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12 36 610 Replacing the electrical machine electronics (EME)

WARNING: High-voltage system - danger to life!
The following points must be strictly observed prior to starting work and during work: 
  • DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM 
  • Observe SAFETY INFORMATION  for working with electric vehicles.
  • Observe notes on EARTH BONDING SCREW CONNECTIONS .
  • The workbay required for the repair of the drive unit must be clean (free of grease, dirt and debris), 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.
  • 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.
  • Remove electrical machine electronics (EME) immediately before removing the packaging.
  • For handling of the electrical machine electronics (EME), always install protection connector (part number: 12 5 7 620 458).
IMPORTANT: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DAMAGE (ESD PROTECTION) .

Necessary preliminary tasks: 

Connection overview of electrical machine electronics (EME): 

  1. Potential compensation line to body
  2. High-voltage connection for electrical machine
  3. Signal lead connection
  4. High-voltage connection to high-voltage battery unit
  5. High-voltage connection for convenience charging electronics (KLE)
  6. Connection for earth wire
  7. Coolant connection (feed line)
  8. Battery positive lead connection
  9. Coolant connection (return line)
    10. Fig 1: Overview Of Electrical Machine Electronics (EME) Connections
    G11103656Courtesy of BMW OF NORTH AMERICA, INC.

Removal: 

Release screws (1).

Unfasten screws (2).

Release sheet metal nuts (3).

Unscrew nuts (4).

Remove heat shield.

Fig 2: Identifying Nuts And Screws
G11103657Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1).

Remove heat shield.

Fig 3: Identifying Heat Shield Screws
G11103658Courtesy of BMW OF NORTH AMERICA, INC.

Unlock and disconnect signal line (1).

Unclip signal line (1) from the electrical machine electronics (EME).

Release screw (2) from the tension relief and remove cover.

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Unlock high-voltage cable (3) and disconnect.

Unclip high-voltage cable (3) from holder for electrical machine electronics (EME).

Remove protective earth connector (part number: 12 52 7 620 458).

Fig 4: Identifying EME Signal Line, Screw And High Voltage Cable
G11103675Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) from high-voltage cable.

Unscrew nuts (2).

Release screws (3) from holder for high-voltage cable.

Release screw (4) from the potential compensation line.

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .
Fig 5: Identifying Screws And Nuts
G11103660Courtesy of BMW OF NORTH AMERICA, INC.

Pull off high-voltage cable.

Release nut (1) from grounding cable.

Remove grounding cable from threaded bolt (grounding cable).

Release nut (2) from grounding cable.

Remove grounding cable from threaded bolt (body).

Unclip grounding cable from the electrical machine electronics (EME).

Fig 6: Identifying Grounding Cable Nuts
G11103661Courtesy of BMW OF NORTH AMERICA, INC.

Unlock coolant line (1) and disconnect.

Unlock coolant line (2) and disconnect.

Pull off cover (3) from the positive battery cable and release the nut beneath it.

Unlock high-voltage cable (4) and disconnect.

Fig 7: Identifying Coolant Lines, Cover And High Voltage Cable
G11103662Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: The following operation must be carried out using a second person.

Slacken screws (1) from electrical machine electronics (EME) (3).

Secure electrical machine electronics (EME) (3) from falling down using another person.

Release screws (2) from electrical machine electronics (EME) (3).

Feed out electrical machine electronics (EME) (3) carefully and remove.

Fig 8: Identifying Electrical Machine Electronics And Screws
G11103663Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: The electrical machine electronics (EME) may not be placed on the aluminium cover.
Use packaging or foam.

Release screws (1) and holder for high-voltage cable.

Release nut (2) from grounding cable.

Fig 9: Identifying Screws And Nut
G11103680Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: The electrical machine electronics (EME) may not be placed on the aluminium cover.
Use packaging or foam.

Release the screws (1) and remove the tension relief.

Release screws (2) from the holder for the electrical machine electronics (EME).

Remove the holder for the electrical machine electronics (EME).

Fig 10: Identifying Screws
G11103681Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

Check diaphragm (1) for damage.

Fig 11: Identifying Diaphragm
G11103664Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: The electrical machine electronics (EME) may not be placed on the aluminium cover.
Use packaging or foam.

