352
9. ABS COMPONENTS	356
9.1. ABS 9.3 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU)	357
9.2. HYDRAULIC CONTROL UNIT	358
9.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED	359
9.4. ABS SYSTEM FAILURE WARNING LIGHT	360
10. MAINTENANCE, ADJUSTMENTS & TEST	361
10.1. FRONT BRAKE MAINTENANCE	361
10.2. REAR BRAKE MAINTENANCE	363
10.3 BRAKE TROUBLE SHOOTING	368
10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO	369
10.5 STOP LIGHT SWITCH ADJUSTMENT	370
11. BRAKE PEDAL ASSEMBLY	371
12. REGENERATION SENSOR REMOVAL	372
13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE	373
14. REPAIRS	374
14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT	375
14.2. REMOVAL OF FRONT BRAKE DISC	380
14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY	381
14.4. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY	384
14.5 REMOVAL & REFITMENT OF WHEELCYLINDER	387
14.6. REMOVAL OF PARKING BRAKELEVER	390
14.7. REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE	391
14.8. PARKING BRAKE CABLE ADJUSTMENT	392
14.9. REMOVAL AND REFITMENT OF ABSECU / HCU	393
14.10. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR	394
14.11. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR	395
15. TROUBLE SHOOTING & DIAGNOSIS	396
16. ABS ECU CONNECTOR (K2)	398
FATC	400
1. TECHNICAL SPECIFICATIONS	404
2. TIGHTENING TORQUES	406
3. PRECAUTIONS	410
4. FATC SYSTEM LAYOUT AND BATTERY COOLING SYSTEM WORKING	411
5. COMPONENTS OF FULLY AUTOMATICCONTROL PANEL (FATC	414
i. AC COMPRESSOR ON / OFF BUTTON	414
ii. BLOWER SPEED CONTROL KNOB (Roundknob)	415
iii. ECON Button	415
iv. MAX DEFROST BUTTON	415
v. REAR WINDOW DEMISTER BUTTON	415
vi. FRESH AIR / RECIRCULATION BUTTON	415
vii. AIR DISTRIBUTION (MODE) BUTTON	415
viii. “OFF” BUTTON	416
ix. AUTO ON SELECTION BUTTON	416
x. TEMPERATURE CONTROL KNOB	416
xi. REMOTE AC MODE	417
6. CONTROL PANEL CONNECTOR DETAILS	418
7. FATC UNIT	420
i. BLOWER	420
ii. LINEAR POWER MODULE (LPM)	421
iii. EVAPORATOR COIL AND TXV (THERMALEXPANSION VALVE)	421
iv. HEATER COIL	421
8. COMPRESSOR	422
9. CONDENSER AND RECEIVER DRIER	423
10. CHILLER UNIT	423
11. COOLANT PUMP	423
12. FATC SENSORS AND ACTUATORS	424
A. EVAPORATER SENSOR	424
B. ON VEHICLE INSPECTION (WITHOUT DISMANTLINGHVAC UNIT)	424
C. LINEAR PRESSURE SENSOR (LPS	425
D. SOLAR LOAD SENSOR	426
E. OAT SENSOR	427
F. IN-CAR SENSOR	428
G. AIR INLET ACTUATOR	428
H. BLOWER CONTROL MODULE	429
13. TROUBLESHOOTING	430
14. MAINTENANCE	440
A. PRELIMINARY INSPECTION	440
i. AC SYSTEM PERFORMANCE TEST	440
ii. OPEN DOOR TEST	441
iii. CLOSED DOOR TEST	442
iv. LEAK DETECTION	443
B. REGULAR MAINTENANCE	443
i. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING	443
ii. RECOVERY AND RECYCLING	444
iii. EVACUATION AND RECHARGING	444
iv. FLUSHING OF AC SYSTEM	444
v. REPLENISHING COMPRESSOR OIL	445
15. ON VEHICLE REPAIRS	447
A. CONTROL PANEL ASSEMBLY REMOVAL	447
B. INFOTAINMENT DISPLAY REMOVAL	447
C. COMPRESSOR	448
D. BLOWER	449
E. LPM	449
F. AIR FILTER	450
G. PTC HEATER	452
H. REAR DUCT	452
I. TXV	453
J. HVAC UNIT	453
K. CONDENSER SEALING DUCT	454
L. CONDENSER	454
M. CHILLER UNIT	454
N. SOLENOID VALVE	455
16. REFRIGERANT HOSES/PIPES	456
17. DO’s & DONT’s	457
BODY	458
1. GENERAL LAYOUT	462
2. TIGHTENING TORQUES	463
3. SPECIAL TOOL	466
4. ON VEHICLE PROCEDURES	467
4.1 BONNET	467
4.2. FLOOR CONSOLE	469
4.3. DASHBOARD SKIN	472
4.4. GLOVE BOX	477
4.5. SIDE AIR VENTS	479
4.6. FRONT BUMPER	480
4.7 REAR BUMPER	481
4.8. FRONT DOOR	482
4.9. FRONT DOOR TRIMS	483
4.10. DOOR INNER LOCK HANDLE	484
4.11. FRONT OUTER DOOR LOCK	485
4.12. FRONT DOOR LATCH	486
4.13. FRONT DOOR GLASS AND WINDOWWINDING MECHANISM	487
4.14. REAR DOOR	488
4.15. REAR DOOR TRIM	489
4.16. REAR OUTER DOOR LOCK	490
4.17. DOOR LATCH REAR	491
4.18. TAIL GATE	492
4.19. TAIL GATE LATCH CABLE	495
4.20. TAIL GATE TRIM	495
4.21. ORVM	496
4.22. INNER REAR VIEW MIRROR	497
4.23. FRONT ROW SEAT	497
4.24. REAR ROW SEAT	498
4.25. FRONT SEAT BELT	500
4.26. REAR SEAT BELT	501
4.27. “A” PILLAR TRIM	502
4.28. FRONT SCUFF PLATE	503
4.29. “B” PILLAR TRIMS	504
4.30. “C” PILLAR TRIMS	505
4.31. GRAB HANDLE	505
4.32. SUNVISOR	506
4.33. ROOF LINEAR	506
4.34. PLENUM COVER	507
4.35. BONNET INSULATION	507
4.36. GLASS	508
4.37. FRONT WHEEL ARCH LINER	509
4.38. REAR WHEEL ARCH LINER	510
4.39. FRONT FENDER	511
4.40. REAR WIPER MOTOR	514
4.41. FRONT WIPER	515
4.42 SUNROOF	516
A. SUNROOF DO’S AND DON’TS	516
B. EXPLODED VIEW	517
C. SUNROOF REMOVAL	518
D. SUNROOF FITMENT	519
E. SUNROOF CHILDPARTS SERVICIABLITY	520
1. WIND DEFLECTOR	520
2. GLASS PANEL	520
3. SUNSHADE	521
4. ELECTRIC DRIVE ASSEMBLY	522
5. REAR WATER CHANNEL ASSEMBLY	523
6. CORNER COVER PIECE	523
7. CONNECTING PART	525
8. COLISSA GUIDE ASSEMBLY	525
9. RETAINING HOOK GUIDE AC	526
10. GUIDE RR AC	527
11. GUIDE FR ASSY	528
12. MECHANISM MAINTENANCE	528
13. WATER CHANNEL MAINTENANCE	530
14. GUIDE RAIL MAINTENANCE	530
15. RE-INITIALIZING THE POWER SUNROOF	530

Made with FlippingBook

RkJQdWJsaXNoZXIy MTIwNTUz