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NEW NEXON EV MY24 SERVICE MANUAL

NEW NEXON EV MY24 SERVICE MANUAL 1
HV ELECTRICALSYSTEM 5
CONTENTS 6
1. GENERAL INFORMATION 9
A. GENERAL TOOLS FOR ELECTRIC VEHICLE 9
B. HAND GLOVES 9
C. PPES FOR HV 10
D. MEASURING TOOLS 13
E. SAFETY INSTRUCTIONS 14
F. DO’S AND DON’TS 15
G. SAFETY WHILE SERVICING 18
H. WASHING INSTRUCTIONS 22
I. ELECTRICAL COMPONENT INFORMATION 23
J. MOTOR COMPARTMENT 25
2. TYPES OF CHARGING 26
A. AC CHARGING (WALL MOUNT UNIT) 27
B. NORMAL CHARGING 29
C. FAST CHARGING 34
3. TIGHTENING TORQUES 36
4. SPECIAL TOOLS 43
5. HV COMPONENTS DETAILS 45
A. E-DRIVE EXPLODED VIEW 45
B. 3IN1 UNIT ASSY 46
C. HV BATTRERY ASSY 47
D. HV SCHEMATICS (KANGER 3.0 ELR) 48
6. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE 49
7. HV CONNECTOR CONNECTION & LOCKING PROCESS 50
A. 3IN1 COMBO BOX TO MCU 50
B. 3IN1 COMBO BOX TO BATTERY 50
C. 3IN1 COMBO BOX TO CCS PORT 51
D. 3IN1 COMBO BOX TO E COMPRESSOR 52
E. COMPRESSOR SIDE CONNECTOR 52
F. 3IN1 COMBO BOX TO AC INPUT 53
G. 3IN1 COMBO BOX TO PTC 53
H. 3IN1 COMBO BOX TO SIGNAL 54
8. ISOLATION MEASUREMENT 55
9. HV COMPONENTS UNDER BONNET COMPARTMENT 58
A. 3IN1 UNIT ASSY REMOVAL 58
B. SERVICIABLE ITEM 3IN1 UNIT 60
C. TOOLS FOR 3IN1 UNIT SERVICIABILTY 62
D. 3IN1 UNIT SERVICIABILTY 63
E. VEHICLE CONTROL UNIT REMOVAL 67
F. E - DRIVE REMOVAL 68
G. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS 71
10. TRACTION COOLING SYSTEM (TCS) 73
A. SYSTEM LAYOUT 73
B. CIRCUIT SCHEMATIC 73
C. TCS COOLANT DRAINING PROCEDURE 74
D. TCS COOLANT FILLING PROCEDURE 74
E. RADIATOR / RADIATOR FAN REMOVAL 75
F. CONDENSOR REMOVAL 76
G. TCS AUX TANK RESERVIOR REMOVAL 78
11. HV BATTERY 79
A. SYSTEM LAYOUT 79
B. HV BATTERY REMOVAL 79
12. BATTERY COOLING SYSTEM (BCS) 82
A. SYSTEM LAYOUT 82
B. CIRCUIT SCHEMATICS 82
C. BCS COOLANT DRAINING PROCEDURE 83
D. BCS COOLANT FILLING PROCEDURE 83
E. BCS AUX TANK RESERVIOR REMOVAL 84
F. COMPRESSOR 84
G. BATTERY COOLING PUMP REMOVAL 86
H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL 86
13. HV / LV CHARGER CABLE 88
A. HV / LV CHARGER PORT & CABLE REMOVAL 88
B. CCS2 INLET ACTUATOR REPLACEMENT PROCEDURE 89
14. CRADLE 92
A. CRADLE EXPLODED VIEW 92
B. CRADLE REMOVAL 93
C. CRADLE FITMENT 94
15. CRADLE MOUNTS 96
16. FRONT FRUNK ASSEMBLY WITH BRACKET REMOVAL & ASSEMBLY REMOVAL 97
BRAKES 98
TABLE OF CONTENTS 99
1. TECHNICAL SPECIFICATIONS 101
2. I-VBAC SPECIFICATIONS 102
3. SYSTEM COMPONENTS 103
4. I/O DIAGRAM OF BRAKE SYSTEM 104
5. TIGHTENING TORQUES 105
6. PRECAUTIONS 109
7. DIAGNOSIS 110
8. NESSECITY OF ABS WITH EBD 114
9. BRAKE HYDRAULIC LINES 115
10. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 116
A. BRAKING WITHOUT ABS IN OPERATION 116
B. BRAKING WITH EBD INTO OPERATION 116
C. BRAKING WITH ABS INTO OPERATION 116
D. FAIL-SAFE FUNCTION 117
11. I - VBAC COMPONENTS 118
A. WORKING OF I - VBAC 118
B. I - VBAC (INTELLIGENT VACUUM LESS BOOST & ACTIVE CONTROL) 119
C. WHEEL SPEED SENSOR 120
D. I - VBAC SYSTEM FAILURE WARNING LIGHT 125
12. I - VBAC HANDLING INSTRUCTIONS 127
13. MAINTENANCE, ADJUSTMENTS & TEST 130
A. FRONT BRAKE MAINTENANCE 130
B. REAR BRAKE MAINTENANCE 131
C. INSPECTION OF CALIPER 133
D. IVBAC BLEEDING PROCEDURE 135
E. STOP LIGHT SWITCH ADJUSTMENT 138
14. BRAKE PEDAL ASSEMBLY REMOVAL 139
15. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 140
16. EXPLODED VIEWS 141
A. I-VBAC UNIT ASSEMBLY 141
B. FRONT CALIPER BRAKE ASSEMBLY 142
C. REAR CALIPER BRAKE ASSEMBLY 143
17. ON VEHICLE REMOVAL 145
A. BRAKE REMOVAL AND REFITMENT 145
B. FRONT BRAKE DISC REMOVAL 152
C. FRONT WHEEL SPEED SENSOR REMOVAL 153
D. I - VBAC UNIT REMOVAL 154
E. REAR BRAKE DISC REMOVAL 158
F. EPB MOTOR REMOVAL 160
G. REAR WHEEL SPEED SENSOR REMOVAL 161
H. YAW RATE SENSOR 162
18. TROUBLE SHOOTING & DIAGNOSIS 165
19. I - VBAC CONNECTOR 167
WHEELS AND TYRES 169
CONTENTS 170
1. GENERAL INFORMATION 171
A. SPECIFICATIONS 171
B. TYRE PRESSURE DETAILS 171
C. CONSTRUCTION 172
2. TIGHTENING TORQUES 175
3. GENERAL SYMPTOMS DIAGNOSIS 176
A. DIAGNOSIS CHART 176
B. TYRE WEAR PATTERN 178
C. WEAR CAUSES 179
D. TYRE VIBRATION DIAGNOSIS 180
4. MAINTENANCE, INSPECTION AND TESTS 181
A. PRELIMINARY INSPECTION 181
B. REGULAR MAINTENANCE 182
I. INFLATION 182
II. WHEEL BALANCING 182
III. TYRE ROTATION 183
IV. WHEEL RUN OUT 184
V. DO'S AND DON’TS 184
5 WHEEL AND TYRE REPLACEMENT 185
A. PRECAUTIONS DURING TYRE REPLACEMENT 185
B. TYRE REPLACEMENT 186
C. WHEEL ASSEMBLY REPLACEMENT 186
D. ALLOY WHEEL PLASTIC INSERT 186
E. WHEEL REMOVAL 187
Tyre Pressure Monitoring System (TPMS) 188
TABLE OF CONTENTS 189
1. GENERAL INFORMATION 190
A. INTRODUCTION 190
B. SYSTEM WORKING 191
C. SYSTEM LAYOUT 191
D. COMPONENTS 192
I. TPMS ECU 192
II. TIRE PRESSURE SENSOR 192
E. ON VEHICLE PROCEDURE 193
I. TPMS ECU REPLACEMENT PROCEDURE 193
II. ECU REPLACEMENT PROCEDURE PREREQUISITE. 193
III. TPMS ECU LEARNING PROCEDURE 194
IV. TPMS SENSOR REPLACEMENT PROCEDURE USING LF TOOL 196
F. TIRE REPLACEMENT 196
G. MOUNTING OF THE TIRE 198
BODY 200
CONTENTS 201
1.PANAROMIC SUNROOF 202
A.SUNROOF DO’S AND DON’TS 202
B.EXPLODED VIEW 209
C.SUNROOF REMOVAL 213
D. SUNROOF FITMENT 215
E.SUNROOF CHILDPARTS SERVICIABLITY 216

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