Notes on repair of high-voltage battery unit (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)

Various organizational prerequisites need to be fulfilled before the repair of a high-voltage battery unit is permitted and can be carried out in an expedient way. These prerequisites concern both, the commercial company and the service employee.

The repair of a high-voltage battery unit is intended to be carried out exclusively by commercial companies featuring the service format BMW i Service Extended Battery or BMW i Service Full.

A commercial company featuring the service format BMW i Service Basic is able to remove and install a high-voltage battery unit but cannot perform any repair work on or in the high-voltage battery unit. If a repair is required according to the test schedule in the diagnosis system, the vehicle or the high-voltage battery unit must be transported to a commercial company featuring the service format BMW i Service Extended Battery or BMW i Service Full. The repair is to be carried out in such a workshop.

The commercial company must make available the required special tools and a suitable workbay for the repair.

The most important special tools are the following: 

• Mobile lift table MHT 1200 + set of adapters to remove and install the high-voltage battery unit
• Charger for cell blocks of high-voltage battery unit
• Diagnosis system for the repaired high-voltage battery unit
• Lifting tackle to remove and install cell blocks
• Panel wedges made of plastic to remove clips within the high-voltage battery unit
• Lifting traverse for the complete high-voltage battery unit
• High-voltage barrier tape
• Yellow cones relating to high-voltage recommended

Only service employees being qualified for the repair of the high-voltage battery unit may carry out this procedure.

This includes training for "experts for work on high-voltage-intrinsically safe vehicles".

Before removing and opening the high-voltage battery unit, troubleshooting is to be carried out by means of the relative diagnosis system using an appropriate scan tool. Only if determined by the test schedule and if the prerequisite "no mechanical damage on the outside" is satisfied, the high-voltage battery unit may be opened and the faulty component identified by the test schedule can be replaced. No other repair work relating to the high-voltage battery unit than the replacement of faulty components is planned.

It is essential to observe the operational steps specified in the repair instructions very precisely in order to carry out the replacement of a faulty component. The use of the special tools listed therein is absolutely essential as well.

• The first step after opening the housing cover to repair the high-voltage battery unit is a visual inspection for mechanical damage.
• A thorough visual inspection of the components inside the working area is required during and/or before and after every operation. When removing one component, all other involved components being accessible need to be checked for damages. If the housing or other internal high-voltage components are damaged, a qualified electrician or Technical Support must be contacted. All repair works relating to the high-voltage battery unit must be stopped immediately for safety reasons
• Check the correct latch mechanism of the connector of the insulation monitoring line at the control unit of the high-voltage battery unit. If this is not fully locked, an isolation fault may not have been detected.
• The separation of the high-voltage cable between the two cell modules mounted on the inside of the housing (across from the connection side of the high-voltage battery unit) is to be always carried out before working on the opened high-voltage battery unit. This procedure ensures the interrupt of the series connection (additional safety)
• The workbay required for the repair of the high-voltage battery unit must be clean (free of grease, dirt and swarf), dry (no leaking fluid) and free of flying sparks. Therefore, avoid close vicinity to areas intended for cleaning of vehicles and to workbays intended for repair work relating to the body. Use movable walls for separation, if needed
• High-voltage barrier tape is required to secure the workbay against unauthorized access (insufficient qualification, customers, visitors, etc.). It is also required in case the high-voltage intrinsic safety is not established or the status is not determined yet. Placing yellow cones with lightning bolt to indicate high-voltage when leaving the working area is recommended
• Do not use tools or other objects with pointed and sharp blades/edges when working on high-voltage components or high-voltage cables and/or in their close vicinity. Diagonal cutting pliers, knives etc. are prohibited. Cable straps inside the low-voltage wiring harness may be opened by means of diagonal cutting pliers

