12 36 018 Removing/installing electrical machine electronics (i3 base, i3s)

Special tools required: 

• 2 356 938 .

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.
• Replacement: Remove electrical machine electronics immediately before removing the packaging.
• For handling of the electrical machine electronics, always install protection connector (part number: 12 5 7 620 458).

Preliminary work needed: 

• Remove complete drive unit. Refer to 12 35 000 REMOVING AND INSTALLING COMPLETE DRIVE UNIT (RANGE EXTENDER) (I3 BASE, I3S) .

Courtesy of BMW OF NORTH AMERICA, INC.

Connection overview of electrical machine electronics (EME): 

1. High-voltage connection to high-voltage battery unit
2. High-voltage connection to convenience charging electronics (only with optional equipment for direct current and/or alternating current quick charging)
3. High-voltage connection to electrical machine (stator winding 1 to 3)
4. Rotor position sensor
5. temp, sensor
6. Potential equalization line to drive module
7. Potential equalization line to electrical machine (only in vehicles with range extender)
8. Cooling water connection (electrical machine electronics return flow to electrical machine)
9. Cooling water connection (radiator feed, electrical machine electronics)
10. High-voltage connection of electric A/C compressor (EKK)
11. High-voltage connection to electric heater
12. High-voltage connection, charging
13. Ground connection 12-V wiring harness
14. Battery ground lead
15. Positive battery cable
16. Signal line

Removal: 

Detach high-voltage cable from attachment points (1).

Release screws (2) and remove engine mounting bracket (3).

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Loosen the screws (1) and remove the sheet metal bracket from the electrical machine electronics (2).

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Pry out clamps (1) and remove sound insulation (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1) of wiring harness ground connection.

Only with quick charging equipment (SA4U7 and/or SA4U8): Disconnect high-voltage cable (2) for convenience charging electronics. Unclip and unthread the high-voltage cable (2).

Disconnect signal line (3).

Detach wiring harness (4) from attachment points.

Disconnect high-voltage cable (5) for electric A/C compressor.

Only with alternating current quick charging equipment (SA4U8): Disconnect high-voltage cable (6) for convenience charging electronics.

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Open clamp (1) and detach coolant hose.

Release screw (2) and remove potential equalization line.

Pry off clamps (3) from sound insulation.

Release screw (4) and remove holder.

Detach and remove high-voltage cable for electric A/C compressor on attachment point (1).

Pry off clamps (2) of sound insulation (3).

Feed out and remove sound insulation (3).

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Release screws (1) and remove service cap (2).

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Release screws (1) from high-voltage cables.

Disconnect plug connections (2).

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Release screws (1) from electrical machine electronics (2).

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Release screws (1) from electrical machine electronics (2).

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Carefully place electrical machine electronics (1) in special tool 2 356 938 .

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

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1. Place electrical machine electronics inverted in special tool 2 356 938 .
   NOTE: High-voltage connections must not be damaged.
2. Check gasket (1) for damage. If damaged, the electrical machine electronics must be replaced.
3. Check gasket (2) for damage. If damaged, the electrical machine electronics must be replaced.
4. Check diaphragm (3) for damage. If damaged, the electrical machine electronics must be replaced.

Tighten screws (1) on electrical machine electronics (2).

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Tighten screws (1) on electrical machine electronics (2).

Tightening torque 12 36 7AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten down screws (1) on high-voltage cables.

Courtesy of BMW OF NORTH AMERICA, INC.

Connect and lock connectors (2) of temperature sensor and rotor position sensor.

Tighten screws (1) on service cap (2).

Tightening torque 12 35 2AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Feed in and position sound insulation (3).

Connect clamps (2) of sound insulation (3).

Attach high-voltage cable for electric A/C compressor to attachment point (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Connect clamps (3) of sound insulation.

Tighten screw (4) on holder.

Tightening torque 12 36 6AZ .

Tighten potential equalization line with screw (2).

Tightening torque 12 36 5AZ .

Connect coolant hose and close clamp (1).

The sound insulation (1) has been secured with only one clamp (2).

The right-hand retaining lug (3) does not feature a clamp. The sound insulation (1) has been secured using window glass adhesive in this area.

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For electrical machine electronics where the retaining lug is too thin only (see above): 

Fold sound insulation (1) upwards.

Clean the adhesive area of the electrical machine electronics using R2 solvent cleaner.

Apply WINDOW GLASS ADHESIVE (2) to the electrical machine electronics as shown.

• Height: 4 mm to 6 mm
• Width: 6 mm to 8 mm

Securely press on the sound insulation (1) to the electrical machine electronics in the adhesive area.

Connect the left-hand clamp to the electrical machine electronics retaining lug.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Only with quick charging equipment (SA4U7 and/or SA4U8): Connect connector (6) of high-voltage cable to convenience charging electronics and lock.

Connect connector (5) of high-voltage cable to electric A/C compressor and lock.

Attach wiring harness (4) to attachment points.

Tighten screw (1) on wiring harness ground connection.

Tightening torque 12 36 4AZ .

Connect connector (3) of signal line and lock.

Only with quick charging equipment (SA4U8): Mount and clip in the high-voltage cable (2). Connect connector (2) of high-voltage cable to convenience charging electronics and lock.

Position sound insulation (2) and connect clamps (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Position the sheet metal bracket on the electrical machine electronics (2) and tighten the screws (1).

Tightening torque 61 12 6AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten screws (2) on engine mounting bracket (3).

Tightening torque 27 00 5AZ .

Attach high-voltage cable to attachment points (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work: 

Install complete drive unit. Refer to 12 35 000 REMOVING AND INSTALLING COMPLETE DRIVE UNIT (RANGE EXTENDER) (I3 BASE, I3S) .

