Recall 22V541 – High Voltage Battery May Short-Circuit – 2022-2023 BMW iX & 2022 i4

July 27, 2022 NHTSA CAMPAIGN NUMBER: 22V541000

High Voltage Battery May Short-Circuit

A short-circuit in a high voltage battery increases the risk of a fire.

 

NHTSA Campaign Number: 22V541

Manufacturer BMW of North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 83

 

Summary

BMW of North America, LLC (BMW) is recalling certain 2022-2023 iX xDrive50, iX M60, 2022 i4 eDrive40, and i4 M50 vehicles. The high voltage battery may have internal damage, resulting in an electrical short-circuit.

 

Remedy

Owners are advised not to drive or charge their vehicles, and to park outside and away from structures until the remedy is complete. Dealers will replace the high voltage battery, free of charge. Interim owner notification letters, informing owners of the safety risk, were mailed September 23, 2022. A second letter will be mailed when remedy parts become available. Owner notification letters were mailed December 23, 2022. Owners may contact BMW customer service at 1-800-525-7417. Owners will also be contacted by phone.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your BMW has a Recall

 


SIB 61 14 22
2023-04-12

RECALL 22V-541: HIGH-VOLTAGE BATTERY

This Service Information Bulletin (Revision 6) replaces SI B61 14 22 dated February, 2023.

 

What’s New:

  • Procedure: High-voltage disclaimer wording updated
  • Parts: Gen 5 HV Battery Cell Module Recall Return Process added
  • Claim Info: Gen 5 HV Battery Condition Certification (BCC) supplemental RO/claim submission procedure for previously recalled/replaced HV cell modules added

 

☐THIS REPAIR IS MOBILE FRIENDLY

 

MODEL

E-SeriesModel DescriptionProduction Date
G26 BEVi4 Gran CoupeNovember 10, 2021 – October 21, 2022

 

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.

BMW AG is conducting a Voluntary Safety Recall (effective July 21, 2022) on a small number of Model Year 2022 BMW i4 Gran Coupe vehicles that were produced between November 22, 2021, and June 13, 2022.

Affected vehicles are not to be driven or charged and to be parked away from any buildings.

 

SITUATION

During supplier production, the high-voltage battery may not have been produced to specifications. A short-circuit could occur which could lead to a thermal event. The affected high-voltage battery cell module will be replaced.

We will be turning VINs green “Remedy Available” based on parts availability. The BMW Customer Relations department will contact the appropriate dealer to have them place a Recall IDS ticket for the parts for a specific vehicle. Then Customer Relations will assist in scheduling an appointment based on the arrival of the parts. It is essential that the allotted IDS part goes to the assigned vehicle.

 

CAUSE

Some high-voltage battery modules may not have been produced to specifications.

 

CORRECTION

Removal and replacement of affected high-voltage cell modules.

 

PROCEDURE

Important Warning for Working on the High-Voltage (HV) systems on BMW Group vehicles:

 

Only properly trained personnel, who passed all applicable HV Technical Training Courses, should perform repairs which require disconnecting, or removal of High Voltage battery components on any Hybrid or Electric Vehicle. Work performed on High Voltage systems by unqualified persons may result in severe injury or damage to the vehicle. Additional safety information is found in Repair Instruction 61 00… “Observe safety instructions when handling electric vehicles”.

 

Prior to disconnecting, or the removal of any HV component, the HV system needs to be disabled and secured (by means of the HV Service Disconnect Switch and lock out) by a properly trained HV technician, who has a minimum HV Qualification level after completing the Technical Training Course “ST2324 High Voltage Drivetrain Systems” which as of 1/2023* includes ST1824 Alternative Drive Part 1.

 

* Note: As of January 2023, the HV component portion of the “ST2205 Generation 5 High-voltage class” (except for the High Voltage Battery) has been merged into “ST2324 High Voltage Drivetrain Systems”.

