12 35 000 Removing and installing complete drive unit (range extender) (i3 base, i3s)

Special tools required:

2 357 222 .
2 357 221 .
2 286 319
0 490 567

WARNING: High-voltage system - mortal hazard
Compliance with the following points is mandatory before beginning work:

DE-ENERGIZING THE HIGH-VOLTAGE SYSTEM .
Observe SAFETY INSTRUCTIONS for handling electric cars.
Observe NOTES ON EARTH BONDING SCREW CONNECTIONS .

Preliminary work needed:

Briefly open the gas cap to reduce pressure in fuel tank.
This prevents dieseling of fuel of an opened fuel line.
Refer to CLAMP OFF BATTERY LEAD FROM NEGATIVE TERMINAL .
NOTE: Before disconnecting the battery cable, it must be ensured that the vehicle goes to sleep.
Refer to DRAINING COOLANT .
Refer to Remove SUPPORT FOR REAR BUMPER PANEL .
Refer to Remove BOTH HORIZONTAL STRUTS .
Refer to Remove VERTICAL STRUT .
With equipment "quick charging direct current" (SA4U7) and "quick charging alternating current" (SA4U6 or SA4U8):
Refer to Remove CONVENIENCE CHARGING ELECTRONICS .
Refer to Remove RANGE EXTENDER ELECTRICAL MACHINE ELECTRONICS .
Refer to Take off REAR CROSS-MEMBER .
Remove output shaft on left and right. Refer to 33 21 002 REMOVING AND INSTALLING/REPLACING RIGHT OUTPUT SHAFT (I3 BASE, I3S) .

REMOVAL:

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Remove luggage compartment floor covering (1).

Release screws (2) and remove service cap (3) towards top.

On vehicles from version 12/2014:

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

Loosen the screws (2) from the holder for tension relief.

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Release potential equalization line (1) from drive module.

Disconnect high-voltage cable (2) from high-voltage battery unit on electrical machine electronics.

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES .

Release nut (3) from battery ground lead on electrical machine electronics.

Take off cover and release nut (4) from positive battery cable on electrical machine electronics.

Fold open sound insulation and unlock and disconnect plug connection of tank vent valve (5).

Unclip the battery ground lead and positive battery cable on both cable clips of the electrical machine electronics.

Detach cable tie (6) from positive battery cable on battery ground lead.

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Depending on equipment version, unlock and disconnect plug connections (1) on power distribution box.

Unclip lines (3) from holder.

Release nut (2) on earth strap.

Release screw (4) from potential equalization on engine support bracket.

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Release screw (1) from potential equalization line (2).

Disconnect plug connection (3) from signal line.

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES .

Disconnect plug connection (4) from high-voltage cable.

Release screws (5) from air conditioning compressor (6).

Secure air conditioning compressor (6) on Drive module (7) with cable tie or luggage strap.

For vehicles built unto 12/2014:

Release screws (1) from conduit (2).

Slip out high-voltage cable with conduit (2) downward and secure on the outer side.

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On vehicles from version 12/2014:

Press the retaining lugs towards the outside and detach the line clip (1).

Unscrew the screws (2).

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On vehicles from version 12/2014:

Detach the retaining lugs from the cable duct (1) of the Drive module (2) in the arrow direction.

Remove the high-voltage cable including cable duct (1) towards the bottom and secure to the side on the outside.

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On vehicles from version 12/2014:

Loosen the screws (1) and remove the shaft (2).

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IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES .

Disconnect plug connections (1) from wiring harness.

Disconnect plug connection (2) from high-voltage cable on electrical machine electronics.

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Detach positive battery cable (1) from clamps (2) on range extender (3).

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IMPORTANT: Fuel leaks when fuel line is detached. Have a suitable collecting vessel ready.
Catch and dispose of leakage fuel. Observe country-specific waste disposal regulations.

Unfasten fuel line (1) and disconnect.

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Undo screws (1) and detach connector of high-voltage cable on Range Extender electrical machine (2).

Unscrew nut (3).

Detach high-voltage cable (4) from Range Extender electrical machine (2) and remove.

Release screw (5) and remove holder for high-voltage cables of Range Extender electrical machine.

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Pry off clamp (1).

Slip out sound insulation (2) and fold away downward.

Undo screws (3) on Range Extender electrical machine (4).

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Left side of vehicle:

Open clamp (1) if necessary and disconnect coolant hose (2).

Unclip coolant hose (2) on Drive module and slip out.

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Right side of vehicle:

Unlock and disconnect coolant hose (1).

Unclip coolant hose (1) on Drive module and slip out.

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Pry off clamps (1).

Feed out and remove sound insulation (2).

