General Electrical System - Repair (G30) (1 Of 3)

• 61 00 General Vehicle Electrical System, Test
  • Information on removing, connecting and changing the battery (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Notes for disconnecting and connecting the vehicle battery (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Notes on handling optical fibres (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Notes on handling the high pressure cleaner (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Notes on handling wiring harnesses and cables (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Parking-residing-driving (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Repairing airbag cables (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Safety information on handling hybrid cars (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Safety instructions for handling vehicle battery (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Programing/encoding the control unit(s) including deletion of fault memory (After vehicle test) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Encode/program control unit(s)
• 61 12 Auxiliary Cable
  • Information on intelligent battery sensor (IBS) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • 61 12 002 Replacing positive battery cable (safety battery terminal) (From battery to rear B+ power distribution box) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Replace positive battery cable
  • 61 12 013 Replacing the battery earth lead (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Remove battery earth lead
    • Install battery earth lead
  • 61 12 013 Replacing the battery ground lead (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Remove battery ground lead
    • Install battery ground lead
  • 61 12 018 Removing and installing/replacing positive battery cable starter motor generator - remote positive terminal (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing the positive battery cable for the starter generator with remote positive terminal
    • Installing the positive battery cable for the starter generator with remote positive terminal
  • 61 12 451 Replacing the high-voltage cable between electrical machine electronics and high-voltage battery unit (530e PHEV 2018-2020, 530e xDrive PHEV 2018-2020)
    • Removing the high-voltage cable
    • Installing the high-voltage cable
  • 61 12 460 Remove and install/replace high-voltage charging socket (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Remove the charging power socket
    • Install the charging power socket
  • 61 12 472 Removing and installing/replacing the high-voltage wiring harness for KLE - EME (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Removing high-voltage connection for electrical machine (vehicle underbody)
    • Removing the high-voltage connection for electrical machine
    • Detaching cable bracket
    • Tightening cable bracket
    • Installing high-voltage connection for the electrical machine
    • Installing high-voltage connection for the electrical machine (vehicle underbody)
• 61 13 Plug Connection, Terminal
  • Butt connector for repairing a plug connection (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Circular connector, 13-pin, system D2.5 (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Connector housing, LCC contact (load current contact) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Crimping annular contacts (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Crimping Micro Power Quadlock contacts (MPQ) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Crimping Micro Quadlock System contacts (MQS) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Crimping of NanoMQS contacts (MQS) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Cutting, strip insulation and crimping optical fibres (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Cutting to length and stripping insulation from cables (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • In-line connectors, 24-/44-pin, Hybrid System MQS/MPQ (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Inline connectors, 6-, 8-pin, System MQS (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Inline plugs, 2-pin, System MPQ 2.8 (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • In-line plugs, 2-pin, System MDK 3 plus 2.8 (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Inline plugs, 3-, 6-pin, System Elo-Power 2.8 (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Inline plugs, 4-, 10-pin, System Elo (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Socket housing (radio connector), Hybrid System MQS/MPQ (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Socket housing 42-, 43-, 46-pin, Hybrid System MQS/MPQ (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Socket housings, 2x21 -, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo Power (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Socket housings, 5-pin, 8-pin, System MQS/MPQ (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Special tools for wiring harness repairs (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Unlocking and disconnecting different plug connections (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • Unlocking and disconnecting various plug connections in electrical and hybrid vehicles (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • 61 13 250 Removing and installing separating element for integral active steering (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing the separating element
    • Installing the separating element
• 61 14 Power Distribution, Power Connection Points
  • 61 14 010 Remove and install/replace power distribution box (Luggage compartment) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing the rear power distribution box
    • Installing the rear power distribution box
  • 61 14 035 Rem. & install/replace power distribution box front positive battery cable (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing the power distribution box of the positive battery cable at the front
    • Installing the front power distribution box