 

Up to Generation 4 Vehicles: Once the vehicle’s HV system is disabled (the “Blitz” – lightning bolt icon is displayed in instrument cluster, see below), a technician without HV Certification may remove a HV component (e.g., EH Heater, EKK Compressor, EME Control Unit, et.), except for the High Voltage Battery.

 

For Generation 5 Vehicles however, the specific vehicle training is required to diagnose, remove and service any HV component and it is NOT allowed for non HV certified technicians to work on the high voltage system.

 

High Voltage Battery removal and rework can ONLY be performed by a High-voltage Certified Technician with a HV Battery Certification level corresponding to a specific Electric or Hybrid vehicle, for example:

 

To repair GEN4 HV battery of G05 PHEV a certification from Technical Training Course “ST2006 – SP44 HV Battery” or equivalent ST1825 – Alternative Drive Part 2 is required (or as of 1/2023 the equivalent “ST 2325 for High Voltage Battery Systems”).

And

To repair A GEN5 HV battery the Technical Training Course “ST2205 Generation 5 High-voltage class” is required or as of 1/2023* the equivalent “ST 2325 for High Voltage Battery Systems”. BMW recommends NOT to drive the vehicle NOR charge the high-voltage battery until all repair work below to remedy the fault has been completed.

 

Caution:

Please create a TSARA case for ALL vehicles prior to any disassembly.

 

The steps below must be followed precisely:

  1. Please perform the cell module read out test plan in ISTA to determine the serial numbers and locations of the high-voltage cell modules installed in the vehicle.

 

Diagnostic path:

Vehicle management > Service function > Electric drive > High-voltage battery unit > High-voltage battery unit: Read out stored serial numbers ABL.

 

The “High-voltage battery unit: Read out stored serial numbers” test plan has been updated to identify the high-voltage cell modules affected by this campaign and their location in the high-voltage battery.

 

Note:

Once the Cell module read out test plan has been performed, please submit a TSARA case titled “Gen 5 HV Battery cell module ID process” for assistance in identifying the affected modules (attach the module serial number read out to the case).

 

It is imperative that once the new replacement cell module arrives, you attach that module serial number to the TSARA case for approval.

 

Only when TSARA approves the replacement module you have clearance to install it in the HV battery and continue the repair.

 

Please do not start the recall or submit a TSARA case if the status of the campaign is NOT Green, as there is not yet a “Remedy Available” for this vehicle.

 

  1. The high-voltage battery must be discharged prior to removal to an average cell voltage of 3.51V using the ISTA test plan below, before the high-voltage battery is opened and the defective modules are removed.

 

Diagnostic path:

Vehicle management > Service function > Electric drive > High-voltage battery unit > High-voltage battery unit discharged to a defined state of charge (SOC) ABL.

 

Note:

The High-voltage battery unit discharged to a defined state of charge (ABL) service function is ONLY available if the high-voltage battery temperature is between 15°C and 35°C (59 to 95 F).

 

  1. Replace the defective high-voltage cell modules using repair instructions 61 27 703 to 61 27 877 depending on the affected cell module location.

G26 BEV SE27 HB Battery module locations shown below-

 

PARTS INFORMATION

Only use and invoice the applicable part listed number below.

G26 BEV

Part NumberDescriptionQuantity
61 27 9454253Multi-purpose bolt (M12X1.5X45)14
61 25 8833851Hexagon bolt (M12x5x130)2
61 25 8833846Hexagon bolt (5×105)6
07 14 6884435ASA Multi-purpose bolt (M10x35)4
33 32 6760340Torx bolt with washer (M12x127-10.9)4
33 30 6861221Torx bolt (ISA M12x35- 10.9)10
61 27 9884703Gasket1
07 14 8860492Screw (M5)82
07 14 8838288Sealing screw (M8x28)20
61 27 9454854Screwas needed (max 63)
61 27 8677639Screw (M6x18)as needed (max. 22)
39 10 6865725Multi-purpose bolt4
07 14 8835104Multi-purpose bolt (M12x1.5×72-10.9)4
07 14 6899140Cage nut (M12x1.5-10- ZNS3)4
depending on the availability
61 27 8847350Cell module, high-voltage batteryUp to 3
61 27 8847342Double module for high-voltage batteryUp to 4
Or
61 27 8847333Cell module, high-voltage batteryUp to 3
61 27 8847327Double module for high-voltage batteryUp to 4