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IMPORTANT: Coordinate determination always begins at the top .

Comply with NOTES REGARDING HANDLING MOBILE TABLE LIFT .

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The following tools from the lifting table attachment set (part number 81 22 2 305 379) are required:

Tool number:	Number:
20	3
80	2

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Structure, table lift:

Position 1:

Position retaining element (20) using special tool 2 357 222 onto table plate {B} at coordinates 7/6.

Position 2:

Position retaining element (20) using special tool 2 357 222 onto table plate {B} at coordinates 7/3.

Position 3:

Position retaining element (20) with support plate (80) onto table plate {B} at coordinates 8/7.

Position 4:

Position special tool 2 357 221 onto table plate {B} at coordinates 9/4.

IMPORTANT: Secure special tool 2 357 221 onto the table lift at a later stage.

Position 5:

Position lower part of special tool 2 357 221 with support plate (80) onto table plate {A} at coordinates 2/4.

NOTE: Drive dowel pin out of special tool 2 357 221 and remove upper section. Insert mounting plate (80) in lower part of special tool 2 357 221 .

Position 6:

Position special tool 2 357 221 onto table plate {A} at coordinates 5/6.

Position 7:

Position special tool 2 357 221 onto table plate {A} at coordinates 5/6.

Overview of mounting points of table lift on electrical machine and range extender:

Position 1:

2 x special tool 2 357 222 with stand 20

Position 2:

1 x mounting plate 80 with stand 20

Position 3:

1 x special tool 2 357 221 .

Position 4:

1 x mounting plate 80 with lower part of special tool 2 357 221 .

Position 5:

1 x special tool 2 357 221 .

Position 6:

1 x special tool 2 357 221 .

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Slide the lifting table under the vehicle from the side (from the right-hand side). Position mounting below drive unit.

Raise the lifting table and position special tool 2 357 222 at the mounting points of the electrical machine.

Position support plate (1) at mounting point of electrical machine.

Position support plate (2) at mounting point of range extender.

Position special tool 2 357 221 on Range Extender electrical machine and fix in place with original screws.

Release screw (1) of engine pendulum support (3).

Release screws (2) and remove engine pendulum support (3).

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Courtesy of BMW OF NORTH AMERICA, INC.

Position special tool 2 357 221 on electrical machine and secure with nut (1).

NOTE: Washer (2) must rest against taper (3) of electrical machine.

Release left and right screws (1) and remove stop pad (2).

Release left and right screws (3) from support bearing.

Carefully lower the lifting table including drive unit.

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Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: If it is necessary to remove the entire drive unit from the table lift, note the following:

Secure special tool 2 286 319 on engine mounting bracket on the left and right (1, 2) with original screws.
Attach special tool 0 490 567 to special tool 2 286 319 .
Release fixations of drive unit on table lift.
Lift drive unit off of table lift with workshop crane.

INSTALLATION:

Check support bearing (4) on left and right for damage. Replace the damaged support bearing.

IMPORTANT: It is also necessary to align the bores in front of the screw connection when installing a new engine mounting bracket or transmission mounting bracket. Align support bearing (4) with the engine mounting bracket/transmission mounting bracket before screwing on with a suitable tool (e.g. drill with shaft diameter of 11 mm).

Carefully lift and position the lifting table including drive unit.

Tighten left and right screws (3) on support bearing (4).

Installation note:

Left side - support bearing on engine mounting bracket of the electrical machine:

Replace screw.

Tightening torque 27 00 8AZ .

Right side - radial bearing on the engine support bracket of the Range Extender electrical machine:

Replace screw.

Tightening torque 27 00 7AZ .

Tighten left and right screws (1) with stop pad (2).

Tightening torque 12 35 1AZ .

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Release nut (1) from electrical machine (3).

Remove special tool 2 357 221 with screw and washer (2).

Tighten screws (2) on engine pendulum support (3).

Tightening torque 27 00 9AZ .

Tighten screw (1) on engine pendulum support (3).

Tightening torque 27 00 10AZ .

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IMPORTANT: Unclamp special tool 2 357 221 before disassembly.

Undo screws on special tools 2 357 221 on Range Extender electrical machine.

Lower the lifting table.

Feed in and position sound insulation (2).

Connect clamps (1).

IMPORTANT: Replace clamps (1).

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Tighten screws (3) on Range Extender electrical machine.

Tightening torque 12 35 9AZ .

Feed in and position sound insulation (2).

Connect clamp (1).

IMPORTANT: Use new clamp (1).

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Tighten screw (5) on holder for high-voltage cables of Range Extender electrical machine.

Tightening torque 61 12 5AZ .