  • 61 14 035 Rem. & install/replace power distribution box front positive battery cable (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Removing power distribution for front positive battery cable
    • Install the front power distribution box
  • 61 14 040 Removing and installing/replacing rear power distribution box positive battery cable (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing the low power distribution box
    • Installing the low power distribution box
  • 61 14 041 Removing and installing/replacing rear power distribution box positive battery cable (rear right luggage compartment trim panel) (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Remove power distributor on the rear positive battery cable
    • Installing the power distribution box for the positive battery cable at the rear
• 61 20 Battery
  • Notes on AGM battery (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • 61 20 503 Vehicle battery - closed-circuit current monitoring (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
  • 61 20 900 Disconnecting and connecting battery earth lead (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Remove right cowl panel cover
    • Disconnecting the negative auxiliary battery lead in the engine compartment
    • Disconnecting the negative battery cable of the 12-V lithium-ion auxiliary battery
    • Removing the luggage compartment floor trim panel
    • Disconnecting the battery earth lead for the active steering
    • Disconnecting the negative battery cable of the system battery
    • Connecting the negative battery cable of the system battery
    • Connecting battery earth lead for active steering
    • Installing the luggage compartment floor trim panel
    • Connecting the negative battery cable of the 12-V lithium-ion auxiliary battery
    • Connect the negative battery lead of the auxiliary battery in the engine compartment
    • Install the right cowl panel cover
    • Activating the 48V electrical system
  • 61 20 900 Disconnecting and connecting battery ground lead (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Remove flap in luggage compartment trim panel on right
    • De-energize the high-voltage system
    • Check that no voltage is applied
    • Disconnecting the negative battery cable (starter unit battery)
    • Remove the rear luggage compartment floor covering
    • Removing the storage tray
    • Disconnecting the negative battery cable of the system battery
    • Connecting negative battery cable of the system battery
    • Installing the storage tray
    • Install the rear luggage compartment floor covering
    • Connecting the negative battery cable (12 V battery)
    • Activate high-voltage system
    • Install flap in right luggage compartment trim panel
  • 61 20 908 Running vehicle battery "power reset" (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Carrying out a voltage interruption of the 12-V battery
• 61 21 Battery With Holder
  • 61 21 003 Removing and installing the 12-V dual storage battery (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing 12 V dual storage system
    • Install 12-V dual storage battery
  • 61 21 004 Replacing the 12-V dual storage battery - registering with battery exchange- (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing 12V dual storage system
    • Remount the ventilation elbow
    • Install 12-V dual storage battery
  • 61 21 006 Removing and installing 48V battery (with holder) (540i 2017-2022, 540i xDrive 2017-2022)
    • Removing the 48 V battery
    • Installing the 48 V battery
  • 61 21 007 Replacing 48V battery, including registering battery swap (540i 2017-2022, 540i xDrive 2017-2022)
    • Removing the 48 V battery
    • Remounting the 48-volt battery
    • Installing the 48 V battery
  • 61 21 010 Removing and installing vehicle electrical system battery (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Remove vehicle battery
    • Install vehicle battery
  • 61 21 010 Removing and installing the vehicle battery (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Remove vehicle battery
    • Install vehicle battery
  • 61 21 017 Replacing vehicle battery - registering with battery replacement- (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Remove vehicle battery
    • Install vehicle battery
  • 61 21 017 Replacing vehicle battery - registering with battery replacement (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Remove vehicle battery
    • Install vehicle battery
  • 61 21 028 Charging battery (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Charging battery
  • 61 21 028 Support voltage of the vehicle electrical system/recharge vehicle electrical system battery (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Charging battery
  • 61 21 065 Removing and installing vehicle electrical system support battery (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing vehicle electrical system support battery
    • Installing the vehicle electrical system support battery
  • 61 21 070 Replacing the vehicle electrical system support battery - including battery replacement registration - (530i 2017-2022, 530i xDrive 2017-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Removing vehicle electrical system support battery
    • Installing the vehicle electrical system support battery
  • 61 21 075 Removing and installing starter unit battery (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Removing the starter unit battery
    • Installing the starter unit battery
  • 61 21 085 Removing and installing the 12-V lithium-ion auxiliary battery (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Replacing the 12-V lithium-ion auxiliary battery
    • Installing the 12-V lithium-ion auxiliary battery
  • 61 21 086 Replace 12-V lithium-ion auxiliary battery - register with battery replacement - (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
    • Replacing the 12-V lithium-ion auxiliary battery
    • Installing the 12-V lithium-ion auxiliary battery
  • 61 21 090 Replacing starter unit battery - including registering battery change (530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022)
    • Removing the starter unit battery
    • Installing the starter unit battery