1 886

NEW NEXON EV SERVICE MANUAL

NEW NEXON EV SERVICE MANUAL 1
TABLE OF CONTENT 4
GENERAL 5
CONTENTS 6
1. TECHNICAL SPECIFICATIONS FOR MR 7
2. TECHNICAL SPECIFICATIONS FOR LR 9
3. VEHICLE DIMENSIONS 10
4. RECOMMENDED LUBRICANTS & COOLANTS 11
5. SERVICE AND MAINTENANCE 12
6. VEHICLE JACKING AND LIFTING POINTS 14
7. JACK AND TOOL BOX LOCATION IN VEHICLE 15
8. TOWING THE VEHICLE 15
9. PUNCTURE REPAIR KIT (IF APPLICABLE) 16
HV ELECTRICALSYSTEM 21
CONTENTS 22
1. GENERAL INFORMATION 25
A. GENERAL TOOLS FOR ELECTRIC VEHICLE 25
B. HAND GLOVES 25
C. PPEs FOR HV 26
D. MEASURING TOOLS 29
E. SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM 30
F. DO’S AND DON’TS 31
G. SAFETY WHILE SERVICING 34
H. WASHING INSTRUCTIONS 38
I. ELECTRICAL COMPONENT INFORMATION 39
J. MOTOR COMPARTMENT 41
2. TYPES OF CHARGING 42
A. AC CHARGING (WALL MOUNT UNIT) 43
B. NORMAL/AC CHARGING 45
C. FAST CHARGING 50
3. TIGHTENING TORQUES 52
4. SPECIAL TOOLS LIST 58
5. HV COMPONENTS DETAILS 60
A. E-DRIVE EXPLODED VIEW 60
B. 3IN1 UNIT ASSY 61
C. HV BATTERY ASSY 62
D. HV SCHEMATICS (KANGER 3.0 LR/MR) 63
6. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE 64
7. HV CONNECTOR CONNECTION & LOCKING PROCESS 66
A. 3IN1 COMBO BOX TO E COMPRESSOR 66
B. PDU TO OBC CONNECTOR 67
C. PDU TO CHARGING CABLE 68
D. PDU TO DC DC CABLE 69
E. PDU TO BATTERY CABLE 70
F. PDU TO E- DRIVE 71
G. PROCEDURE TO FIT BADA CONNECTORS TO 3IN1 COMBO BOX 73
8. ISOLATION MEASUREMENT 76
9. HV COMPONENT IN UNDER BONNET COMPARTMENT 79
A. 3IN1 UNIT ASSY REMOVAL 79
B. SERVICIABLE ITEM 3IN1 UNIT 81
C. TOOLS FOR 3IN1 UNIT SERVICIABILTY 83
D. 3IN1 UNIT SERVICIABILTY 84
E. VEHICLE CONTROL UNIT REMOVAL 88
F. E-DRIVE REMOVAL 89
G. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS 92
10. TRACTION COOLING SYSTEM (TCS) 94
A. SYSTEM LAYOUT 94
B. CIRCUIT SCHEMATIC 94
C. TCS COOLANT DRAINING PROCEDURE 95
D. TCS COOLANT FILLING PROCEDURE 95
E. RADIATOR / RADIATOR FAN REMOVAL 96
F. CONDENSER REMOVAL 97
G. TCS AUX TANK RESERVIOR REMOVAL 99
11. HV BATTERY 100
A. SYSTEM LAYOUT 100
B. HV BATTERY REMOVAL 100
12. BATTERY COOLING SYSTEM (BCS) 103
A. SYSTEM LAYOUT 103
B. CIRCUIT SCHEMATIC 103
C. BCS COOLANT DRAINING PROCEDURE 104
D. BCS COOLANT FILLING PROCEDURE 104
E. BCS AUX TANK RESERVIOR REMOVAL 105
F. COMPRESSOR 105
G. BATTERY COOLING PUMP REMOVAL 107
H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL 107
13. HV / LV CHARGER CABLE 109
A. HV / LV CHARGER PORT & CABLE REMOVAL 109
