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)
Attention!
Observe the following repair instructions for handling high-voltage plug connections:
- Damaged high-voltage plug connections must be replaced completely. Repair is not permitted.
- Dirt contamination must be removed before opening the plug connection.
Disconnect the Hirschmann high-voltage connector:
Press the lock (1) on the left and right on the connector in the direction of the arrow.
Pull off connector (2) in direction of arrow.
Attention!
Connector (2) is difficult to pull off.
In the event of damage to high-voltage connector (2), the complete high-voltage cable must be replaced!
Connect the Hirschmann high-voltage connectors:
Slide the connector (1) on in the direction of the arrow.
Disconnect the Kostal high-voltage connector:
Unlock and disconnect high-voltage interlock loop (1).
Push the lock (1) fully to the front.
Lift the connector (2) and remove it entirely
Attention!
Plug connection (3) is difficult to pull off.
The connector (2) must be completely pulled off the opposite housing in one step. Damage may be caused to contact protection if connector is only partly pulled off and then closed again!
Check the Kostal high-voltage connector and connection for damage:
Check the touch protection for damage and correct positioning (1).
If the contact protection (1) has been pushed to the bottom (2), the high-voltage connector must be refitted.
If contact protection (1) remains in bottom position (2) after reinstallation, the contact protection is faulty and the component must be replaced!
Check the high-voltage connector (1) for damage.
Connect the Kostal high-voltage connector:
Connect the connector (2) in one single movement to the counter-housing.
Push the lock (1) fully to the rear.
Attention!
Plug connection (3) must be correctly locked by lock (2), otherwise there is a risk of damage.
Connect the connector for the high-voltage interlock.
Three-phase high-voltage connector:
Connect and disconnect the connector straight.
Attention!
The system is designed to only offer limited protection against damage caused by connectors that are inserted at an angle.
Increased tilted connections will increase the connecting force and the risk of danger.
Disconnect the high-voltage connector from the high-voltage connection of the KLE:
Slide lock (1) in direction of arrow up to stop.
Press lock (1).
Open the lock (1) completely and disconnect the connector (2).
Connect the high-voltage connector to the high-voltage connection of the KLE:
Connect the connector (1) to the limit position and close the lock (2).
Attention!
Lock (2) must snap audibly into place.
The retaining lug of the lock (2) must be positioned completely under the lock (2).
Slide the lock (1) on to the stop in the direction of the arrow.
High-voltage connector on the high-voltage connection of the high-voltage battery unit:
Press down unlocking (1) in direction of arrow and pull off connector in direction of arrow (2).
Attention!
Contact protection is no longer provided in the event of a damaged connector housing.
In this case, contact technical support.
High-voltage connector on the cell module I01:
Press unlocking device (1) together and pull off connector upwards (2).
Attention!
Contact protection is no longer provided in the event of a damaged connector housing.
In this case, contact technical support.
High-voltage connector on the cell module (cell module connecting line):
Press unlocking (1) in direction of arrow and pull off connector in direction of arrow (2).
Attention!
Contact protection is no longer provided in the event of a damaged connector housing.
In this case, contact technical support.