 


SIB 61 15 22
2023-04-12

RECALL 22V-541: HIGH-VOLTAGE BATTERY

This Service Information Bulletin (Revision 7) replaces SI B61 15 22 dated November, 2022.

 

What’s New:

  • Procedure: High-voltage disclaimer wording
  • Parts: Gen 5 HV Battery Cell Module Recall Return Process added
  • Claim Info: Gen 5 HV Battery Condition Certification (BCC) supplemental RO/claim submission procedure for previously recalled/replaced HV cell modules added

 

MODEL

E-SeriesModel DescriptionProduction Date
I20iX Sports Activity Vehicle (SAV)November 10, 2021 – October 21, 2022

 

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.

BMW AG is conducting a Voluntary Safety Recall (effective July 21, 2022) on a small number of Model Year 2022 – 2023 BMW iX SAV vehicles that were produced between November 10, 2021 and October 21, 2022.

Affected vehicles are not to be driven or charged and to be parked away from any buildings.

 

SITUATION

During supplier production, the high-voltage battery may not have been produced to specifications.  A short-circuit could occur which could lead to a thermal event. The affected high-voltage battery cell module will be replaced.

We will be turning VINs green “Remedy Available” based on parts availability. The BMW Customer Relations department will contact the appropriate dealer to have them place a Recall IDS ticket for the parts for a specific vehicle. Then Customer Relations will assist in scheduling an appointment based on the arrival of the parts. It is essential that the allotted IDS part goes to the assigned vehicle.

 

CAUSE

Some high-voltage battery modules may not have been produced to specifications.

 

CORRECTION

Removal and replacement of affected high-voltage cell modules.

 

PROCEDURE

 

Important Warning for Working on the High-Voltage (HV) systems on BMW Group vehicles:

Only properly trained personnel, who passed all applicable HV Technical Training Courses, should perform repairs which require disconnecting, or removal of High Voltage battery components on any Hybrid or Electric Vehicle. Work performed on High Voltage systems by unqualified persons may result in severe injury or damage to the vehicle. Additional safety information is found in Repair Instruction 61 00… “Observe safety instructions when handling electric vehicles”.

 

Additional Information:

Scheduled Maintenance, or Quality Certification 1 (Pre-Delivery Inspection) on Electric or Hybrid vehicles does not require HV technical training.

Prior to disconnecting, or the removal of any HV component, the HV system needs to be disabled and secured (by means of the HV Disconnect Switch) by a properly trained technician, who has a minimum HV Qualification level after completing the Technical Training Course ST1824 (Alternative Drive Part 1). Once the vehicle’s HV system is disabled (the “Blitz” – lightning bolt icon displayed in instrument cluster, see below), a technician without HV Certification may remove a HV component (e.g., EH Heater, EKK Compressor, EME Control Unit, et.), except for the High Voltage Battery.

High Voltage Battery removal and rework can be performed ONLY by a HV Specialist Technician (certified by the Technical Training Course ST1825 – Alternative Drive Part 2), AND with a HV Battery Certification level corresponding to a specific Electric or Hybrid vehicle (e.g., to repair GEN4 battery of G05 PHEV, certification from Technical Training Course “ST2006 – SP44 HV Battery” is required).

 

Therefore, to perform this SIB 61 15 22 a GEN5 battery Certification is required from Technical Training Course “ST2205 Generation 5 High-voltage” class).

