BMW 3 Owners & Service Manuals

BMW 3: High-voltage cables

The high-voltage cables connect the high-voltage components and are identified by orange cable sleeves. The manufacturers of hybrid cars have agreed on a uniform identification of the high-voltage cable with the orange warning color. An overview of the high-voltage cables used in the G20 PHEV is provided here.

G20 PHEV, high-voltage components and high-voltage cables

  1. Electric Motor Electronics (EME)
  2. High-voltage battery unit
  3. Convenience charging electronics (KLE)
  4. Charging socket
  5. Electrical heating
  6. Electric A/C compressor (EKK)
  7. Electric motor

High-voltage cables must not be repaired. In the event of damage, the high-voltage cable must be fully replaced!

Bending radius of a high-voltage cable

  1. High-voltage cable
  2. Bending radius must be greater than 70 mm

The high-voltage cables must not be excessively bent or kinked The bending radius must not be less than 70 mm Excessive kinking/bending of the high-voltage cable may result in damage to the cable shielding and thus to an isolation fault in the high-voltage vehicle electrical system.

Work on live high-voltage components is expressly prohibited. Prior to every operation which involves a high-voltage component, it is essential to disconnect the high-voltage system from the voltage supply and to secure it against unauthorized return to service.

  1. Charging plug is not connected to the vehicle.
  2. Enter the PARK vehicle condition (e.g. by holding down the media button of the head unit).
  3. Wait until the vehicle enters "sleep mode" (identifiable by the fact that the START-STOP button is not illuminated).
  4. Open high-voltage safety connector.
  5. Secure the high-voltage system against restarting at the high-voltage service disconnect.
  6. Activate PAD mode (e.g. by operating the START-STOP button three times within 0.8 s).
  7. Wait until the Check Control message "High-voltage system switched-off" is displayed in the instrument cluster.
  8. Enter PARK vehicle condition.


     Removing the flat high-voltage connector

    Bridge for high-voltage interlock loop Before the high-voltage connector can be disconnected, the bridge for the high-voltage interlock loop must first be removed. The bridge closes the circuit

     Removing the round high-voltage connector

    The following figures show the approach for releasing the round high-voltage connector, as used for example on the high-voltage cable from the Electrical Machine Electronics to the convenience charg

     Connection for potential compensation lines

    The isolation monitoring determines whether the isolation resistance between active high-voltage components (e.g. high-voltage cables) and ground is above or below a required minimum value. If the i


     Hands-free system

    General information Calls that are being made on the hands-free system can be continued on the mobile phone and vice versa. From the mobile phone to the hands-free system Calls that were begun outside of the Bluetooth range of the vehicle can be continued on the hands-free system with standby state

     Rear collision preparation

    Concept The system reacts to vehicles approaching from behind. General information Two radar sensors in the rear bumper monitor the area behind the vehicle. When a vehicle approaches from the rear at a certain speed, the system responds as follows: Active Protection: when a collision seems to b

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