Attach high-voltage cable (4) on Range Extender electrical machine (2).

Tighten nut (3).

Tightening torque 12 35 8AZ .

Tighten screws (1) on high-voltage cable connector on Range Extender electrical machine (2).

Tightening torque 12 35 7AZ .

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Connect fuel line (1) and lock.

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Attach positive battery cable (1) in clamps (2) on range extender (3).

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Left side of vehicle:

Slip in coolant hose (1) on Drive module and clip in.

Connect coolant hose (1) and lock.

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Right side of vehicle:

Slip in coolant hose (2) on Drive module and clip in.

Connect coolant hose (2) and close clamp (1).

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IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES .

Connect connector (2) of high-voltage cable on electrical machine electronics and lock.

Connect connector (1) of wiring harness and lock.

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On vehicles from version 12/2014:

Position the shaft (2) and tighten the screws (1).

Tightening torque 61 12 9AZ .

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On vehicles from version 12/2014:

Attach the retaining lugs of the cable duct (1) in the arrow direction at the Drive module (2).

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On vehicles from version 12/2014:

Insert the high-voltage cable including cable duct towards the top.

Position the high-voltage cable and clip in the line clip (1).

Tighten down screws (2).

Tightening torque 61 12 4AZ .

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For vehicles built unto 12/2014:

Feed in high-voltage cable with conduit (2) in an upward direction.

Tighten screws (1) on conduit (2).

Tightening torque 61 12 4AZ .

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Release fixation of air conditioning compressor (6) on Drive module (7).

Tighten screws (5) on air conditioning compressor (6).

Tightening torque 64 52 2AZ .

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES .

Connect connector (4) of high-voltage cable and lock.

Connect connector (3) of signal line and lock.

Tighten potential equalization line (2) with screw (1).

IMPORTANT: Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !

Tightening torque 64 52 3AZ .

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Tighten potential equalization line with screw (4) on engine support bracket.

IMPORTANT: Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 35 6AZ .

Tighten nut (2) for ground strap on drive module.

IMPORTANT: Risk of damage! The tightening torque must be observed without fail.

Tightening torque 61 12 3AZ .

Depending on equipment version, connect and lock connector (1) on power distribution box.

Clip lines (3) into holder.

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Fold open sound insulation and connect and lock plug connection of tank vent valve (5).

Tighten battery ground lead with nut (3) at EME.

IMPORTANT: Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 2AZ .

Tighten nut (4) for positive battery cable on electrical machine electronics and connect cover.

Tightening torque 12 36 3AZ .

Clip the battery ground lead and positive battery cable into both cable clips of the electrical machine electronics.

Carefully pull positive battery cable towards the rear end of the vehicle and secure with cable tie (6) on battery ground lead.

IMPORTANT: Secure and position positive battery cable in such a way that there is no contact to the Carbon Fiber Reinforced Plastic body in the rear seat area!

Connect and lock connector (2) of high-voltage cable to high-voltage battery unit on electrical machine electronics.

Observe notes on UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES .

Tighten potential equalization line with screw (1) at Drive module.

IMPORTANT: Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 1AZ .

On vehicles from version 12/2014:

Tighten the screws (2) of the tension relief holder.

Tightening torque 61 12 7AZ .

Position tension relief and tighten screws (1).

Tightening torque 61 12 8AZ .

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IMPORTANT: Check the neoprene nuts of the screw connections (2) and gasket (4) for damage and replace if necessary.

Position service cap and tighten screws (2).

Tightening torque 51 47 4AZ .

Insert luggage compartment floor covering (1) .

Required follow-up work:

Install left and right output shaft. Refer to 33 21 002 REMOVING AND INSTALLING/REPLACING RIGHT OUTPUT SHAFT (I3 BASE, I3S) .
Refer to Install RANGE EXTENDER ELECTRICAL MACHINE ELECTRONICS .
Refer to Install REAR CROSS-MEMBER .
With equipment "quick charging direct current" (SA4U7) and "quick charging alternating current" (SA4U6 or SA4U8):
Refer to Install CONVENIENCE CHARGING ELECTRONICS .
Refer to Install VERTICAL STRUT .
Refer to Attach SUPPORT FOR REAR BUMPER PANEL .
Refer to Install BOTH HORIZONTAL STRUTS .
Refer to CONNECTING BATTERY CABLE TO NEGATIVE TERMINAL .
Refer to FILLING AND VENTING COOLING SYSTEM .
Check oil level:

After work on range extender:

Connect diagnostic system:

Service functions
Drive
Range extender digital engine electronics
Service start range extender

Carry out leakage test for 20 min.

IMPORTANT: If there is an oil leak, engine must be cleaned thoroughly.