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BMW i3 Charge Module Replacement: Proper Repair Procedures

Working on modern electric vehicles, like the BMW i3, requires more than just technical skill, it requires specialized knowledge and continuous education. At our service centre,  (Techmax Auto) we pride ourselves on staying ahead of the curve by regularly attending training sessions and certification courses focused on the vehicles we work on every day. This dedication ensures that we provide our customers with the highest quality service, using the most up-to-date techniques and tools available.

BMW i3 REX

A great example of this is the replacement of the KLE (charge module) in a 2015 BMW i3 REX. The process requires careful handling of the high-voltage system, which operates at 380 volts. Disconnecting this system properly is crucial to avoid any potential damage. There’s a special procedure to follow when disconnecting the high-voltage system, as simply pulling the safety disconnect connector may cause significant damage to the high-voltage relay (master switch). This is due to the risk of arcing, which can damage the switch’s contactors.

What makes this process even more critical is that the system only allows for a limited number of disconnects before the high-voltage switch can fail completely. Once the switch is damaged, it may no longer work, leaving the system inoperable. That’s why we make it a priority to stay up-to-date on the best practices in the industry. We attend specialized courses that teach the proper procedures, and we ensure that our technicians receive factory training materials for the best possible results.

BMW Diagnostics

In addition to our technical knowledge, we also invest in the best diagnostic tools available. We use factory-specific hardware and software to ensure that we can update and re-flash all onboard computer systems. By connecting directly to the manufacturer’s server, we ensure that all software is the latest version, giving our customers the most reliable and efficient performance from their BMW i3.

BMW i3 Charge Module Replacement Photos

If you have any questions or need assistance with your BMW, don’t hesitate to reach out. We’re here to help with any of your European vehicle service needs.

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(1) 905.795.0419.

Related Article: BMW Hybrid Repair

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Factors To Consider When Buying Your Next Car

Internal combustion engine, Hybrid, or Electric Vehicles: Which one Should You Invest in Next?

We are living in interesting, changing times where we have an environmental impact. Knowingly or unknowingly we do make a difference and especially for our kids in the near future. The most intriguing fact is I found many of my clients buy the wrong car for their intended use or intended purpose. This in many cases results in premature wear and excessive cost over time. It is a very complex problem as everyone has a different need and especially after the pandemic perhaps a different criteria for their daily needs. We don’t have a system where you can just ask AI what should I buy as my next automobile,  here are my needs and this is what I do daily.

What do you think? Should I buy an electric (BEV) or a hybrid (PHEV) or a mild hybrid, or perhaps a traditional Internal combustion engine (ICE) vehicle for my daily needs?

First, let me briefly summarize the main differences between electric (BEV), hybrid (PHEV), and internal combustion engine (ICE) vehicles:

Electric vehicles (EVs) run solely on electricity stored in batteries that can be recharged from an external power source. They have zero tailpipe emissions, high efficiency, low maintenance costs, and instant torque. However, they also have higher initial costs, limited range, longer charging times, and dependence on charging infrastructure.

Hybrid vehicles (PHEVs) combine an electric motor and a gas engine that can work together or separately to power the vehicle. They can run on electricity, gas, or both, depending on the driving conditions and battery level. They have lower emissions, better fuel economy, and more flexibility than ICE vehicles. However, they also have higher initial costs, lower performance, and more complexity than EVs or ICE vehicles.

Internal combustion engine (ICE) vehicles run on gasoline, diesel, or other fossil fuels that are burned in an engine to produce power. They have lower initial costs, longer range, shorter refueling times, and more availability than EVs or PHEVs. However, they also have higher emissions, lower efficiency, higher maintenance costs, and more noise and vibration than EVs or PHEVs.

There are more factors to consider, when you purchase your  next vehicle.

Your driving habits: How often and how far do you drive? Do you drive mostly in the city or on the highway? Do you need a lot of power or speed? Do you face a lot of traffic or congestion?

Your budget: How much can you afford to spend on the purchase, operation, and maintenance of your vehicle? How much do you value fuel savings, tax incentives, or resale value?

Your environmental impact: How much do you care about reducing your carbon footprint, air pollution, or noise pollution? How do you source your electricity or fuel?

Your convenience: How easy is it for you to access charging stations or gas stations? How much time are you willing to spend on charging or refueling? How comfortable are you with using new technology or features?

I listed above a few, factors to consider when you buy a new car, however I can talk about this subject for hours. Contact me for more.