B. CCS2 INLET ACTUATOR REPLACEMENT PROCEDURE 110
14. CRADLE 113
A. CRADLE EXPLODED VIEW 113
B. CRADLE REMOVAL 114
C. CRADLE FITMENT 115
15. CRADLE MOUNTS 119
Low Voltage Electrical System (LV) 121
TABLE OF CONTENTS 122
1. GENERAL PRECAUTIONS 127
2. BATTERY 131
3. LIGHTING SYSTEM 133
A. BULB SPECIFICATIONS 133
B. FASTENERS TORQUE VALUE TABLE 134
C. GENERAL SYMPTOMS AND DIAGNOSTICS 135
D. HEAD LAMP 138
E. DRL LAMP 143
F. POSTION LAMP 144
G. POSTION LAMP 145
H. TAIL LAMP 145
I. ROOF LAMP 148
J. GLOVE BOX LAMP 149
K. FRONT FOG LAMP 150
L. REGISTRATION PLATE LAMP 151
M. LOAD AREA LAMP 151
4. HORN 152
5. WIPER & WASHER SYSTEM 154
A. FRONT WIPER AND WAHSER SYSTEM LAYOUT 154
B. REAR WIPER AND WAHSER SYSTEM LAYOUT (IF APPLICABLE) 155
C. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 156
D. WIPER AND WIPER CARE 157
6. POWER SOCKETS 159
7. SWITCHES 161
A. COMBI SWITCH 161
B. FASCIA SWITCHES (IF APPLICABLE) 167
C. DRVIE MODE SWITCH 169
D. ELECTRONIC PARK BRAKE (EPB) SWITCH (IF EQUIPPED) 172
E. AUTOMATIC VEHICLE HOLD (IF EQUIPPED) 174
F. REGERATION SWITCH 176
G. MIRROR SWITCH 179
H. POWER WINDOW SWITCHES & INHIBIT SWITCH 182
I. STEERING WHEEL SWITCH 186
J. DOOR HANDLE SWITCH 189
K. TAILGATE HANDLE SWITCH 190
L. ENGINE START STOP OFF SWITCH 191
M. WINDOW WINDING MODULE 193
N. I-CALL & B-CALL SWITCH 195
O. SUNROOF SWITCH 196
P. PAB SWITCH 198
Q. MONOSTABLE SHIFTER ASSEMBLY FOR AMT AND DCT TRANSMMISION 200
I. FUNCTIONALITY OF MONOSTABLE SHIFTER 200
II. EXPLODED VIEW MONOSTABLE SHIFTER 202
III. MONOSTABLE SHIFTER SHIFT MAPPING 202
IV. GSM WARNING MESSAGES 203
V. DO’S & DON’TS FOR MSS 203
VI. CONNECTOR DETAILS 204
VII. REMOVAL OF MONOSTABLE SHIFTER 205
R. V2X SWITCH 206
8. INFOTAINMENT SYSTEM 213
A. INFOTAINMENT DISPLAY 213
B. SPEAKERS 215
C. ANTENNA (AM+FM+GPS) (IF APPLICABLE) 216
D. MICROPHONE 217
E. TWEETERS 218
F. SILVER BOX (IF APPLICABLE) 220
9. INSTRUMENT CLUSTER 224
A. INSTRUMENT CLUSTER FEATURE MAPPING 225
B. TELL TALES INFORMATION 226
C. REMINDER FEATURES (AUDIO ALERTS) 231
D. TEXT MESSAGE 233
E. FAULT LEVEL INDICATIONS ON INSTRUMENT CLUSTER 234
F. CHIMES 236
G. WARNING ON TFT SCREEN 236
H. CONNECTOR DETAILS 241
I. REMOVAL OF INSTRUMENT CLUSTER 243
10. INSTRUMENT CLUSTER 244
A. INSTRUMENT CLUSTER FEATURE MAPPING 244
B. TELL TALES INFORMATION 246
C. REMINDER FEATURES (AUDIO ALERTS) 251
D. TEXT MESSAGE 253
E. FAULT LEVEL INDICATIONS ON INSTRUMENT CLUSTER 254
F. CHIMES 256
G. WARNING ON TFT SCREEN 256