Position holder for electrical machine electronics (EME) with the rubber mount.

Tighten screws (2) from the holder for the electrical machine electronics (EME).

Fig 12: Identifying Screws
G11103681Courtesy of BMW OF NORTH AMERICA, INC.

Tightening torque 12 36 9AZ .

Position tension relief and tighten screws (1).

Tightening torque 12 36 14AZ .

IMPORTANT: The electrical machine electronics (EME) may not be placed on the aluminium cover.
Use packaging or foam.

Tighten nut (2) of the grounding cable.

IMPORTANT:

Observe notes on EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 6AZ .

Fig 13: Identifying Screws And Nut
G11103680Courtesy of BMW OF NORTH AMERICA, INC.

Position holder for high-voltage cable and tighten screws (1).

Tightening torque 12 36 15AZ .

IMPORTANT: The following operation must be carried out using a second person.

Feed electrical machine electronics (EME) (3) carefully into screws (1).

Secure electrical machine electronics (EME) (3) from falling down using another person.

Tighten screws (2) from electrical machine electronics (EME) (3).

Fig 14: Identifying Electrical Machine Electronics And Screws
G11103663Courtesy of BMW OF NORTH AMERICA, INC.

Tightening torque 12 36 8AZ .

Tighten screws (1) from electrical machine electronics (EME) (3).

Tightening torque 12 36 8AZ .

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Connect and lock high-voltage cable (4).

Tighten nut (3) and connect cover of positive battery cable.

Tightening torque 12 36 7AZ .

Connect coolant line (2) and lock.

Connect and lock coolant line (1).

Fig 15: Identifying Coolant Lines, Cover And High Voltage Cable
G11103662Courtesy of BMW OF NORTH AMERICA, INC.

Tighten grounding cable (2) on body.

IMPORTANT:

Observe notes on EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 5AZ .

Tighten grounding cable (1) on the grounding cable (2).

IMPORTANT:

Observe notes on EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 5AZ .

Fig 16: Identifying Grounding Cable Nuts
G11103661Courtesy of BMW OF NORTH AMERICA, INC.

Clip in grounding cable to the electrical machine electronics (EME).

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Connect high-voltage cable.

Tighten screws (1) of high-voltage cable.

Tightening torque 12 36 1AZ .

Tighten nuts (2) of high-voltage cable.

Tightening torque 12 36 16AZ .

Tighten screws (3) of holder for high-voltage cable.

Tightening torque 12 36 2AZ .

Fig 17: Identifying Screws And Nuts
G11103660Courtesy of BMW OF NORTH AMERICA, INC.

Tighten screw (4) from potential compensation line.

IMPORTANT:

Observe notes on EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 3AZ .

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Remove protection connector.

Connect and lock high-voltage cable (3).

Clip in high-voltage cable (3) on holder for electrical machine electronics (EME).

Position cover for the tension relief and tighten screw (2).

Tightening torque 12 36 17AZ .

Connect and lock signal line (1).

Clip in signal line (1) on the electrical machine electronics (EME).

Fig 18: Identifying Electrical Machine Electronics Signal Line, Screw And High Voltage Cable
G11103659Courtesy of BMW OF NORTH AMERICA, INC.

Position heat shield.

Tighten down screws (1).

Fig 19: Identifying Heat Shield Screws
G11103658Courtesy of BMW OF NORTH AMERICA, INC.

Position heat shield.

Tighten down nuts (4).

Tightening torque 12 36 18AZ .

Tighten sheet metal nuts (3).

Tightening torque 12 36 18AZ .

Tighten down screws (2).

Tightening torque 12 36 18AZ .

Tighten down screws (1).

Tightening torque 12 36 18AZ .

Fig 20: Identifying Nuts And Screws
G11103657Courtesy of BMW OF NORTH AMERICA, INC.

Required reworking: 

Carry out VEHICLE PROGRAMMING/ENCODING .

Connect BMW diagnosis system:

  1. Service functions
  2. Power train
  3. Hybrid car
  4. Electrical machine electronics
  5. Motor position sensor adjustment
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