Wholesale BMW i3 Battery High-Voltage Cable Harness – The $220 Lifeline Behind “Sudden Power Loss” in 1 in 7 DIY Battery Swaps (Now Available in Bulk with OEM-Certified 600V Insulation & HVIL Integrity)
“A technician in Oslo installed a used 62kWh battery into a 2020 BMW i3—only to have the car shut down mid-drive on the E6 highway.
No warning. No error codes at first. Just total propulsion loss.
After towing, diagnostics revealed an open High-Voltage Interlock Loop (HVIL).
He traced it to the high-voltage cable harness: the previous owner had spliced in a non-OEM connector that didn’t fully engage the HVIL pin.
Under vibration, the interlock signal dropped—and the BMS killed power instantly.
He replaced it with a CNS-sourced BMW i3 Battery High-Voltage Cable Harness, and the car ran flawlessly for 8,000 km.”
If you replace or rebuild BMW i3 battery packs, you know that the high-voltage cable harness isn’t just a power cord—it’s a safety-critical system integrating power delivery, interlock logic, and thermal monitoring.
Yet this essential assembly is often substituted with:
- Generic EV cables lacking proper HVIL circuitry
- DIY-spliced connectors that compromise sealing and alignment
- Non-certified insulation rated below 600V, risking dielectric breakdown
- Incorrect length or routing, straining connectors during pack installation
The consequence? Sudden shutdowns, failed safety inspections, and worst-case scenarios involving arc flash or fire—all from a harness that looked “good enough.”
CNS BATTERY now offers Wholesale BMW i3 Battery High-Voltage Cable Harness—fully engineered to OEM electrical, mechanical, and safety standards, with integrated HVIL, certified insulation, and factory-validated terminations for plug-and-play reliability.
Our BMW i3 Battery High-Voltage Cable Harness features:
- ⚡ 600V DC rating with double-layer XLPO insulation—exceeds BMW GS 95024 requirements
- 🔒 Integrated HVIL loop: Hardwired continuity from pack connector to vehicle interface—no bypasses
- 🔌 OEM-style connectors: Exact match to Tyco/TE AMP+ series with IP67 sealing and positive lock
- 🌡️ -40°C to +150°C operational range: Stable under Nordic winters and desert summers
- 📦 Bulk packaging: Individually coiled, labeled by model (45/50/62kWh), and shipped with QC certificate
Designed for all liquid-cooled BMW i3 models (2017–2021), connecting the battery output to the junction box or inverter.
Why This Harness Is Your First (and Last) Line of High-Voltage Safety
The BMW i3’s high-voltage cable harness does three non-negotiable jobs:
- Deliver 400V+ power with minimal resistance and zero arcing risk
- Maintain HVIL continuity—a broken loop = instant power cutoff
- Seal against moisture, dust, and coolant at both ends
A compromised harness doesn’t just fail—it triggers failsafes that strand drivers or, worse, fails silently until catastrophic.
“We used a ‘universal’ HV cable once. Passed initial test—but failed MOT due to missing HVIL. Cost us €400 in rework. Now we only use CNS. Their harnesses pass inspection every time.”
— Nordic EV Solutions, Oslo
Built for Professionals Who Treat High Voltage with Respect
- Bulk pricing: Save up to 40% on orders of 150+ units
- 100% end-of-line tested: Every harness undergoes dielectric strength (2.5kV AC), HVIL continuity, and IP67 leak testing
- Material traceability: Insulation and connectors sourced from BMW-approved suppliers
- Global compliance: Meets ISO 6722-1, LV216, ECE R100, and UL 2237 for EV high-voltage cables
Ideal for battery installers, fleet depots, and certified repair centers who understand: in high-voltage systems, there are no second chances.
Frequently Asked Questions: Wholesale BMW i3 Battery High-Voltage Cable Harness
Q: What’s the conductor size?
A: 50mm² tinned copper—matches OEM current capacity (up to 400A peak).
Q: Does it include temperature sensors?
A: No—the HV harness carries only power and HVIL. Temperature signals run through the low-voltage harness.
Q: Can I reuse the original harness with a new pack?
A: Not recommended. Repeated bending, heat cycles, and connector wear degrade insulation and contact integrity.
Q: Is it compatible with aftermarket battery packs?
A: Yes—if your pack uses standard BMW i3 high-voltage output geometry and HVIL pinout (which CNS packs do).
Q: What’s the warranty?
A: 24 months—because we treat this as a core safety component, not just a cable.
In EV High-Voltage Systems, Trust Flows Through Certified Conductors
And with CNS, every amp delivered comes with peace of mind.
Don’t Risk Stranding Your Customers—or Failing Inspection—with Substandard Cabling. Equip Every Installation with OEM-Spec BMW i3 Battery High-Voltage Cable Harnesses That Guarantee HVIL Integrity, Dielectric Safety, and Plug-and-Play Reliability. Order in Bulk and Ensure Every Pack You Install Powers Confidently, Safely, and Without Compromise.
Because when the road demands power, your harness shouldn’t hesitate.
Secure Your Bulk Supply Today—Specify Quantity and i3 Model Range, and Receive Factory-Certified, Safety-Tested High-Voltage Cable Harnesses Ready for Professional, Code-Compliant BMW i3 Battery Installations:
👉 https://cnsbattery.com/ev-battery-home/ev-battery-contact/