 

BMW recommends NOT to drive the vehicle NOR charge the high-voltage battery until all repair work below to remedy the fault has been completed.

 

Caution:

Please create a TSARA case for all vehicles prior to any disassembly.

 

  1. Please perform the cell module read out test plan in ISTA to determine the serial numbers and locations of the high-voltage cell modules installed in the vehicle.

 

Diagnostic path:

Vehicle management > Service function > Electric drive > High-voltage battery unit > High-voltage battery unit: Read out stored serial numbers ABL.

The “High-voltage battery unit: Read out stored serial numbers” test plan has been updated to identify the high-voltage cell modules affected by this campaign and their location in the high-voltage battery.

 

Note:

Once the Cell module read out test plan has been performed, please submit a TSARA case titled “Gen 5 HV Battery cell module ID process” for assistance in identifying the affected modules (attach the module serial number read out to the case).

It is imperative that once the new replacement cell module arrives, you attach that module serial number to the TSARA case for approval.

Only when TSARA approves the replacement module you have clearance to install it in the HV battery and continue the repair.

Please do not start the recall or submit a TSARA case if the status of the campaign is NOT Green, as there is not yet a “Remedy Available” for this vehicle.

 

  1. The high-voltage battery must be discharged prior to removal to an average cell voltage of 3.51V using the ISTA test plan below, before the high-voltage battery is opened and the defective modules are removed.

 

Diagnostic path:

Vehicle management > Service function > Electric drive > High-voltage battery unit > High-voltage battery unit discharged to a defined state of charge (SOC) ABL.

 

Note:

The High-voltage battery unit discharged to a defined state of charge (ABL) service function is ONLY available if the high-voltage battery temperature is between 15°C and 35°C (59 to 95 F).

 

  1. Replace the defective high-voltage cell modules using repair instructions 61 27 703 to 61 27 877 depending on the affected cell module location.

 

I20 xDrive50/xDrive60 – SE10 HV Battery module locations shown below-

 

PARTS INFORMATION

Note: Please order the “as required” hardware based on the module you are replacing.

Part NumberDescriptionQuantity
07 14 9487466Screw (12×1.5×50 10.9)18
61 27 9487465Screw (12×1.5×100 10.9)10
31 11 6899302Multi-purpose bolt (10×45 ZNS3)14
61 27 9487464Screw8
51 16 1881149Expanding rivet6
61 27 9468425Screw94
07 14 8838288Sealing screw (M8x28)Order as required
61 27 9468423Housing seal1
61 27 9454855ScrewOrder as required
33 32 6775040Hex bolt with washer (M14x1.5×148)2
61 27 9893951Screw (M8GFX46-10.9)Order as required
61 27 9454854ScrewOrder as required
61 27 9893948ASA combination bolt (M8x84-10.9)Order as required
Depending on the availability
61 27 8846469Double cell module for high-voltage batteryUp to 5
61 27 8846470Double cell module for high-voltage batteryUp to 6
Or:
61 27 8838260Double cell module for high-voltage batteryUp to 5
61 27 8838259Double cell module for high-voltage batteryUp to 6

 


Safety Recall 22V-541
High-Voltage Battery
Model Year 2022-2023 BMW iX, i4
Issue Date: 10/04/2022

 

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

A small number of Model Year 2022-2023 BMW iX and i4 models in the US, produced between November 2021 and June 2022, are potentially affected.

 

Q2. What is the specific issue?

The high-voltage battery manufacturer may not have produced the battery to specifications.  As a result, a short-circuit could occur and lead to a thermal event.

 

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

Other models have been manufactured 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?

No, please do not drive your vehicle until it is repaired.

 

Q6. Can I charge my vehicle?

No, please do not charge your vehicle until it is repaired.

 

Q7. Should I park my vehicle outside and away from structures?

Yes, please park your vehicle outside and away from structures.