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(1) 905.795.0419.

 

Related:
Proper Maintenance of European Import Cars

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Lithium Ion Battery in your BMW

We are happy to announce that now we can recover most dead Lithium ion or LiPoe batteries for BMW, Porsche and alike. The issue at hand is that, if the owner goes on holiday for extended periods, like 3 weeks or more, if the vehicle is stationary for an extended period of time, it may lose voltage entirely in the Lithium ion battery.

Modern European Cars & Lithium Ion Battery

This will introduce a no-start condition: the vehicle will start with a boost but will not start again thereafter. Most modern European cars will have a Lithium Ion battery as a primary or secondary battery, if dual battery equipped. These batteries became more prevalent after 2018, although BMW M model cars had it already from 2016 onward.

Lithium Ion Battery Charger

In case you want to put your vehicle into storage or intend to park it for over 3 weeks, you will need to install a specific Lithium ion battery charger, either from the manufacturer or from CTEK.

We can potentially install one for you permanently.  All you have to do is plug it in, and it will remain fresh once you disconnect it. Furthermore, with some care and common sense, we can most likely revive it for you. Therefore, you will not need to replace it just because the stationary voltage drops too low.

Please note that there is an internal relay within the Lithium ion battery pack. It will suddenly disconnect the positive battery terminal if the residual voltage drops below 10.5 volts.

Do you have any questions, how may we help? Give us a call to:
(1) 905.795.0419.

Related:

BMW Hybrid Repair – Hybrid Maintenance

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Should I Buy an Electric Car or Not

The great conundrum is, should I buy an electric car or not?

The movement towards electrification is on us, we are told all around us. Correct?! Electric cars are not for everyone yet, due to lack of proper affordable and convenient infrastructure in general. The electric car prices are still too high, especially with current interest rates.

Electric Car Sales Are Stalling

Not so fast, presently the electric car sales are stalling, dealers are sitting on piles of unsold electric cars. What is really happening, what will happen to all the mandated percentage of electric cars that must be sold across the board?

Consider this, your entire life or civilization is supported by oil across the board. The food you eat was raised, grown, planted and harvested by machines which are fueled by diesel or gasoline.

Tractors Running on Diesel

To grow food you need soil, then you need potash which needs to be mined then transported to the field.  Then you need some additional fertilizer which is made from natural gas. The field needs to be plowed by tractors, seeds planted. Then if all goes well it needs to be harvested by tractors running on diesel.

When all is said and done then the harvest has to be transported from the farm to the factory for further processing, and from there has to be transported to your favorite grocery store.

The Human Civilization Based on Crude Oil

When you look deep inside our civilized world, the entire human civilization, production, transportation is all based on the mighty crude oil, on average 20 million barrels a day!

Humanity built our life, our society around the availability of crude oil and its derivatives for the last hundred years or so. Therefore it will take at least two decades to switch over to an alternative source of energy.

Probably en mass by 2050 perhaps due to lack of infrastructure, lack of charging and lack of available materials to manufacture the required high capacity batteries.

Reasonably Priced – Not Yet

This whole conversion has to be reasonably priced, widely available and convenient to use. Otherwise we will have even more out priced electric cars on dealer’s lots to be sold at enormous incentives.

Did you know a lithium mine takes at least a decade to put into production? Then you need to refine that lithium salt which is currently very energy intensive, and most of it done in China. The mining equipment is all running on diesel, including the generators. The lithium has to be shipped by bunker oil on gigantic boats across the ocean. After the refinery it must be shipped again to another destination for final manufacturing. Then the batteries have to be shipped to the auto manufacturer. When all said and done the electric vehicle must be transported to the dealership with a diesel  truck of course.

 Electrification Will Take Decades

Then for final words, look around. There is a lot of plastic around you, all made from crude oil. I’m not a skeptic, I like to think realistically, electrification will take decades, so hang on to your chair so to say it will be a bumpy ride occasionally.

I am Driving Hybrids, Should I buy an Electric Car or Not?

Mind you I have been driving hybrids for over 9 years and to boot I commute to work by bicycle daily.

Related:

Hybrid vehicle repair, service  and preventative maintenance

Hybrid BMW repair Hybrid BMW service

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Brake Sets For German Import Cars

Give me a break, will you?

We often use a lot’s of brake components rotors and pads genuine or reputable German “aftermarket” except you may not know all the aftermarket rotors and pads has to live up to a strict European standard called the ECE R-90. It states the fact, it must be at least as good as the genuine components (at times could be better! This applies to only European made brake components. A brake pad is a brake pad, right?! In short nope!