H. CONNECTOR DETAILS 261
I. REMOVAL OF INSTRUMENT CLUSTER 263
11. BODY CONTROL MODULE (BCM) 264
A. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX 270
B. BCM FUNCTIONS 278
12. PASSIVE ENTRY PASSIVE START (PEPS) 279
A. PEPS ECU 279
B. START STOP SWITCH 281
C. ELECTRONIC STEERING COLUMN LOCK (ESCL) 282
D. DOOR HANDLE SWITCHES WITH HARNESS 284
E. LF ANTENNAS 284
13. FRONT AND REAR REVERSE PARK ASSIST SYSTEM (IF APPLICABLE) 287
A. FRONT AND REVERSE PARK ASSIST SYSTEM DETAILS 287
B. ECU TO SENSOR ELECTRICAL INTERFACE 291
C. REVERSE PARK ASSIST WITH CAMERA (IF EQUIPPED) 298
D. REAR VIEW CAMERA (VGA) (IF EQUIPPED) 299
E. REAR VIEW CAMERA (HD) (IF EQUIPPED) 303
F. TROUBLESHOOTING 307
14. FUSE AND RELAY BOX DETAILS 309
A. FUSE AND RELAY BOX LAYOUT 311
B. UNDER BONNET FUSE AND RELAY BOX 311
C. CABIN FUSE AND RELAY BOX 315
D. FUSE AND RELAY REPLACEMENT 317
15. RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE) 318
A. RAIN LIGHT SENSOR 318
B. FUNCTIONAL DETAILS 322
C. FAIL SAFE MODES OF RLS & BCM 324
16. ELECTRIC CHROMIC MIRROR (EC-IRVM) 325
17. TELEMATICS 327
A. TATA MOTORS CONNECTED CAR SYSTEM 327
B. THE CONNECTED CAR MODULE RECORDS THE FOLLOWING INFORMATION 327
C. TCM LOCATION 327
D. PRE-CHECKS FOR INSTALLATION OF THE TELEMATICS CONTROL MODULE 327
E. PRE-CHECKS / TASKS TO BE DONE BEFORE REPLACING THE TELEMATICS CONTROL MODULE 327
F. I/P - O/P BLOCK DIAGRAMS 328
G. LED INDICATION ON TCM 329
H. CONNECTOR PIN & USB DETAILS 330
I. TCM REMOVAL PROCEDURE 331
18. WIRELESS CHARGING (IF APPLICABLE) 332
A. WIRELESS CHARGING COMPONENTS 332
B. INTERFACE DIAGRAM 333
C. CHARGING FUNCTION 333
D. CHARGING STATUS DISPLAY FUNCTION 333
E. CONDITIONS TO CHARGE PHONE PROPERLY 333
F. CONNECTOR PIN & DETAILS 334
G. WPC EPC TROUBLE SHOOTING PROCEDURE 334
H. DO’S AND DON’T 337
I. WPC ECU REPLACEMENT PROCEDURE 338
19. SURROUND VIEW SYSTEM (SVS) (IF EQUIPPED) 343
A. SURROUND VIEW SYSTEM DETAILS 343
I. SVS FUNCTION WORKING PROCEDURE 343
II. CAMERA LOCATION 343
III. ACTIVATION OF SVS 344
IV. DEACTIVATION OF SVS 344
V. SURROUND VIEW SYSTEM FEATURES 345
VI. 2D VIEW 345
VII. 3D VIEW 347
VIII. FRONT CORNER VIEW 347
IX. REAR CORNER VIEW 348
X. FULL VIEW 348
XI. SETTINGS 350
XII. CANCEL ICON 352
XIII. UNDERSTANDING GUIDELINES INDICATION 353
XIV. PDC GUIDELINES SETTINGS 355
XV. BLIND VIEW MONITOR 356
XVI. ACTIVATION OF BLIND VIEW MONITOR 357
XVII. DEACTIVATION OF BLIND VIEW MONITOR 358
XVIII. UNDERSTANDING STATIC OVERLAYS INDICATION 358
