Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2021 BMW i3 Range ExtenderFACTORY OEM SERVICE PROCEDURE
General Electrical System -- Repair (I01)
- 61 00 General Information
- Safety instructions on handling hybrid or electric vehicles
- Safety instructions for handling vehicle battery
- Diagnosis for Condition Based Service
- Encode/program control unit(s)
- Notes for disconnecting and connecting the vehicle battery
- Notes on electrical properties of Carbon Fiber Reinforced Plastic body
- Notes on handling optical fibers
- Notes on handling the high pressure cleaner
- Notes on handling wiring harnesses and cables
- Repairing airbag cables
- 61 00 730 Programming/encoding the control unit(s) including deletion of fault memory (after vehicle test)
- 61 12 Positive Battery Cable, Vehicle Charging Port
- Notes on intelligent battery sensor (IBS)
- Replacing positive battery cable with safety battery terminal
- 61 12 001 Replacing positive battery cable (from battery to front power distribution box)
- 61 12 013 Replacing negative battery lead
- 61 12 451 Replacing the high-voltage cable between electrical machine electronics and high-voltage battery unit
- 61 12 460 Removing and installing/replacing charging power socket
- 61 12 970 Reworking the charging power socket
- 61 13 Electrical Connectors
- Butt connector for repairing a plug connection
- Circular connector, 13-pin, system D2.5
- Circular connector, 7-pin, 8-pin, system D2.5
- Circular plugs, 4-, 7-, 10- 12-, 25-pin, System D1.5/D2.5
- Circular connector, 20-pin, system D2.5
- Connector housing, LCC contact (load current contact)
- Control unit plugs, 25-, 35-, 55-, 83-, 88-pin
- Crimping annular contacts
- Crimping Micro Quadlock System contacts (MQS)
- Crimping optical fibers
- Crimping Micro Power Quadlock contacts (MPQ)
- Cutting, strip off insulation and crimping optical fibers
- Cutting to length and strip off insulation from cables
- Cutting to length and stripping insulation from cables
- Handling cables and optical fibers
- In-line connectors, 24-/44-pin, Hybrid System MQS/MPQ
- Inline connectors, 15-pin, System D2.5
- In-line connectors, 30-pin, System D2.5
- Inline connectors, 6-, 8-pin, System MQS
- In-line connectors, 30-pin, Hybrid System MQS/MPQ
- In-line plugs, 2-pin, System JPT ELA
- Inline plugs, 4-, 10-pin, System Elo
- In-line plugs, 20-pin, System D2.5
- Inline plugs, 2-pin, System MPQ 2.8
- Inline plugs, 3-, 6-pin, System Elo-Power 2.8
- In-line plugs, 2-pin, System MDK 3 plus 2.8
- Inline plugs, 8-, 12-pin, System D2.5
- In-line plugs, 6- to 50-pin, System Elo
- In-line plugs, 4-pin, System DFK ELA
- Installing comb connector for retrofitting/repairs
- Notes for opening contacts and locks of different plug contact systems
- Opening plug housings and removing contacts of different plug systems
- Socket housing 42-, 43-, 46-pin, Hybrid System MQS/MPQ
- Socket housings, 2x21-, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo Power
- Socket housing (radio connector), Hybrid System MQS/MPQ
- Socket housings, 5-pin, 8-pin, System MQS/MPQ
- Special tools for wiring harness repairs
- Unlocking and disconnecting different plug connections
- Unlocking and disconnecting various plug connections in electrical and hybrid vehicles
- 61 13 910 Connect a cable to the butt connector
- 61 14 Power Distribution Box
- 61 20 Battery, General Information
- 61 21 Vehicle Battery (12V)
- 61 25 High-Voltage Battery System
- Notes on repair of high-voltage battery unit
- 61 25 010 Removing and installing high-voltage battery unit
- 61 25 200 Remove and install convenience charging electronics
- 61 25 200 Removing and installing/replacing convenience charging electronics
- 61 25 701 Replacing the KLE (after vehicle diagnosis)
- 61 25 900 Disconnect high-voltage system from power
- 61 25 200 Remove and install convenience charging electronics (i3s)
- 61 25 701 Replacing the KLE (after vehicle diagnosis) (i3s)
- 61 27 High-Voltage Battery Unit, Individual Components
- 61 27 500 Replacing the lid for the high-voltage battery unit (high-voltage battery unit removed)
- 61 27 501 Remove and install cover for high-voltage battery unit (high-voltage battery unit removed)
- 61 27 521 Replacing venting unit (high-voltage battery unit removed)
- 61 27 531 Replacing high-voltage connection (high-voltage battery unit removed)
- 61 27 541 Replacing CSC (After vehicle diagnosis) (high voltage battery unit removed)
- 61 27 551 Replace safety box (After vehicle diagnosis) (high voltage battery unit removed)
- 61 27 561 Replacing CSC wiring harness (high-voltage battery unit removed)
- 61 27 565 Remove and install the communication wiring harness (high-voltage battery unit removed)
- 61 27 571 Replacing battery management electronics (SME) (High voltage battery unit removed) (following vehicle diagnosis)
- 61 27 581 Replace the housing pan for the high-voltage battery unit (high-voltage battery unit removed)
- 61 27 591 Replacing high voltage connecting wire (high-voltage battery unit removed)
- 61 27 596 Replacing the radiator for high-voltage battery unit (high-voltage battery unit removed)
- 61 27 601 Replacing temperature sensor (high-voltage battery unit removed) (after vehicle diagnosis)
