Electric vehicles (EVs) are the future of driving, offering eco-friendly performance and cutting-edge technology. However, like any vehicle, they can face issues that require careful troubleshooting. In this article, we’ll dive into common problems faced by the Tata Nexon EV, a popular electric SUV, and how to address them effectively. From alignment issues to system faults, we’ll break down the process in a way that’s easy to understand, even if you’re not a mechanic. Let’s get started!
Tags: Tata Nexon EV, electric vehicle, SUV, troubleshooting, EV maintenance
Common Issues with the Tata Nexon EV
The Tata Nexon EV, despite being a reliable vehicle, can encounter issues like steering misalignment, traction control failures, and electronic system malfunctions. In this case, the vehicle exhibited several problems:
- Hill Assist Failure: The hill assist system, designed to prevent rollback on slopes, wasn’t functioning.
- Traction Control Issues: The traction control system, crucial for maintaining grip, was malfunctioning.
- Steering Misalignment: The steering was pulling to one side, making driving risky.
- Mode Limitations: The vehicle was stuck in Eco mode, with City and Sport modes failing to engage, resulting in reduced pickup.
- System Faults: Multiple warning lights, including ESP (Electronic Stability Program) and Auto Hold malfunctions, were displayed.
These issues were evident in a 2024 model with just 867 km on the odometer, indicating that even new EVs can face challenges.
Step-by-Step Troubleshooting Process
Step 1: Initial Diagnosis
The first step was to identify the root cause of the issues. The vehicle wouldn’t start initially, and multiple warning lights were active. A diagnostic scanner (commonly referred to as a “think tool”) was used to read fault codes, revealing issues with the ESP, traction control, hill descent control, and auto hold systems.
| Issue | Symptoms | Initial Action |
| Hill Assist Failure | No rollback prevention on slopes | Check fault codes with scanner |
| Traction Control Failure | Warning light; loss of grip control | Inspect wiring and connections |
| Steering Misalignment | Vehicle pulls to one side | Perform alignment and camber check |
| Mode Limitation (Eco Only) | City/Sport modes not engaging | Test electrical systems (12V circuit) |
| System Malfunctions | Multiple warning lights (ESP, Auto Hold) | Clear fault codes and retest |
Step 2: Safety First
Working on an EV requires strict safety measures due to high-voltage systems. The orange-colored wires in the engine compartment (or DCDC converter area) carry high voltage and should never be touched without proper insulated tools and gloves. For this repair, the focus was on the 12V low-voltage system, which is safer to work on.
- Safety Tips:
- Always disconnect the fuse from the fuse box before starting repairs.
- Work only in designated safe areas (e.g., fuse box or low-voltage components).
- Avoid contact with high-voltage orange wires.
- Use a diagnostic scanner to confirm system status before and after repairs.
Step 3: Addressing Steering and Alignment Issues
The steering was pulling significantly, making it unsafe to drive without constant correction. A road test confirmed the issue, and an initial steering calibration attempt failed. The diagnosis pointed to misaligned camber and a potential issue with the knuckle or shock absorber.
- Inspection Findings:
- The right-side shock absorber and knuckle showed a significant gap, indicating a bent knuckle.
- Previous repair attempts were evident (e.g., bolt marks and repainted areas), but the alignment wasn’t properly fixed.
- The camber was out of alignment, causing the wheel to tilt abnormally.
- Solution:
- Replaced the bent knuckle with a new one from the left side to test the fix.
- Adjusted the camber using bolts to eliminate the upper gap, ensuring proper alignment.
- Reinstalled the original shock absorber after confirming it wasn’t bent, saving unnecessary replacement costs.
Step 4: Fixing Electrical System Faults
The vehicle’s inability to switch to City or Sport mode was linked to electrical faults. After replacing the knuckle and aligning the wheels, the diagnostic scanner was used again to clear fault codes. A final test confirmed:
- No warning lights for ESP, traction control, or auto hold.
- Successful engagement of Sport mode, delivering the expected high-performance pickup.
- Stable steering, even when briefly released during a road test.
Step 5: Final Road Test
A thorough road test was conducted to ensure all repairs were successful. The vehicle now operated smoothly in Sport mode, with no warning lights or steering issues. The alignment was zeroed out, and the camber was perfectly set, allowing the vehicle to drive straight even on uneven roads with potholes.
Key Takeaways for EV Owners and Mechanics
- Diagnose Thoroughly: Use a diagnostic scanner to pinpoint fault codes before disassembling components.
- Prioritize Safety: Always disconnect fuses and avoid high-voltage areas unless properly equipped.
- Check Alignment: Misalignment can cause multiple system failures, so inspect camber and knuckles carefully.
- Test Incrementally: Swap parts (e.g., knuckle) to isolate issues without unnecessary replacements.
- Trust OEM Parts: Use genuine parts (e.g., Tata-approved knuckles) for reliable repairs.
Why These Issues Happen
Even a new vehicle like the Tata Nexon EV can face issues due to manufacturing defects, improper prior repairs, or road conditions. In this case, the bent knuckle likely caused the alignment and system issues, triggering multiple fault codes. The low mileage (867 km) suggests these problems may have stemmed from an early defect or an unreported minor accident.
Conclusion
Fixing a Tata Nexon EV with multiple system failures is no small feat, but with the right approach, it’s manageable. By addressing the bent knuckle, aligning the wheels, and clearing electrical faults, the vehicle was restored to its full potential, delivering the thrilling Sport mode performance EV owners love. Whether you’re a mechanic or an EV enthusiast, understanding these troubleshooting steps can save time, money, and frustration.
If you found this guide helpful, share it with fellow EV owners or mechanics tackling similar issues. Got questions or your own EV repair story? Drop a comment below—we’d love to hear from you! Stay tuned for more tips on keeping your electric vehicle in top shape.
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