XIX. DO’S AND DON’TS 358
XX. CLEANING CAMERA 358
XXI. WARNING 359
B. SVS INPUT OUTPUT BLOCK DIAGRAM 360
C. SURROUND VIEW SYSTEM COMPONENTS REMOVAL 361
I. FRONT BUMPER CAMERA 361
II. TAILGATE CAMERA 362
III. ORVM LH/RH CAMERA 363
IV. ORVM CAMERA SERVICE SOP AND CARE 364
D. TROUBLESHOOTING CHART 366
E. TROUBLESHOOTING CHART 368
F. CAMERAS CALIBRATION 369
G. DO’S AND DON’TS WHILE PERFORMING CALIBRATION 370
20. INDIRECT TIRE PRESSURE MONITORING SYSTEM (ITPMS) 371
21. ECU LOCATION LAYOUT 373
22. WIRING HARNESS LAYOUT 374
23. WH LOCATION 375
24. GROUND TOPOLOGY LAYOUT 376
25. NETWORK TOPOLOGY LAYOUT 377
26. LOCATION OF INLINE CONNECTOR 378
DRIVESHAFT 379
TABLE OF CONTENTS 380
1. INTRODUCTION 381
2. DRIVE SHAFT PARTS 382
3. GENERAL GUIDELINES FOR TESTING 383
4. TESTING FOR NOISE 384
5. TIGHTENING TORQUES 386
6. SPECIAL TOOLS 387
7. EXPLODED VIEW 388
8. ON VEHICLE REMOVAL OF DRIVE SHAFT (LH & RH SIDE) 389
9. ON VEHICLE ASSEMBLY OF DRIVE SHAFT (LH & RH SIDE) 390
10. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT 391
11. ASSEMBLY PROCEDURE FOR DRIVESHAFT 393
12. PRECAUTION TO AVOID THE DAMAGE TO DRIVE SHAFT 394
13. DO’S AND DON’T’S FOR DRIVE SHAFT 396
SUSPENSION_MR 397
CONTENTS 398
1. GENERAL INFORMATION 400
2. TECHNICAL SPECIFICATIONS 404
3. TIGHTENING TORQUES 405
4. SPECIAL TOOLS 410
A. FRONT SUSPENSION 410
B. REAR SUSPENSION 414
5. DIAGNOSIS 415
6. PRECAUTIONS 416
7. EXPLODED VIEWS FRONT SUSPENSION 417
A) ASSEMBLY FRONT STRUT 417
B) ANTI ROLL BAR MOUNTING 418
C) LOWER LINK 419
D) FRONT AXLE ASSEMBLY 420
8. EXPLODED VIEWS REAR SUSPENSION 421
A) REAR SHOCK ABSORBER AND SPRING 421
B) REAR HUB ASSEMBLY 422
C) PIVOT MOUNTING BRACKET AND BUSH 423
9. ON VEHICLE PROCEDURE 424
A. FRONT STRUT ASSEMBLY 424
B. FRONT STRUT ON BENCH 425
C. WHEEL HUB REMOVAL 428
D. SUBFRAME ASSEMBLY 430
i. REMOVAL OF SUBFRAME ASSEMBLY 430
ii. REMOVAL OF ANTI ROLL BAR 432
iii. REMOVAL OF LOWER ARM BALL JOINT 433
iv. REMOVAL OF LOWER ARM RUBBER BUSHES 434
v. INSTALLATION OF SUBFRAME ASSEMBLY 435
E. REAR SHOCK ABSORBER AND COIL SPRINGS 436
I. REMOVAL OF REAR SHOCK ABSORBER AND COIL SPRINGS 436
II. INSTALLATION OF REAR SHOCK ABSORBER AND COIL SPRINGS 438
F. TORSION BEAM 440
10. SUSPENSION PRE-LOADING CONDITION 444
SUSPENSION_LR 445
CONTENTS 446
1. GENERAL INFORMATION 448
2. TECHNICAL SPECIFICATIONS 452
3. TIGHTENING TORQUES 453
4. SPECIAL TOOLS 458
A. FRONT SUSPENSION 458
B. REAR SUSPENSION 460
5. DIAGNOSIS 461