  Allowed:  Plastic wedges

• Cable straps relating to high-voltage cable may not be cut open. Damaged clips remain on the high-voltage cable. The remaining, damaged clip must be pushed to a position on the high-voltage line where the clip can not rub. A new clip must then be installed
• Defective or damaged high-voltage cables must be made unusable to ensure they are not reused
• No tools must be forgotten inside the high-voltage battery unit. Check whether all tools are present in the tool box before closing the housing cover
• It is absolutely essential to remove all small parts/screws that fell into the high-voltage battery unit. The use of magnetized screws is generally recommended in order not to lose any screws in the high-voltage battery unit during the repair
• When interruptions of work occur: Secure housing cover against unintended opening by screwing in several screws. Enclose the working area by means of high-voltage barrier tape
• Due to the very slim construction of the radiator, the risk of damage during disassembly and installation is high. Careful handling is absolutely necessary as the cooling of the cell blocks may not be guaranteed when the radiator is damaged (bent, dented). The consequence is a major loss of the electrical range and of the power of the vehicle. In extreme cases, even a breakdown may occur
• Very careful handling is necessary when disconnecting and connecting the insulation detector line at the control unit of the high-voltage battery unit (safety box coming) since high-voltage is present in the thin orange lines. Do not pull on the lines (e.g. to unplug the connector etc.)! The connector must be locked securely when plugged in
• Make sure the plastic lids of the modules are not removed when working on the cell modules (loosing screws, raising and lifting...). The live cell contacting system is located thereunder. Continuing to work with the lid being removed is not permitted. A qualified electrician or Technical Support must be contacted
• A schematic diagram with limiting sample examples in the training is necessary to get to know the limits. These show when the further work for the "experts for intrinsically safe vehicles" is no longer possible due to absent intrinsic safety, and the Technical Support or a qualified electrician must be contacted
• Remove residual moisture and coarse contamination around the lid of the high-voltage battery unit before beginning the disassembly
• Clean gaskets and sealing surfaces (venting unit, high-voltage connector, signal connector, radiator connection) with a specified cleaning agent before reassembly
• If contamination is present in the high-voltage battery unit, check the cause and carefully clean the affected areas

  Approved cleaning agent: 

  • Spirit
  • Windscreen cleaner
  • Glass cleaner
  • Distilled water
  • Vacuum cleaner with plastic top
• Visual inspection for contamination and damage of housing as well as of connections and degassing unit when installed (underfloor). A damaged diaphragm within the venting unit may indicate damaged storage cells. In this case, special carefulness is required when checking and opening the high-voltage battery unit
• Electrolyte

  The majority of the electrolyte is a mixture of lithium-nickel-manganese-cobalt oxide in bound state The quantity of free electrolyte in the high-voltage battery unit is very small. It is a noxious and irritant fluid. Absolutely avoid direct contact of skin with leaking fluid as acid burns may occur. In case of contact with eyes or skin, flush with plenty of clear water and consult a doctor immediately. Burning or evaporating electrolyte is also hazardous. CAREFUL: do not inhale! Ensure sufficient fresh air supply. If breathing ceases, apply artificial respiration and immediately consult a doctor. Notify fire brigade in case of fire. Clear the area immediately and make accident scene safe. Attempt to extinguish the fire without putting persons in danger and use suitable extinguishant, e.g. water

• The high-voltage battery unit is a component of large dimensions and heavy weight. Only the combination of the housing and the cell blocks mounted therein provides the high-voltage battery unit with complete stability (rigidity), as required for driving. Therefore, it is necessary to ensure that the housing is positioned on the relative mounting/adapter of the lifting table during replacement and fixation of cell blocks. In this way, one can prevent the housing from bracing during the repair work and ensure the high-voltage battery unit is not installed in the BMW 101 in this condition
• It is extremely important to enter the serial numbers and the installation positions of the replaced components in the SME via the testing device, as well as to carry out the transmission into the diagnosis system. Otherwise, the new installation position will be assigned automatically by the SME. The consequence is an incorrect location data, as the SME does not set correct positions. For a replaced repair of the high-voltage battery unit, the diagnosed faults for the incorrect installation position will be displayed. The consequence is that replacement is done at the wrong location
• In diagnosis, it is not possible to enter the serial numbers of the cell supervision circuits. The serial numbers are transmitted from the cell supervision circuit to the SME using the CAN bus. The SME then sets a corresponding position assignment. This assignment is not always fault-free. That is why the serial number and installation position of the exchanged cell supervision circuit must be checked in the diagnosis after completed repair. If the positions do not match, a position change can be performed with diagnosis. A new serial number of a cell supervision circuit is not entered
• Attention:   Do not use powered wrenches as the screws/threads located in the high-voltage battery unit may break due to the low torques!
• The seal must be replaced every time the housing cover is removed to guarantee tightness of the high-voltage battery unit
• The screws are thread-tapping, so pre-insert them manually before tightening them with a tool. Otherwise, the threads of the lower housing section may be damaged!