SIB 61 13 21 Recall 20V-601: High-Voltage Battery – 2020-2021 BMW 3 Series, 5 Series, 7 Series, X3 SAV, X5 SAV

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MODEL

E-Series Model Description Production Date
G01 X3 Sports Activity Vehicle – PHEV only June 3, 2020 – January 22, 2021
G05 X5 Sports Activity Vehicle – PHEV only June 6, 2020 – January 14, 2021
G12 7 Series Sedan – PHEV only March 16, 2020 – May 7, 2020
G20 3 Series Sedan – PHEV only March 5, 2020 – September 24, 2020
G30 5 Series Sedan – PHEV only March 4, 2020 – November 23, 2020

 

AFFECTED VEHICLES

Vehicles which require this Recall Campaign to be completed will show it as “Open” when checked either in AIR, the “Service Menu” of DCSnet (Dealer Communication System), ISPA Next or Warranty Vehicle Inquiry.

 

SITUATION

BMW AG is conducting a Voluntary Safety Recall (effective September 24, 2021) on certain Model Year 2020-2021 BMW Plug-In Hybrid-Electric (PHEV) vehicles that were produced between March 4, 2020 and January 22, 2021.   This is an expansion to recall 20V-601 from 2020.

The high-voltage battery may not have been produced to specifications.  When charging the battery, this could lead to a short-circuit and, in rare cases, a thermal event.  The affected high-voltage battery module(s) will be replaced.

Please do not charge the vehicle’s high-voltage battery until further notice.

The Recall Notice and Q&A have been attached for further information.

The bulletin will be updated when additional information becomes available.  We anticipate being able to start at the end of October.

 

CAUSE

On Plug-in Hybrid Electric Vehicle (PHEV) models, the HV battery may not have been produced to specifications.  When charging the battery to near its full state of charge, this could lead to a short-circuit and, in rare cases a thermal event.

 

CORRECTION

The vehicle will be inspected and, if necessary, HV module(s) will be replaced.

 

PROCEDURE

Important warning for working on the high-voltage systems on BMW Group vehicles:

Only properly trained personnel, who have passed all applicable technical training courses, should perform any maintenance or repairs on any Hybrid or Electric Vehicle. Work performed by unqualified persons may result in severe injury or damage to the vehicle. Additional information is found in Repair Instruction 61 00… Observe safety instructions when handling electric vehicles.

The defective modules must be returned by following the proper module recycling procedure depicted in the Recall Part Retention section of this bulletin. These modules must be at the lowest possible SOC (State of Charge) for return.

 

Carrying Out the Battery Service Measure

 

  1. Connect the vehicle to the diagnosis and carry out a Vehicle Test.
  1. If a cell module is affected, ISTA sets the fault S 0795.
  1. Perform the associated test module in the test plan to determine the affected cell modules to be replaced. For PHEV with SP41, SP45 or SP44 High-voltage battery unit: Cell modules (ABL-DITAT6127_SP0XZM available with ISTA version 4.32.1x, released October 21, 2021).
  1. The test plan will identify the affected modules one at a time. Therefore, it is imperative to select NEXT all the way to the end of the test plan to ensure that all affected modules which are needed to complete the repair are displayed.
  1. If cell modules are prompted for replacement, replace the corresponding cell modules. Follow the proper repair instructions for the specific vehicle; see REP 61 27 XXX “Removing and Replacing High-voltage Battery Cell Modules”.
  1. If a cell module exchange is not instructed, the vehicle is OK. -> No further measures required.

Note:

Please verify that the replacement cell modules you receive are the ones you ordered and were boxed correctly. The part numbers received must cross-reference to the EPC part# POS (positive) or NEG and install them in the correct position in the high-voltage battery as per the illustration below.

Note:

The replacement cell modules voltages need to be balanced prior to installation, as per the repair instructions (Preliminary work – Adjust charging voltages of the replacement module(s) to remaining modules). This operation is included in the allocated time below.

Note:

Please make sure to update your high-voltage equipment (EOS tester and Deutronics charger) to the latest software .

Note:

We will require the ISTA Operations Report from the test session (ISTA Protocol) to be attached to the Recall IDS ticket to verify the correct of modules are ordered.