6. PRECAUTIONS 462
7. EXPLODED VIEWS FRONT SUSPENSION 463
A. ASSEMBLY FRONT STRUT 463
B. ANTI ROLL BAR MOUNTING 464
C. LOWER LINK 465
D. FRONT AXLE ASSEMBLY 466
8. EXPLODED VIEWS REAR SUSPENSION 467
A. REAR SHOCK ABSORBER AND SPRING 467
B. REAR HUB ASSEMBLY 468
C. PIVOT MOUNTING BRACKET AND BUSH 469
9. ON VEHICLE PROCEDURE 470
A. FRONT STRUT ASSEMBLY 470
B. FRONT STRUT ON BENCH 471
C. FRONT WHEEL HUB WITH GEN 3 BEARING ASSY REMOVAL 472
D. SUBFRAME ASSEMBLY 475
i. REMOVAL OF SUBFRAME ASSEMBLY 475
ii. REMOVAL OF ANTI ROLL BAR 476
iii. REMOVAL OF LOWER ARM BALL JOINT 477
iv. REMOVAL OF LOWER ARM RUBBER BUSHES 478
v. INSTALLATION OF SUBFRAME ASSEMBLY 479
E. REAR SHOCK ABSORBER AND COIL SPRINGS 480
I. REMOVAL OF REAR SHOCK ABSORBER AND COIL SPRINGS 480
II. INSTALLATION OF REAR SHOCK ABSORBER AND COIL SPRINGS 482
F. REMOVAL OF REAR GEN 3 BEARING 484
G. TORSION BEAM 486
10. SUSPENSION PRE-LOADING CONDITION 489
WHEELS AND TYRES 490
CONTENTS 491
1. GENERAL INFORMATION 492
A. SPECIFICATIONS 492
B. TYRE PRESURE DETAILS 492
C. CONSTRUCTION 493
2. TIGHTENING TORQUES 496
3. GENERAL SYMPTOMS DIAGNOSIS 497
A. DIAGNOSIS CHART 497
B. TYRE WEAR PATTERN 499
C. WEAR CAUSES 500
D. TYRE VIBRATION DIAGNOSIS 501
4. MAINTENANCE, INSPECTION AND TESTS 502
A. PRELIMINARY INSPECTION 502
B. REGULAR MAINTENANCE 503
I. INFLATION 503
II. WHEEL BALANCING 503
III. TYRE ROTATION 504
IV. WHEEL RUN OUT 505
V. DO'S AND DON’TS 505
5. WHEEL AND TYRE REPLACEMENT 506
A. PRECAUTIONS DURING TYREREPLACEMENT 506
B. TYRE REPLACEMENT 507
C. DEFECTIVE WHEEL ASSEMBLY REPLACEMENT 507
D. ALLOY WHEEL PLASTIC INSERT 507
E. WHEEL REMOVAL 508
STEERING_MANDO 509
TABLE OF CONTENTS 510
1. GENERAL INFORMATION 511
A. SPECIFICATIONS 511
B. SYSTEM LAYOUT 511
C. GENERAL DESCRIPTION 512
D. EPAS SYSTEM FLOW DIAGRAM 512
E. EPAS SYSTEM BLOCK DIAGRAM 512
F. TIGHTENING TORQUES 513
G. SPECIAL TOOLS 515
2. MAINTENANCE, INSPECTION AND TEST 516
A. PRELIMINARY INSPECTION 516
B. REGULAR MAINTENANCE 517
C. ON VEHICLE REPAIRS 519
I. STEERING WHEEL REMOVAL 519
II. STEERING COLUMN REMOVAL 520
III. INTERMEADIATE SHAFT REMOVAL 524
IV. ECU REMOVAL 525
V. MOTOR REMOVAL 526
VI. RACK & PINION ASSEMBLY REMOVAL 526
3. OVERHAULING 529
A. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 529
B. PRECAUTIONS 530
C. DISMANTLING, INSPECTION & ASSEMBLY 530
I. DISASSEMBLY OF RACK & PINON 530
II. INSPECTION OF DISMANTLED PARTS 531
III. ASSEMBLY OF RACK & PINON 531
IV. OBJ ON-VEHICLE REMOVAL 533