After Market German Brake Pads

This was legislated back in 2018, some manufacturers complied with this even before that. The E designation is a compliance approval which says the brake component is build after the genuine components performance requirements at minimum therefore it must be as good but it could be better. This ensures a minimum standard across the board.

Going deeper into the subject, there is a lot of interesting information you can find, for instance Pagid (TMD friction) does exceed the original genuine brake pad specifications, ( see page 6 or the picture provided with chart) according to them. Knowing this gives us some comfort talking to our clientele, in turn you’re not installing an inferior product on their beloved fancy automobile if they choose other than genuine braking components. Suffice to say most often the manufacturer is a genuine OEM component manufacturer under contract.

Brembo Brake for your German Import Car

Brembo Break for your car? Read more about this on Brembo website.

Going one step further, I have seen a new legislation the pending Euro 7 vehicle emission regulation wants to reduce the brake particulate matter starting 2025 onward. I’m like jeee,  what a heck, don’t we have enough regulation already?!

Rest assured this politicians they never seize to amaze me with all the rules and regulations, if this keeps on going we will be back to horses and donkeys. I suggest to read it as you can be assured this will end up on our plate rather sooner than later. Additionally digging in there I found this interesting, there is a Spanish company called Rimsa, which is the most common supplier to the actual raw material of the said brake pads to most manufacturers.

That was quiet surprising as I thought brake pad friction material is a kind of a witchcraft, thought everyone has their own recipe to “cook ” their own concoction. Looking at some brake pad’s origins, makes sense now, it was manufactured in Spain, but often says only, Made in EU. You want to read on it more it’s here : 300 projects /30 countries/37 years their record.

If you’re interested in this subject, I highly recommend to read the New Euro Emission Regulations  in here.

Brembo Brake Pads

The range of Brembo brake pads offers more than 1,500 articles ECE R 90 approved. ECE R 90 certification is part of the 98/12/EC directive, applied and acknowledged by all European markets. The pads have a different abbreviation (E1, E2, E4…) depending on the country that has issued the certification. The certification is valid in all European countries.

The only reason I got Brembo in here, since offer some insight to this subject. I’m sure all the others do the same if you willing to dig deeper.

The conclusion,  there is way more to brakes and brake performance than you think . Give me a break is way more complex and progressing forward, going to be even more complex as time goes on .

Do you have any questions, how may we help? Give us a call to:
(1) 905.795.0419.

Related:

Brake sets for German import cars

Brake dust free brake pads

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Pre-winter Car Maintenance

This time of the year the days are getting shorter and the weather getting cooler. Most people start doing their pre-winter automobile maintenance, other than regular timely oil changes. If you drive in winter, you should have your winter tires ready for the oncoming season.

You should have your vehicle inspected before the snow starts to fall.

Don’t Hesitate – Prepare Your Car for Winter

Randomly we will find some surprises like a somewhat worn tire which looks just fine from the outside but it may hide a serious belt separation at the inside.

Like the BMW tire on the picture which was at the right front, unfortunately it was destroyed, because worn bushings and misalignment. The owner said he was driving it at 130 kph and felt OK. This could end up in a crash or cause a serious mishap while endangering others.

worn tiresTypes Of Services Offered by Techmax Auto

Tire safety and vehicle safety is your responsibility and is a serious matter, which should not be taken lightly. Always regularly check for excessive tire and suspension wear and correct it in a timely manner. It will save your tires, fuel and excessive wear and tear in the long term. There is no magic to having a safe vehicle, it should be second nature.

Whenever we do regular maintenance on any car, we do provide a visual comprehensive inspection on the car, with you as a car owner / driver safety in the forefront to get you to your destination.

Get Ready for Winter Driving Again

Don’t forget to clean your windshield drains from leafs this time of the year, or your electronics may go for a “swim” ! See pictures for partially clogged drains on a 3 series BMW.

Click on the thumbnail to view bigger photo.

Do you have any questions, how may we help? Give us a call to:
(1) 905.795.0419.

 

Related:

Time to think about winter driving again

Get Your BMW and Mercedes Benz Winter Ready

Mini Cooper pre winter check

More information on our  winter service.