Note:

The diagnosis of the cell modules is only available with the ISTA version 4.32.1x.

Note:

A TC case is NOT necessary to order the replacement HV battery cell modules as per this campaign. However, in the case of a vehicle that is showing the campaign as OPEN, but the test plan reveals NO defective modules; please submit a TSARA case for “SIB 61 13 21 – no defective modules detected” for further instruction .

Note:

The date in the serial number of the High-voltage module can be displayed in two different formats:

 


Safety Recall 20V-601
High-Voltage Battery
Model Year 2020-2021
PHEV [BMW 3 Series, 5 Series, 7 Series, X3 SAV, X5 SAV / MINI Countryman]
Issue Date: 09/24/2021
Last Update: 09/24/2021

 

Q1. Which BMW Group models in the US are potentially affected by this Safety Recall?

Certain Plug-In Hybrid-Electric Vehicles (PHEV), specifically Model Year 2020-2021 BMW 3 Series, 5 Series, 7 Series, X3 SAV, X5 SAV, and MINI Countryman models in the US are potentially affected.

 

Q2. What is the specific issue?

On PHEV models, the high-voltage battery may not have been produced to specifications.

Charging the battery could lead to a short-circuit and in rare cases, a thermal event.

 

Q3. Why are other models / vehicles not included in this Safety Recall?

Other models have been produced with a high-voltage battery that has been produced to specifications.

 

Q4. How did BMW Group become aware of the issue?

BMW Group became aware of the issue through our quality control procedures.

 

Q5. Can I continue to drive my vehicle?

Yes.  However, please DRIVE IN HYBRID MODE ONLY. DO NOT USE SPORT MODE OR THE SHIFT PADDLES (if equipped) AS THIS WILL CHARGE THE BATTERY

If you are not the only driver of this vehicle, please advise all other drivers of this important information.

However, if the issue occurs while driving, which may manifest itself with a displayed Check Control message for HV Battery/Drivetrain malfunction and a vehicle in a failsafe mode, carefully move away from traffic as soon as possible, pull over to a safe location, and shut off the power.  Do not continue to drive the vehicleAll occupants should exit the vehicle and move to a safe location.

Dial 911 in the event of an emergency. If it is not an emergency, contact BMW Roadside Assistance at 1-800-332-4269 or MINI Roadside Assistance at 1-866-646-4772 to have your vehicle brought to the nearest BMW center or MINI dealer.

 

Q6. Can I charge my vehicle?

No, DO NOT PLUG IN OR CHARGE YOUR VEHICLE.

 

Q7. How can I check my battery state of charge?

The state of charge of the high-voltage battery corresponds to the displayed range in electric mode. If an electric range is near zero, the high-voltage battery is nearly discharged.

 

Q8. Is it recommended that I drain the high-voltage battery?  If so, how do I do that?

Yes. It is recommended to drain the high-voltage battery.  Specific instructions are below for models affected by this recall.

 

For BMW 3 Series, 5 Series, 7 Series, X3, X5:

  • Using iDrive, go to Settings > Driving mode > Battery Control > Set or leave the charging state at 30%.

 

For MINI Countryman:

  • Press the eDrive switch > Select MAX eDRIVE or AUTO eDRIVE > Confirmation will show in the Central Display.

 

Q9. Should I park my vehicle outside?

The possibility of a thermal event is extremely rare.  Once the battery has been drained, the possibility decreases even further.

 

Q10. How will I be informed of this Safety Recall?

Letters will be mailed to owners in November via First Class mail advising them of this Safety Recall and the availability of the remedy with applicable instructions.

To ensure BMW and MINI have the most up-to-date contact and vehicle information, owners should register their vehicle at www.bmwusa.com/myBMW or https://ol.miniusa.com/. Registration is free and will give them access to other information specific for their BMW or MINI.

 

Q11. How and when will my vehicle be repaired?

The affected battery modules will be replaced for free.

 


Remedy Instructions and TSB

2021-11-02

RCRIT-20V601-7733.pdf 2520.471KB

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Remedy Instructions and TSB

2021-09-24

RCRIT-20V601-2684.pdf 404.424KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V601&docType=RCL

 


 

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