V. DO’S & DON’TS 533
VI. WHEEL ALIGNMENT 535
4. TROUBLESHOOTING AND DIAGNOSIS 538
5. STEERING ANGLE CALIBRATION 543
6. TUNING DATA SELECTION 551
7. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD 552
ELECTRONIC STABILITY CONTROL INTEGRATED PROGRAM (ESCi) 556
TABLE OF CONTENTS 557
1. GENERAL INFORMATION 558
A. NECESSITY OF ESCi AND TCS 558
B. SPECIFICATIONS 559
C. TIGHTENING TORQUES 560
D. SYSTEM LAYOUT 561
2. WORKING OF ESCi 562
3. COMPONENTS 564
4. ON VEHICLE REPAIRS 570
5. TROUBLESHOOTING 572
BRAKES 573
CONTENTS 574
1. PRECAUTIONS 575
2. TECHNICAL SPECIFICATIONS 576
3. TIGHTENING TORQUES 578
4. DIAGNOSIS 581
5. NESSECITY OF ABS with EBD 584
6. BRAKE HYDRAULIC LINES 585
7. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 586
8. I - VBAC COMPONENTS 590
9. MAINTENANCE, ADJUSTMENTS & TEST 594
10. BRAKE PEDAL ASSEMBLY 603
11. REGENERATION SENSOR REMOVAL 604
12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 605
13. REPAIRS 606
13.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT 608
13.2. REMOVAL OF FRONT BRAKE DISC 613
13.3. FRONT WHEEL SPEED SENSOR REMOVAL 614
13.4. I - VBAC UNIT REMOVAL 615
13.5. TMC REMOVAL 618
13.6 REAR BRAKE ASSEMBLY 620
13.7. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY 621
13.8 REMOVAL & REFITMENT OF WHEEL CYLINDER 625
13.9 PARKING BRAKE ASSEMBLY 627
13.10. REMOVAL AND REFITMENT OF ABS ECU / HCU 631
13.11. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR 632
14. YAW RATE SENSOR 633
15. TROUBLE SHOOTING & DIAGNOSIS 634
16. I - VBAC CONNECTOR (K2) 636
BRAKES_LR 638
TABLE OF CONTENTS 639
1. TECHNICAL SPECIFICATIONS 641
2. I-VBAC SPECIFICATIONS 642
3. SYSTEM COMPONENTS 643
4. I/O DIAGRAM OF BRAKE SYSTEM 644
5. TIGHTENING TORQUES 645
6. PRECAUTIONS 648
7. DIAGNOSIS 649
8. NESSECITY OF ABS WITH EBD 652
9. BRAKE HYDRAULIC LINES 653
10. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 654
A. BRAKING WITHOUT ABS IN OPERATION 654
B. BRAKING WITH EBD INTO OPERATION 654
C. BRAKING WITH ABS INTO OPERATION 654
D. FAIL-SAFE FUNCTION 655
11. I - VBAC COMPONENTS 656
A. WORKING OF I - VBAC 656
B. I - VBAC (INTELLIGENT VACUUM LESS BOOST & ACTIVE CONTROL) 657
C. WHEEL SPEED SENSOR 658
D. I - VBAC SYSTEM FAILURE WARNING LIGHT 659
12. MAINTENANCE, ADJUSTMENTS & TEST 660
A. FRONT BRAKE MAINTENANCE 660
B. REAR BRAKE MAINTENANCE 660
C. INSPECTION OF CALIPER 663
D. BLEEDING PROCEDURE 665
E. STOP LIGHT SWITCH ADJUSTMENT 668
13. BRAKE PEDAL ASSEMBLY REMOVAL 669