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BMW Differential Repair

Commending Techmax Auto for an Outstanding Job on My BMW Differential Repair

Dear Techmax Auto Team,

I hope this email finds you in good health and high spirits. I am writing to express my utmost satisfaction and heartfelt gratitude for the exceptional work your team, specifically Atilla Jasszai, recently accomplished in repairing the differential of my 2009 BMW. The results have been nothing short of miraculous, transforming my driving experience into one that feels akin to gliding on clouds.

From the moment I brought my vehicle to your facility in Mississauga, I was impressed by the professionalism, expertise, and dedication displayed by Atilla Jasszai. He demonstrated an in-depth understanding of BMW mechanics and applied his skills to diagnose and rectify the issue promptly. I appreciate the thoroughness with which he approached the repair process, ensuring that no stone was left unturned.

The repair itself has far exceeded my expectations. The differential is functioning flawlessly, and the improvements in ride quality are truly remarkable. The smoothness and precision with which my BMW now handles the road are exceptional, thanks to Atilla’s meticulous workmanship and attention to detail.

In addition to Atilla’s technical prowess, I want to acknowledge the excellent customer service I received throughout the entire process from your staff members. They were friendly, attentive, and always willing to provide updates on the progress of the repair. Their commitment to transparency and clear communication, coupled with Atilla’s expertise, ensured that I felt involved and well-informed every step of the way.

I firmly believe that a job well done deserves recognition, and I wholeheartedly recommend Techmax Auto, particularly Atilla Jasszai, to anyone in need of automotive repairs, especially those concerning BMW vehicles. Atilla’s dedication to excellence, paired with his evident passion for his work, are truly commendable.

Once again, thank you, Atilla, and the entire Techmax Auto team, for your outstanding service. I am genuinely delighted with the results and cannot emphasize enough how much of a positive impact your expertise, particularly Atilla’s, has had on my driving experience. I look forward to entrusting my vehicle to Techmax Auto for any future automotive needs that may arise.

Wishing you continued success and prosperity.

Sincerely,

George Rajesh

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BMW M3 CSL Carbon Fiber Roof

I personally love innovation, especially creative innovation which contributes to the benefit of all drivers. Let me explain.

BMW has been working on trying to lower the center of gravity of their M cars with some innovative ways. Therefore they wanted to replace the roof of the vehicle (being the highest point of it by lowering the center of gravity) with a lightweight but strong component.  The obvious choice was aluminum but it’s not exactly the strongest material for that.

Then they figured carbon fiber has been used in motorsport extensively and in some ultra high end vehicle manufacturing but it’s cumbersome to make and gets expensive.  Then their engineering department got the assignment to develop the carbon fiber roof structure for the BMW M3 CSL in 2003 .

You need to know carbon fiber manufacturing is expensive because it’s a long tedious process. Multiple steps, a lots of time, a lot of energy required, which makes it a rather slow process and expensive to boot .

BMW came up with a clever solution: What if we combine some of the processes? This way we can reduce the time and effort required to make the lightweight but 5 times as strong as steel carbon fiber roof for the application.  Carbon fiber usually comes in large woven rolls and pre-pregged for ease of use. Then it gets applied to a mold in 5 to 6 layers each in a different direction and then it gets flooded with epoxy resin.

Next step is having all wrapped in a cloth which would soak up the excess resin and then the whole thing get wrapped in a plastic bag with suction ports attached to it.  After that,  it is put under vacuum, placed into an autoclave and gets baked for hours on end under pressure.

This entire process is essential to make strong but light carbon fiber components. The suction is required to remove any potential air bubbles and the entire thing is put under pressure in the autoclave for best results.

Once again, BMW came up with a clever idea.  They made 2 molds, a positive and a negative mold and put 6 layers of carbon cloth sheets over each other but not pre-preg just dry sheets in different  directions. Then squeeze the the sheets of carbon fiber between the mold and inject the resin. Then they bake the whole thing in a single but efficient process. They get the CFRP (carbon fiber reinforced plastic) which gets done in 20 minutes or less. Therefore this can be done efficiently and quickly with phenomenal results for the application fully automated.

The ready to install panel gets trimmed and cut with a high pressure water jet to make it precisely shaped and ready to glue in place in a very efficient manner.

Once they perfected this process we came to the next chapter. The i3 and the i8 BMWs’ life structures gets developed  with the same process. According to BMW  they saved 50% energy and 70% water for the equivalent sheet metal body panels.

Remember the initial process was developed for the 2003 BMW M3 CSL,  therefore BMW took 10 years to get into the partnership with SGL and build up a supply chain with every step on the way to ensure a near zero CO2 output for a full environmentally friendly process.

