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[return to "BMW PHEV: Safety fuse replacement is extremely expensive"]
1. CraigJ+is[view] [source] 2025-12-05 06:22:04
>>mikela+(OP)
€4000 euros plus tax to replace the module that contains the fuse. Insane.

The ford transit custom PHEV costs £4500 to replace the timing belt. Access issues mean dropping the hybrid battery and parts of the sub frame. Compare with the mk8 transit, i've done the wet belt myself on that and it requires no special tools (well, i bought a specific crank pulley puller for £20) and can be done in a day on the driveway. I believe in some markets the replacement schedule is down to 6 years for the new phev due to all the wet belt failures on older models.

So far my favourite brand to work on has been Mazda, the engineering is very thoughtfully done with consideration for repairs.

I hear a lot of praise for toyota but it's from people who haven't worked on a car themselves rather than mechanics and they must be talking about toyotas from a bygone era because i'm not impressed with a 2019 corolla engineering at all, specifically various parts of the electrical system. I believe that was the most popular car in the world at that time.

Tesla is remarkably well done. Simplicity is under rated. So much so i bought one with the intention to keep for a looooong time.

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2. jinzo+8A[view] [source] 2025-12-05 08:00:39
>>CraigJ+is
Is it insane? I'm working in this field, and I know how quickly you can come up with such a number if you are BMW and you are deathly afraid that someone will get electrocuted while working on your car, driving it or rescuing someone in a crash. It's a safety and liability issue, where they go to great lengths to actually re-certify a battery after crash. The whole thing is setup so, that even the dummy electricians in an average BMW shop can safely certify that this battery is still safe. It's a lot easier to kill yourself (or someone else) when working on a EV Battery than wet belt. Also a lot harder to repair said battery than wet belt. And that goes for all EVs and manufacturers that actually care about people (Tesla, demonstrably does not).
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3. close0+KD[view] [source] 2025-12-05 08:31:51
>>jinzo+8A
The article and comment aren't debating whether the fuse plays an essential role. There's no reason to make the process of fixing the issue after a minor incident expensive, extremely convoluted, and very prone to error.

Making it a very complicated and expensive fix isn't what's saving your rescuer or mechanic from getting electrocuted while working around your car.

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4. gmueck+8F[view] [source] 2025-12-05 08:46:48
>>close0+KD
You seem to be ignoring the fact that the battery pack status after a crash is essentially unknown. It should go through a thorough and competently conducted safety inspection or it may kill someone in the future. Of course, this doesn't excuse extra red tape tacked into the procedure, but the core idea of an inspection is just unavoidable.
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5. close0+ZV[view] [source] 2025-12-05 10:00:14
>>gmueck+8F
> Of course, this doesn't excuse extra red tape tacked into the procedure

That's exactly it. I understand the importance of safety but reading the list of complaints I just cannot believe that safety is the key driver for the design decisions.

> ISTA’s official iBMUCP replacement procedure is so risky that if you miss one single step — poorly explained within ISTA — the system triggers ANTITHEFT LOCK.

> Meaning: even in an authorised service centre, system can accidentally delete the configuration and end up needing not only a new iBMUCP, but also all new battery modules.

> BMW refuses to provide training access for ISTA usage

Everything about this screams greed driven over-engineering. Since when are error prone processes and lack of access to information better for safety?

We live in a world where everyone justifies taking user hostile actions with some variation of "safety". Software and hardware are locked down, backdoored, need manufacturer approval to operate even when original parts are used, etc.

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6. jinzo+351[view] [source] 2025-12-05 11:16:31
>>close0+ZV
I won't go into details about 'training access for ISTA usage' - cause I don't know what exactly Vanja means by this - but generally speaking in EU BMW provides the easiest access from all OEMs for aftermarket repair. Everyone has to provide it by law, but BMW has the most straightforward way of registering/paying/using it. For sure not ideal, but far from really being problematic IMHO.

But other than that I mostly agree, I don't think that the over-engineering is greed driven - but the EU Manufacturers (but honestly, even other ones) have a really hard time with anything software based. Be it in car or outside of it. But BMW is far from the worst on that front.

P.S: VW ODIS original diagnostic is based on Eclipse :D

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7. gmueck+WP2[view] [source] 2025-12-05 20:02:49
>>jinzo+351
My experience with many German mechanical and electrical engineers is that they have a tendency to think of software like a magical cheap and malleable part on a BOM that can make their arbitrary design work. Especially the mechanical engineers like a nice little black box that they screw on and wire into their machine to make it go brrr once they turn it on.

That kind of thinking along with some calcification of organizational structures in/around R&D teams seems to be the cause for the rather dysfunctional software development at the German car companies. Software dev doesn't thrive in this environment.

Volkswagen probably had the right idea on paper when they created Cariad as a subsidiary software development company to isolate the devs, but then they ruined it by importing their own culture into it again.

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