Removal and Replacement

61 25 010 Removing And Installing (Replacing) High-Voltage Battery Unit

Special tools required:







WARNING: High-voltage system - danger to life.







WARNING:
The following points must be strictly observed prior to starting work:
- Disconnect high-voltage system from power
- Observe safety information for handling hybrid cars







Necessary preliminary tasks:
- Drain off air conditioning system
- Disconnect battery earth cable
NOTE: Before disconnecting the minus battery cable, it must be ensured that the vehicle goes to sleep. Observe a waiting period of at least 2 minutes.

- Remove all luggage compartment trim panels







WARNING: Observe notes on high-voltage battery unit prior to staring work.







Unfasten plug connection (1) and disconnect.
Undo bolt (2) of high-voltage cable.
Tightening torque 61 25 1AZ.
Pull high-voltage cable (3) from high-voltage battery unit.
Release screw (4).
Tightening torque 61 25 2AZ.
Pull air conditioning lines (5) from high-voltage battery unit.







Slacken nut (1).
Tightening torque 61 25 3AZ.
Detach earthing cable (2) from high-voltage battery unit.
Release screw (3).

IMPORTANT: Observe screwing sequence.

Slacken hose clamp (4) and pull off condensate drain from below.







Release screw (1).

IMPORTANT: Observe screwing sequence.







Insert luggage compartment storage shelf (1) in luggage compartment.







Attach special tool 2 221 148 (fitting aid) to high-voltage battery unit. Lock guide pin (1) to eye bolt of high-voltage battery unit.
Unscrew nuts (2).

IMPORTANT:
Observe screwing sequence.
Ensure that special tool 2 221 148 (fitting aid) is clean.
Do not trap lines with special tool 2 221 148 (fitting aid).







Installation note:
Observe screw-fitting sequence:
1. Tighten nuts 2, 3, 4, 5, 6 manually
2. Remove special tool 2 221 148 (fitting aid)
3. Tighten new screw 1. Tightening torque 61 25 4AZ.
4. Tighten nuts 2, 3, 4, 5, 6. Tightening torque 61 25 5AZ.
5. Tighten new screw 7. Tightening torque 61 25 6AZ.







Pull high-voltage battery unit (1) from high-voltage battery unit holder (3) at grab handle (2) of special tool 2 221 148 (fitting aid) in direction of arrow.

IMPORTANT: The high-voltage battery unit (1) is connected to the degassing tube of the high-voltage battery unit holder (3) via an O-ring.







IMPORTANT:
Additional assembly weight. Conduct this operation with the assistance of a second person
Risk of tipping. Carefully turn high-voltage battery unit (1) on its side immediately after dismantling from high-voltage battery unit holder.

Lift high-voltage battery unit (1) out of luggage compartment.

Replacement:
Detach special tool 2 221 148 (fitting aid) from high-voltage battery unit (1).







Installation note:
Fit new O-ring (1) to degassing tube connection (2).







IMPORTANT:
After an accident, the high-voltage battery unit must be subjected to a visual inspection.
Observe inspection criteria for high-voltage battery unit after an accident.







Replacement:
Perform vehicle programming and encoding.







Replacement:
Connect BMW diagnosis system.
- Service function
- Powertrain
- Hybrid car
- High-voltage battery unit
- Starting up the high-voltage battery unit







Recycling:
Pay attention to the recycling instructions in the information bulletin for the high-voltage battery unit.
Information bulletin for high-voltage battery unit is stored in the Aftersales Assistance Portal (ASAP).