12 35 506 Replacing electrical machine (range extender) (i3 base, i3s)

Special tools required: 

• 2 286 332 
• 2 356 947 
• 2 357 269 
• 2 285 545 

The following points must be strictly observed prior to starting work and during work: 

• Observe SAFETY INSTRUCTIONS for working with electric vehicles.
• Observe NOTES ON EARTH BONDING SCREW CONNECTIONS .
• The workbay for the repair of the drive unit must be clean (free of grease, dirt and shavings), dry (no leaking fluid) and free of flying sparks. Therefore, avoid close vicinity to areas intended for cleaning of vehicles and to workbays intended for repair work relating to the body. Use movable walls and high-voltage barrier tapes for separation, if needed.
• It is absolutely essential to remove all small parts/screws that fell into the electrical machine.
• Perform a visual inspection for contamination and damage of the housing, connections and gaskets or sealing surfaces of the electrical machine and electrical machine electronics.

Preliminary work needed: 

• Refer to Remove ELECTRICAL MACHINE ELECTRONICS .
• Refer to Remove E-TRANSMISSION .

Removal: 

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Open clamp (1) and detach coolant hose.

Release screw (1) from potential equalization line.

Pry off clamps (3) of sound insulation (5).

Remove sound insulation (5).

Release screw (4) from potential equalization line.

Release screws (1) and remove support (2).

Detach coolant hose from clamp (3).

Open gripper clamp (4) and detach coolant hose.

Lever out clamp (3) and remove.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Screw special tools 2 286 332  all the way into electrical machine (1).

Fasten special tool 2 356 947  using special tool 2 357 269  at special tool 2 286 332  .

Release screw connection of table lift support on electrical machine (1).

Position new electrical machine (1) on table lift with workshop crane and secure with table lift support.

Installation: 

Read adaptation value of rotor position sensor (3) from nameplate (2) of new electrical machine (1). Nameplate (2) is located on the underside of the electrical machine (1).

The new adaptation value of the rotor position sensor (3) must be read in via the diagnostic system when the rotor position sensor is adjusted.

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The full grease quantity (4 g) must be applied to the hub base of rotor shaft (1). The gearing must not be greased. When the transmission is joined with the electrical machine, the grease is distributed uniformly on the connection.

Screw special tools 2 285 545  into electrical machine. Transmission must be assembled with electrical machine using special tools 2 285 545  .

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Connect coolant hose and close clamp (4).

Attention! 

Lugs of clamp (4) must be positioned on the side. When positioned at the top, collision occurs with the electrical machine electronics.

Mount clamp (3).

Attach coolant hose in clamp (3).

Tighten support (2) with screw (1).

Attention! 

Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 35 4AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Position sound insulation (5).

Connect clamps (3) of sound insulation (5).

Attention!

Replace clamps (3).

Connect coolant hose and close clamp (1).

Tighten potential equalization line with screw (2).

Attention!

Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 35 5AZ .

Tighten potential equalization line with screw (4).

Attention!

Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 35 5AZ .

Required follow-up work: 

• Refer to Attach ELECTRICAL MACHINE ELECTRONICS .
• Refer to Mount E-TRANSMISSION .

Connect BMW diagnostic system: 

1. Service functions
2. Drive
3. Electrical machine electronics
4. Motor position sensor adjustment