 

Q8. How will I be informed of this Safety Recall?

Potentially affected customers are being contacted by phone and email, and arrangements are being made for the Safety Recall to be performed.  Alternate transportation will be accommodated.  You can locate your nearest authorized BMW center at www.bmwusa.com/dealer

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

 

Q9. How and when will my vehicle be repaired?

The affected battery cell modules will be replaced.  Owners will be notified again as soon as the remedy is available.

 


22V-541
Chronology
October 26, 2022

On April 16, 2022, BMW became aware of a non-US field incident involving a 2022 BMW i4 eDrive40. An engineering investigation was initiated, and the supplier was contacted.

A review of the battery supplier production records for the vehicle from the April incident was performed. Analyses suggested an irregularity during the supplier’s production process which may have allowed debris to enter into a battery cell. Further analyses were able to identify cathode pieces within the battery cell.

On June 3, 2022, BMW became aware of a US field incident involving a Model Year 2022 iX xDrive50, and on June 19, 2022, BMW became aware of a non-US field incident involving a 2022 BMW iX M60. Similar analyses were performed, and similar findings were identified involving an irregularity during the supplier’s production process.

Vehicle assembly information and supplier production and process records were reviewed to determine the number, and production dates, of potentially affected vehicles.

On July 20, 2022, BMW decided to conduct a voluntary safety recall.

BMW has not received any reports, nor is BMW otherwise aware, of any accidents or injuries related to this issue.

On July 29, 2022, BMW became aware of a field incident involving a Model Year 2022 i4 M50 company-owned vehicle.

Further analyses were performed by the supplier involving the battery cell production process. As a result of these analyses, and through parts tracing, additional vehicles were identified as having potentially suspect battery cells.

Accordingly, on August 26, 2022, these vehicles were added to the recall.

On August 4, 2022, a non-US field incident involving a 2022 BMW iX occurred. Reviews of supplier production records, and previous analyses of battery cell images, were not able to explain this incident. Therefore, additional engineering analyses were necessary.

During August, further in-depth analyses of supplier production records to identify other possible anomalies were performed and were identified. These findings were then used in combination with new/additional in-depth battery cell image analyses.

Between August and October, the analyses involved further pattern recognition processes of the battery cell images. As a result of these additional analyses, the August 4th incident was able to be identified as well as additional potentially suspect battery cells. Parts tracing was performed to identify potentially affected vehicles.

On October 19, 2022, BMW decided to add additional potentially affected vehicles to the voluntary safety recall.

 


3 Affected Products

Vehicles

MAKEMODELYEAR
BMWI42022
BMWIX2022-2023

 


23 Associated Documents

Recall Acknowledgement

RCAK-22V541-2017.pdf 697.913KB

 


Defect Notice 573 Report

RCLRPT-22V541-1655.PDF 215.456KB

 


Manufacturer Notices(to Dealers,etc) – Manufacturer notice to Dealers re BMW Recall 22V-xxx: High-Voltage Battery (Stop Drive/Stop Charge)

RCMN-22V541-5322.pdf 384.175KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Notification re IX and I4 HV batteries blocked from dealer ordering

RCMN-22V541-3887.pdf 150.588KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V541-7410.pdf 708.473KB

 


Recall 573 Report – 8/31/22

RCLRPT-22V541-6704.PDF 215.613KB

 


Remedy Instructions and TSB

RCRIT-22V541-9726.pdf 1992.754KB

 


Miscellaneous Document – Chronology

RMISC-22V541-9573.pdf 52.905KB

 


Remedy Instructions and TSB

RCRIT-22V541-8563.pdf 1098.331KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Message re BMW Recall 22V-541: High-Voltage Battery – Update 10/26/2022

RCMN-22V541-1022.pdf 391.078KB

 


Remedy Instructions and TSB

RCRIT-22V541-2838.pdf 1081.594KB

 