They actually build with SGL a carbon fiber manufacturing plant in by the largest electric dam at Moses lake, the Grand Coulee Dam.

Carbon fiber strain is an  extremely expensive process where you have to bake the high quality polimer at an airless space under very high heat to convert the molecules into carbon fiber.

The actual strains are woven into a cloth in at Wackesdorf Innovation Park and then shipped to Leipzig for final manufacturing and assembly.

The Leipzig plant was the first ever solar and wind only powered plant in the world. You could walk around without ear protection in there as well.

Any questions, how may we help? Contact us for more at:
(1) 905.795.0419

Related:

The New 2023 BMW M4 CSL with carbon fiber roof

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BMW Rear Differential Noise

The differential noise on your BMW is a typical whining noise, from the back of the car which is rather annoying on longer trips.

BMW E90 and BMW E83‘s Differentials

This is a relatively common occurrence on the BMW E90 and BMW E83 platforms. The issue at hand is the rear differentials are kind of a new design by deleting the tapered roller bearings to a multi row ball bearings to reduce frictional losses within the differential assembly.

This is a another angle to try to maximize the efficiency of the entire vehicle. Unfortunately the bearings randomly fail, due to metallic particles build up over time within the oil and having a “lifetime” oil doesn’t help.

There are no parts available to repair this noisy differentials in North America. Fortunately this is not the case in Europe, therefore we started refurbishing this noisy rear differentials by ordering the replacement parts, bearings from Europe.

Original Made in Germany Bearings for your BMW

Somehow the original bearings are not allowed to be sold in North America, BMW makes more money to sell a complete rear differential assembly, which is prohibitively expensive. We naturally do some modifications to ensure the replacement bearings will last much longer than the originals installed by the factory.

BMW differential
Visit our Facebook for More BMW’s  Differential Photos

What will happen if you ignore your BMW’s differential noise?

The differential noise is the result of damaged bearings, it’s imperative to replace the damaged final drive bearings or they could cause permanent damage to the internal components.

Please note, a damaged differential may lock up inadvertently causing loss of control essentially. A locked up differential potentially a scary thing, which may cause additional damage to other components, possibly rendering the vehicle stationary unable to move anywhere.

Any questions, how may we help? Contact us for more at:
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BMW Differential Repair | BMW Automatic Transmission Service

The lost art of repair versus replacing worn components.

BMW differential repairClick on the thumbnail to view bigger photo.

The complaint is on this fine 2008 X3 BMW the excessive differential noise. This is a relatively common occurrence unfortunately because the ball bearings develop a wear pattern from lack of maintenance (BMW lifetime fill). The fine metallic particles will get caught in the ball bearings and will make the bearings noisy.

Replacement Differential  for BMW Cost  Over $3,000

Please keep in mind, this proprietary bearings are not sold separately in North America but they’re available in Europe.  A BMW replacement differential is cost over $3,000, therefore it’s more economical to repair the existing one if only requires new bearings and seals.

Used BMW Differentials

bmw differential bearingsClick on the thumbnail to view bigger photo.

Used BMW differentials with low mileage are getting rare and a used differential could get noisy exhibiting the same symptom as the existing one.

BMW Differentials Repair

We fortunately found a supplier for BMW differentials replacement repair kit from the original manufacturer from Germany. This way we can reliably repair your existing rear differential assembly.

BMW Differential Assemblies

BMW differential being repairedClick on the thumbnail to view bigger photo.

We recommend a standard service interval at 50,000 kilometers, actually it’s the same as for the BMW M model’s differentials which makes perfect sense for reliable lifelong service.

I like to point it out most of the BMW differential assemblies has no actual drain plug, ditto for the transfer case, therefore we have to use a suction machine to remove the tired old fluid.

BMW Automatic Transmission Service

We also recommend to service BMW’s transfer case and the automatic transmission at regular one hundred thousand kilometers to ensure component longevity.

The same applies to the front differential assembly, as well in the case of a four wheel drive vehicle.

Proper timely maintenance does pay back, for instance our 2006 BMW 325i has 467,000 kilometers in, under our care since 2009, it speaks volumes about proper timely maintenance.

Any questions, how may we help? Contact us for more at:
(1) 905.795.0419

Related:

BMW Transmission Maintenance

Hybrid BMW Repair

BMW Hybrid Repair – Hybrid Maintenance

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