Special tools required: 

• 2 356 938 .

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.
• Replacement: Remove electrical machine electronics immediately before removing the packaging.
• For handling of the electrical machine electronics, always install protection connector (part number: 12 5 7 620 458).

Preliminary work needed: 

• Refer to Remove COMPLETE DRIVE UNIT .

Courtesy of BMW OF NORTH AMERICA, INC.

Connection overview of electrical machine electronics (EME): 

1. High-voltage connection to high-voltage battery unit
2. High-voltage connection to convenience charging electronics (only with optional equipment for direct current and/or alternating current quick charging)
3. High-voltage connection to electrical machine (stator winding 1 to 3)
4. Rotor position sensor
5. temp, sensor
6. Potential equalization line to drive module
7. Potential equalization line to electrical machine (only in vehicles with range extender)
8. Cooling water connection (electrical machine electronics return flow to electrical machine)
9. Cooling water connection (radiator feed, electrical machine electronics)
10. High-voltage connection of electric A/C compressor (EKK)
11. High-voltage connection to electric heater
12. High-voltage connection, charging
13. Ground connection 12-V wiring harness
14. Battery ground lead
15. Positive battery cable
16. Signal line

Removal: 

Detach high-voltage cable from attachment points (1).

Release screws (2) and remove engine mounting bracket (3).

Courtesy of BMW OF NORTH AMERICA, INC.

Loosen the screws (1) and remove the sheet metal bracket from the electrical machine electronics (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Pry out clamps (1) and remove sound insulation (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1) of wiring harness ground connection.

Only with quick charging equipment (SA4U7 and/or SA4U8): Disconnect high-voltage cable (2) for convenience charging electronics. Unclip and unthread the high-voltage cable (2).

Disconnect signal line (3).

Detach wiring harness (4) from attachment points.

Disconnect high-voltage cable (5) for electric A/C compressor.

Only with alternating current quick charging equipment (SA4U8): Disconnect high-voltage cable (6) for convenience charging electronics.

Release screw (1) from potential equalization line.

Unlock coolant line (2) and disconnect.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Open clamp (1) and detach coolant hose.

Release screw (2) and remove potential equalization line.

Pry off clamps (3) from sound insulation.

Release screw (4) and remove holder.

Detach and remove high-voltage cable for electric A/C compressor on attachment point (1).

Pry off clamps (2) of sound insulation (3).

Feed out and remove sound insulation (3).

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) and remove service cap (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) from high-voltage cables.

Disconnect plug connections (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) from electrical machine electronics (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) from electrical machine electronics (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Carefully place electrical machine electronics (1) in special tool 2 356 938 .

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

Courtesy of BMW OF NORTH AMERICA, INC.

1. Place electrical machine electronics inverted in special tool 2 356 938 .
   NOTE: High-voltage connections must not be damaged.
2. Check gasket (1) for damage. If damaged, the electrical machine electronics must be replaced.
3. Check gasket (2) for damage. If damaged, the electrical machine electronics must be replaced.
4. Check diaphragm (3) for damage. If damaged, the electrical machine electronics must be replaced.

Tighten screws (1) on electrical machine electronics (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten screws (1) on electrical machine electronics (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten down screws (1) on high-voltage cables.

Courtesy of BMW OF NORTH AMERICA, INC.

Connect and lock connectors (2) of temperature sensor and rotor position sensor.

Tighten screws (1) on service cap (2).

Tightening torque 12 35 2AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Feed in and position sound insulation (3).

Connect clamps (2) of sound insulation (3).

Attach high-voltage cable for electric A/C compressor to attachment point (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Connect clamps (3) of sound insulation.

Tighten screw (4) on holder.

Tightening torque 12 36 6AZ .

Tighten potential equalization line with screw (2).

Tightening torque 12 36 5AZ .

Connect coolant hose and close clamp (1).

The sound insulation (1) has been secured with only one clamp (2).

The right-hand retaining lug (3) does not feature a clamp. The sound insulation (1) has been secured using window glass adhesive in this area.

Courtesy of BMW OF NORTH AMERICA, INC.

For electrical machine electronics where the retaining lug is too thin only (see above): 

Fold sound insulation (1) upwards.

Clean the adhesive area of the electrical machine electronics using R2 solvent cleaner.

Apply WINDOW GLASS ADHESIVE (2) to the electrical machine electronics as shown.

• Height: 4 mm to 6 mm
• Width: 6 mm to 8 mm

Securely press on the sound insulation (1) to the electrical machine electronics in the adhesive area.

Connect the left-hand clamp to the electrical machine electronics retaining lug.

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten potential equalization line with screw (1).

Connect coolant line (2) and lock.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Only with quick charging equipment (SA4U7 and/or SA4U8): Connect connector (6) of high-voltage cable to convenience charging electronics and lock.

Connect connector (5) of high-voltage cable to electric A/C compressor and lock.

Attach wiring harness (4) to attachment points.

Tighten screw (1) on wiring harness ground connection.

Tightening torque 12 36 4AZ .

Connect connector (3) of signal line and lock.

Only with quick charging equipment (SA4U8): Mount and clip in the high-voltage cable (2). Connect connector (2) of high-voltage cable to convenience charging electronics and lock.

Position sound insulation (2) and connect clamps (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Position the sheet metal bracket on the electrical machine electronics (2) and tighten the screws (1).

Tightening torque 61 12 6AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten screws (2) on engine mounting bracket (3).

Tightening torque 27 00 5AZ .

Attach high-voltage cable to attachment points (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work: 

Install complete drive unit. Refer to 12 35 000 REMOVING AND INSTALLING COMPLETE DRIVE UNIT (RANGE EXTENDER) (I3 BASE, I3S) .