Remedy Instructions and TSB

RCRIT-22V541-8729.pdf 977.136KB

 


Remedy Instructions and TSB

RCRIT-22V541-4371.pdf 1018.68KB

 


Remedy Instructions and TSB

RCRIT-22V541-4682.pdf 986.894KB

 


Remedy Instructions and TSB

RCRIT-22V541-5014.pdf 993.441KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V541-6708.pdf 707.976KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V541-8636.pdf 675.063KB

 


Remedy Instructions and TSB

RCRIT-22V541-8297.pdf 996.147KB

 


Recall Quarterly Report #1, 2022-4

RCLQRT-22V541-6336.PDF 211.134KB

 


Remedy Instructions and TSB

RCRIT-22V541-9896.pdf 1003.139KB

 


Remedy Instructions and TSB

RCRIT-22V541-8176.pdf 1772.737KB

 


Remedy Instructions and TSB

RCRIT-22V541-5038.pdf 1788.309KB

 


Recall Quarterly Report #2, 2023-1

RCLQRT-22V541-5466.PDF 211.235KB

 


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NexCyber Level 2 EV Charger(WiFi APP/Plug-Play), 48A Nema 14-50p, 25ft Cable ETL Certified, Home Level 2 EVSE Car Charger w/ J1772 Connector, Electric Vehicle Charging Stations (46)
  • [Up to 9x Faster Charging Speed]: Provides up to 46 miles/hour charging speed via hardwired connection (48 amp - up to 9x faster than a standard wall outlet) or up to 38 miles/hour via the NEMA 14-50 plug (40 amp). Professional installation recommended for optimal safety and performance. [Install The Power Outlet Cord]: No smaller than 8AWG if charge 40-48A, we suggest 6AWG cord.(1.The input side is belongs to the electrician electric automobile regulation scope, need to use three 6AWG cable wires for 48A; 2.The charging cable belongs to the automotive connector certification standard, so the 8AWG cable can meet the 48A.)
  • [DESIGNED WITH J1772 Connector for All North America j1772 Connector EVs/PHEVs. Not fits for Tesla/Nacs Connector Cars(j1772 to Tesla adapter needed)]: Compatible with Tesla cars (Adapter needed, not included), Ford, GM, Audi, Kia, Honda, Kia, Hyundai, Gmc, Chevrolet Bolt, VW ID 4, Nissan Leaf, Ford Mustang Mach-E, IONIQ 5 2024 and before, BMW i3, i4, iX, Jeep Wrangler 4xe, etc. [Not fits for Nac connector cars-Kia EV6 2025/EV9,Ariya 2025&2025 loniq 5(J1772 to Tesla adapter needed)]
  • [Safety & Faster Charging with ETL, FCC, Energy Star Certified]: Meets the Safety Criteria Defined by: SAE J1772, UL2231-1/-2, UL 991, UL 2231, UL 2251, UL1998 and UL 2594. (ETL and FCC certified EV car charger with 3-year Warranty)
  • [Plug-play Mode(The Default Setting), Smart Touch Screen, No APP Needed]: Clearly show the charging amperage, charging speed, input voltage, delay time, etc. For the touch buttons: 1. Pull out the charging gun before press the buttons, otherwise no respond; 2. Long press "Ⓐ" or "Time" button to enter the setting interface, then you can adjust the amperage from 16A to 48A freely or Set the charging start time; 3. You can do "factory reset" if doesn't charging.
  • [Smart WIFI APP, You can Set the Charging Period]: By APP, you can wirelessly check the charging cost, history, fully-charged notification, track the charging status, during off-peak period, etc. [Wi-Fi Reset/Factory Reset Function, Add New Device Quickly]: If you can't find your device or you have replaced a new phone, just pull out the charging latches, simultaneously long press the Ⓐ button and time adjustment button on the product screen until it shows "Factory Reset", then wait 3-5 seconds and re-start your device.

 


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