Battery in luggage compartment under spare wheel: Installation

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

Remove faulty fuses and carry out troubleshooting.

Fig 1: Disconnecting Supply Cable For Vehicle Electrical System

G03152937

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Pay attention to interface.
The repair cable is always a standard length.
The heavy-current connector of the repair cable has a larger diameter than the battery positive lead.
In some Series (e.g. E46 touring), the heavy-current connector of the repair cable can lead to installation problems.
This is the case when the interface is in the area of the close-fitting trim panels.
Find matching interface (e.g. approx. 10 cm behind rear seat backrest in E46 touring).

Lay repair cable parallel to battery positive lead.

Mark interface of battery positive lead at end of repair cable.

Fig 2: Laying Repair Cable Parallel To Battery Positive Lead

G03152938

Courtesy of BMW OF NORTH AMERICA, INC.

Release cable ties (1).

Disconnect plug connection (2).

Fig 3: Releasing Cable Ties

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Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Do not use bolt cutters or similar tools to cut through the cable.
A cable end that has been squashed flat will no longer fit into the clamping sleeve.

Saw through battery positive cable at marked point with an iron saw.

Fig 4: Identifying Cable End

G03152940

Courtesy of BMW OF NORTH AMERICA, INC.

Strip insulation - length (A) - from cable end.

Distance (A) = 15 mm.

Fig 5: Identifying Battery Positive Cable End Length

G03152941

Courtesy of BMW OF NORTH AMERICA, INC.

Push heavy-current connector (1) over stripped cable end and screw into position.

Fig 6: Identifying Heavy-Current Connector

G03152942

Courtesy of BMW OF NORTH AMERICA, INC.

Push shrink-fit hose (3) over repair cable.

Screw threaded sleeve (1) of repair cable (2) to heavy-current connector.

Fig 7: Pushing Shrink-Fit Hose Over Repair Cable

G03152943

Courtesy of BMW OF NORTH AMERICA, INC.

Push shrink-fit hose (1) over connecting point and shrink on with a hot-air blower (2).

Fig 8: Identifying Hot-Air Blower

G03152944

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Heat up shrink-fit hose until it has settled completely around the connection point.

Fig 9: Heating Shrink-Fit Hose

G03152945

Courtesy of BMW OF NORTH AMERICA, INC.

When laying the repaired battery positive cable, observe the following:

The shrink-fit hose must not be scuffed during any movement.
The repair cable must not cause any disturbing noises during driving operation.

NOTE: Offsetting cutting line by approx. 10 cm produces excess length of battery positive lead (1).
Lay battery positive lead (1) without kinks or abrasions. (Shown on E46 touring.)

Fig 10: Installing Battery Positive Lead Without Kinks Or Abrasions

G03152946

Courtesy of BMW OF NORTH AMERICA, INC.