14. REGENERATION SENSOR REMOVAL 670
15. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 671
16. EXPLODED VIEWS 672
A. TMC ASSEMBLY 672
B. FRONT CALIPER BRAKE ASSEMBLY 673
C. REAR CALIPER BRAKE ASSEMBLY 674
17. ON VEHICLE REMOVAL 676
A. BRAKE REMOVAL AND REFITMENT 676
B. FRONT BRAKE DISC REMOVAL 681
C. FRONT WHEEL SPEED SENSOR REMOVAL 682
D. I - VBAC UNIT REMOVAL 683
E. TMC REMOVAL 687
F. REAR BRAKE DISC REMOVAL 688
G. EPB MOTOR REMOVAL 689
H. REAR WHEEL SPEED SENSOR REMOVAL 690
I. YAW RATE SENSOR 691
18. TROUBLE SHOOTING & DIAGNOSIS 693
19. I - VBAC CONNECTOR 695
FATC 697
CONTENTS 698
1. TECHNICAL SPECIFICATIONS 701
2. TIGHTENING TORQUES 703
3. PRECAUTIONS 707
4. FATC SYSTEM LAYOUT AND BATTERY COOLING SYSTEM WORKING 708
5. FATC CONTROL PANEL DETAILS 710
A. AC COMPRESSOR ON / OFF BUTTON 711
B. BLOWER SPEED CONTROL TOGGLESWITCH 711
C. ECON Button 711
D. MAX DEFROST 711
E. “OFF” BUTTON” 711
F. REAR WINDOW DEMISTER 711
G. FRESH AIR / RECIRCULATION 712
H. AIR DISTRIBUTION (MODE) 712
I. AUTO ON SELECTION 712
J. TEMPERATURE CONTROL KNOB 712
K. REMOTE AC MODE 713
L. CLIMATE SETTINGS CHANGE POPUP 713
M. XPRESS COOLING 713
6. CONTROL PANEL CONNECTOR DETAILS 714
7. FATC UNIT 715
A. BLOWER 715
B. LINEAR POWER MODULE (LPM) 716
C. EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE) 716
D. HEATER COIL 716
8. COMPRESSOR 717
9. CONDENSER AND RECEIVER DRIER 718
10. CHILLER UNIT 718
11. COOLANT PUMP 718
12. FATC SENSORS AND ACTUATORS 719
A. EVAPORATER SENSOR 719
B. ON VEHICLE INSPECTION (WITHOUT DIS-MANTLING HVAC UNIT) 719
C. LINEAR PRESSURE SENSOR (LPS) 720
D. OAT SENSOR 721
E. IN-CAR SENSOR 722
F. AIR INLET ACTUATOR 722
G. BLOWER CONTROL MODULE 722
13. TROUBLESHOOTING 724
14. MAINTENANCE 734
A. PRELIMINARY INSPECTION 734
i. AC SYSTEM PERFORMANCE TEST 734
ii. OPEN DOOR TEST 735
iii. CLOSED DOOR TEST 736
iv. LEAK DETECTION 737
B. REGULAR MAINTENANCE 737
i. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 737
ii. RECOVERY AND RECYCLING 738
iii. EVACUATION AND RECHARGING 738
iv. FLUSHING OF AC SYSTEM 738
v. REPLENISHING COMPRESSOR OIL 739
vi. PRESSURE TEST USING MANIFOLD GAUG-ES 740
15. ON VEHICLE REMOVAL PROCEDURE 742
A. CONTROL PANEL ASSEMBLY REMOVAL 742
B. INFOTAINMENT DISPLAY REMOVAL 742
C. COMPRESSOR REMOVAL 743
D. BLOWER REMOVAL 744
E. LPM REMOVAL 744
F. AIR FILTER 745
G. PTC HEATER REMOVAL 748
H. REAR DUCT REMOVAL 748
I. TXV 749
J. HVAC UNIT REMOVAL 749
K. CONDENSER SEALING DUCT REMOVAL 750
