12 36 010 Removing and installing/replacing power electronics box

WARNING: This page is about a different car, the 2010 BMW X6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life!

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

DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM
Observe SAFETY INFORMATION for handling with hybrid cars

Necessary preliminary tasks:

REMOVE AUXILIARY POWER MODULE (APM)
REMOVE POWER ELECTRONICS BOX.

Fig 1: Unclipping Connector From Power Electronic Box Holder
Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) from hybrid power distribution box.

Tightening torque 12 36 10AZ .

Detach high-voltage cable from attachment points (2).

Detach lines at attachment point (3).

Unclip high-voltage cable from attachment points (4).

NOTE: In case of replacement, the holder for the coolant line must be remounted.

Detach line at attachment point (5).

Unclip connector (6) in direction of arrow from holder for power electronic box.

Unclip coolant line from attachment point (1).

NOTE: In case of replacement, the holder for the coolant line must be remounted.

Detach high-voltage cable from attachment points (2).

Fig 2: Identifying Coolant Line And High-Voltage Cable Attachment Points

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) from power distribution box (2).

Tightening torque 12 36 13AZ .

Release nut (3) from reverse polarity protection.

Tightening torque 12 36 16AZ .

Release nut (4) from grounding cable.

Tightening torque 12 36 17AZ .

Installation note:

Ensure that the contact surfaces on the holder for the power electronic box are clean.

Fig 3: Identifying Power Distribution Box, Mounting Nuts And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1).

Tightening torque 12 36 11AZ .

Loosen cap nuts (2).

Tightening torque 12 36 12AZ .

Fig 4: Identifying Power Electronics Box Cap Nuts And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 5: Identifying Power Electronic Box, Auxiliary Power Module And Grounding Cable

Courtesy of BMW OF NORTH AMERICA, INC.

Replacement:

Install an additional grounding cable (1). The new holder for the power electronic box has an additional ground pin.

Slip grounding cable (1) behind holder for power electronic box.

Screw grounding cable onto auxiliary power module (2).

Tightening torque 12 36 15AZ .

Screw grounding cable onto additional ground pin of holder for power electronic box (3).

Tightening torque 12 36 15AZ .

Installation note:

Ensure that the contact surface on the holder for the power electronic box for the grounding cable are clean.

Fasten the grounding cable onto the power electronic box (4) with cable straps.