- 61 27 611 Replacing high voltage cell module connector (high-voltage battery unit removed) (after vehicle diagnosis)
- 61 27 621 Replacing a cell module (high-voltage battery unit removed) (after vehicle diagnosis)
- 61 27 650 Set up high-voltage battery unit for replacement (after vehicle diagnosis)
- Install venting unit
- Install high-voltage connection
- Installing the high-voltage battery unit radiator
- Installing cell monitoring electronics
- Install all cell modules
- Installing the holder with the cell module connector
- Install high-voltage connecting line
- Installing communication wiring harness
- Connecting the connector for the communication wiring harness
- Installing the wiring harness of the cell monitoring electronics
- Installing the safety box
- Install battery management electronics (SME)
- Install temperature sensor
- Installing the lid of the high-voltage battery unit
- 61 27 910 Repair of temperature sensor (negative temperature coefficient) on a cell module (cell module removed)
- 61 31 Switches, Sensors
- 61 31 008 Removing and installing (replacing) steering column switch cluster
- 61 31 021 Removing and installing/replacing emergency starting coil
- 61 31 037 Removing and installing/replacing light operating facility
- 61 31 041 Removing and installing/replacing operating element for assist system
- 61 31 043 Remove and install roof switch center
- 61 31 043 Removing and installing the FZD
- 61 31 075 Removing and installing (replacing) fuel filler door release switch
- 61 31 080 Removing and installing/replacing switch for hazard warning flashers
- 61 31 082 Removing and installing/replacing switch for (left or right) central locking system
- 61 31 083 Removing and installing (replacing) tailgate release switch
- 61 31 117 Removing and installing/replacing power window switch (driver's side)
- 61 31 118 Replacing the power electric windows on the passenger's side
- 61 31 133 Removing and installing/replacing A/V connecting socket
- 61 31 134 Removing and installing/replacing USB audio interface connecting socket
- 61 31 172 Removing and installing/replacing switch for electromechanical parking brake
- 61 31 195 Removing and installing (replacing) front controller
- 61 31 197 Remove and install/replace center console operating facility
- 61 31 221 Removing and installing/replacing both multifunction steering wheel switches
- 61 31 241 Remove and install/replace hood/hood contact switch
- 61 31 321 Removing and installing radio and A/C control panel
- 61 31 342 Removing and installing/replacing gear selector switch
- 61 31 362 Removing and installing (replacing) receiver for radio remote control
- 61 31 401 Removing and installing (replacing) engine compartment unlocking switch
- 61 31 492 Replace level switch for windshield washer system
- 61 31 492 Replace washer fluid level switch for washer system
- 61 31 499 Remove and install/replace the microswitch on the trunk lid (open)
- 61 31 544 Replacing roof switch cluster
- 61 33 Horn
- 61 34 Cigarette Lighter, Power Sockets
- 61 35 Control Units, Modules
- Notes on ESD protection (Electro Static Discharge)
- Overview, rain sensor (additional work when replacing the windshield/sensor replacement)
- Removing and installing/replacing the Car Sharing Module
- Removing and installing/replacing the external reader (Car Sharing Module)
- Removing and installing (replacing) charging interface module control unit
- 61 35 095 Removing and installing/replacing control unit/module for seat heating
- 61 35 179 Replacing and installing (replacing) the solar rain/driving-light sensor and condensation sensor
- 61 35 278 Removing and refitting (replacing) body domain controller (BDC)
- 61 35 360 Removing and installing/replacing control unit for camera-based driver support systems (KAFAS)
- 61 35 953 Removing and installing/replacing interior antenna for Comfort Access (front storage compartment)
- 61 35 954 Remove and install/replace interior antenna for comfort access system (rear center console)
- 61 35 975 Removing and installing/replacing bumper antenna for Comfort Access
- 61 35 980 Removing and installing/replacing antenna for Comfort Access on left (or right)
- 61 61 Windshield Wiper
- Check angle of attack of left or right windshield wiper (series LI)
- 61 61 021 Replacing left or right windshield wiper blade
- 61 61 041 Replace both windshield wiper blades
- 61 61 081 Replacing the left or right wiper arm
- 61 61 100 Remove and install/replace both windshield wiper arms
- 61 61 131 Replacing both wiper blades (Bosch AeroTwin)
- 61 61 252 Removing and installing/replacing left wiper motor
- 61 61 253 Removing and installing/replacing right wiper motor
- 61 61 800 Basic setting for windshield wipers
- 61 62 Rear Window Wiper
- 61 71 Windshield Washer System
- 61 71 030 Removing and installing/replacing all spray nozzles of windshield washer system
- 61 71 061 Remove and fit/replace water tank for washer system
- 61 71 100 Removing and installing/replacing windshield washer pump
- 61 71 150 Remove and install/replace rear windshield washer pump for windshield washer system
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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