L. CONDENSER 750
M. CHILLER UNIT REMOVAL 751
N. SOLENOID VALVE REMOVAL 752
O. AIR PURIFIER (IF APPLICABLE) 753
16. REFRIGERANT HOSES/PIPES 755
17. PREACUTIONS 756
18. DO’s & DONT’s 757
19. PRECAUTION FOR E-COMPRESSOR LUBRICATING OIL 759
BODY 760
TABLE OF CONTENTS 761
1. GENERAL LAYOUT 763
2. TIGHTENING TORQUE 764
3. SPECIAL TOOL 767
4. ON VEHICLE PROCEDURES 768
A. BONNET REMOVAL 768
B. FLOOR CONSOLE REMOVAL 770
C. ARM REST REMOVAL 774
D. WIRELESS CHARGER MAT CLEANING 775
E. DASHBOARD SKIN REMOVAL 775
F. GLOVE BOX REMOVAL 780
G. SIDE AIR VENTS & CENTER AIR VENT REMOVAL 781
H. FRONT BUMPER REMOVAL 783
I. REAR BUMPER REMOVAL 784
J. FRONT DOOR REMOVAL 785
K. RONT DOOR TRIMS 786
L. DOOR INNER LOCK HANDLE REMOVAL 787
M. FRONT OUTER DOOR LOCK REMOVAL 788
N. FRONT DOOR LATCH REMOVAL 789
O. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM REMOVAL 790
P. REAR DOOR REMOVAL 791
Q. REAR DOOR TRIM REMOVAL 792
R. REAR OUTER DOOR LOCK REMOVAL 793
S. DOOR LATCH REAR REMOVAL 794
T. TAIL GATE REMOVAL 795
U. TAIL GATE LATCH CABLE 797
V. TAIL GATE TRIM REMOVAL 799
W. ORVM REMOVAL 799
X. INNER REAR VIEW MIRROR REMOVAL 800
Y. FRONT ROW SEAT REMOVAL 801
Z. VENTILATED SEAT (IF APPLICABLE) 802
AA. FRONT SEAT BELT 811
AB. FRONT SEAT BELT BUCKLE REMOVAL 813
AC. REAR ROW SEAT REMOVAL 813
AD. REAR SEAT BELT REMOVAL 815
AE. REAR SEAT BELT BUCKLE REMOVAL 816
AF. “A” PILLAR TRIM 816
AG. FRONT SCUFF PLATE REMOVAL 817
AH. “B” PILLAR TRIMS REMOVAL 818
AI. “C” PILLAR TRIMS REMOVAL 819
AJ. GRAB HANDLE 820
AK. SUNVISOR REMOVAL 820
AL. ROOF LINER REMOVAL 821
AM. PLENUM COVER REMOVAL 821
AN. BONNET INSULATION REMOVAL 822
AO. GLASS 822
AP. FRONT WHEEL ARCH LINER REMOVAL 824
AQ. REAR WHEEL ARCH LINER REMOVAL 824
AR. FRONT FENDER REMOVAL 825
AS. REAR WIPER MOTOR REMOVAL 827
AT. FRONT WIPER REMOVAL 828
AU. SUNROOF 829
I. SUNROOF DO’S AND DON’TS 829
II. EXPLODED VIEW 830
III. SUNROOF REMOVAL 832
IV. SUNROOF FITMENT 834
V. SUNROOF CHILDPARTS SERVICIABLITY 834
SRS 847
TABLE OF CONTENTS 848
1. WORKING OF RESTRAINTS 849
2. SYSTEM LAYOUT 851
3. SAFETY PRECAUTIONS 853
4. DISPOSAL OF FAULTY AIR BAG UNIT 856
5. SRS POST ACCIDENT PROCEDURE 858
6. TIGHTENING TORQUES 859
7. COMPONENTS 863
A. RESTRAINT WITHOUT AIRBAGS 863
B. RESTRAINT WITH AIRBAGS 863
I. ECU 863
II. SENSORS 867
III. AIR BAGS 869
IV. RPLL BELTS 874
V. CLOCK SPRING 878
VI. PAB DEACTIVATION SWITCH 881
VII. PAB INDICATOR 883

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