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September 13, 2022 NHTSA CAMPAIGN NUMBER: 22V683000
Battery Electrode Improperly Sized
A short-circuit in the battery cell can increase the risk of fire.
NHTSA Campaign Number: 22V683
Manufacturer BMW of North America, LLC
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 1
Summary
BMW of North America, LLC (BMW) is recalling one 2022 745e hybrid electric vehicle. The high voltage battery may have been produced with a battery cell electrode that was improperly sized during the laser cutting process, which may result in an electrical short-circuit.
Remedy
Dealers will replace the affected battery cell module, free of charge. Interim owner notification letters informing owners of the safety risk were mailed on November 30, 2022. Owners were contacted by phone and by First Class mail on October 28, 2022. Owners may contact BMW customer service at 1-800-525-7417.
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 21 22
2022-11-03
RECALL 22V-683: REPLACING THE CELL MODULES OF THE HIGH-VOLTAGE BATTERY
This Service Information Bulletin (Revision 1) replaces SI B61 21 22 dated October 2022.
What’s New (Specific text highlighted):
- Recall # added to title
- Cause, Correction, Procedure, Parts, Claim sections added
Please perform the procedure outlined in this Service Information on all affected vehicles before customer delivery. In the event the customer has already taken delivery of the vehicle, please perform the procedure the next time the vehicle is in the shop.
MODEL
E-Series | Model Description | Production Date |
I01 | i3 and i3 Range Extender (REx) | November 1, 2018 – May 26, 2021 |
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 October 5, 2022) on a small number of Model Year 2019 – 2021 BMW i3 vehicles that were produced between November 1, 2018 and May 26, 2021.
As part of the quality controls carried out on an ongoing basis at the BMW Group, it was found that, in some cases, certain high-voltage battery cells may not have been produced to specifications. In very rare cases, this could lead to a short-circuit which may cause a thermal event.
CAUSE
Some high-voltage battery modules may not have been produced to specifications.
CORRECTION
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).
The steps below must be followed precisely:
- Please perform the cell module read out test plan in ISTA to determine the serial numbers and locations of the highvoltage cell modules installed in the vehicle.
Diagnostic path:
Vehicle management > Service function > Power train > 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 highvoltage cell modules affected by this campaign and their location in the high-voltage battery.
The update will be included in ISTA version 4.38.2x, estimated available as of November 04, 2022 (pending verification).
Only one (1) HV battery cell module should be identified as needing replacement.
Note:
If the test plan is not yet available at the time of the repair or the test plan was inconclusive in identifying the affected modules, please submit a TSARA case titled “i3 Battery cell module ID process” for assistance.
- Replace the defective high-voltage cell module per REP 61 27 621 – Replacing a cell module (High-voltage battery unit removed) (after vehicle diagnosis).
PARTS INFORMATION
Only use and invoice the applicable part listed number below.
Part Number | Description | Quantity |
07 11 9 908 006 | Torx screw with washer | 26 |
61 27 8 626 650 | Sealing bolt | 4 |
61 27 7 644 532 | Thread-tapping Torx screw | 56 |
61 27 7 625 062 | High voltage battery lid | 1 |
07 12 9 907 467 | Hexagon nut | 4 |
64 53 8 375 742 | Sealing ring | 1 |
64 50 8 374 959 | Sealing ring | 1 |
61 27 7 933 747 | Cell module of high-voltage battery (120AH) | 1 |
Bulk Material (Top Up Quantity) – Sublet
Part Number | Description | Quantity |
83 1 9 2 446 563 | BMW Group R-1234YF – (10 lb / 160 oz) (1 oz. unit) | Qty in sublet needed |
Safety Recall 22V-683
High-Voltage Battery
Model Year 2019-2021
BMW i3 BEV, i3 Rex
Issue Date: 10/05/2022
Q1.Which BMW Group models in the US are potentially affected by this Safety Recall?
A small number of Model Year 2019-2021 BMW i3 BEV and i3 Rex models in the US, 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?
Yes.
Q6. Can I charge my vehicle?
Yes.
Q7. How will I be informed of this Safety Recall?
Owners of potentially affected vehicles will be notified via First Class mail and requested to schedule an appointment with an authorized BMW center to have the remedy performed. Owners can locate their 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.
Q8. How and when will my vehicle be repaired?
When the remedy is available, the affected battery cell module will be replaced. Owners will be notified again as soon as the remedy is available.
Chronology :
On May 25, 2022, a 2021 BMW 320e xDrive Touring experienced a thermal event in Finland. An engineering investigation was initiated.
Preliminary information suggested that the issue might be related to 20V-601, in which debris was able to enter a battery cell during supplier production, but further information and analyses were necessary. In order to accurately determine the root cause of the incident, access to the vehicle and the battery would be needed.
In June and July, BMW contacted the vehicle owner and the insurance company in an attempt to gain access to the vehicle. However, it was not until mid-July that the vehicle was made available.
In mid-July, the vehicle analysis was able to commence in Finland. Initial analyses of the vehicle did not result in an identification of the root cause, and therefore, analyses of the battery would also be necessary.
In mid-August, the battery was shipped to BMW for analysis. Analyses consisted of CT scans of battery cells, and battery module and cell disassembly in conjunction with the battery supplier. Analyses of CT scan data and disassembled components were performed.
In early September, it was finally determined that the root cause of the field incident was a damaged electrode within a cell, which was further confirmed by reviews of supplier production records in which certain electrodes may not have been properly sized during the laser cutting process.
On September 6, 2022, BMW decided to conduct a voluntary safety recall.
BMW continued to analyze the issue with the high-voltage battery supplier. It was determined that additional battery cells may not have been produced to specifications. Parts tracing was performed to correlate battery cells to battery modules, and battery modules to potentially affected vehicles.
On September 28, 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 regarding this issue.
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
BMW | 745E | 2022 |
12 Associated Documents
Recall Acknowledgement
RCAK-22V683-7815.pdf 645.175KB
Manufacturer Notices(to Dealers,etc) – Dealer Notification re BMW Recall 22V-xxx: High-Voltage Battery
RCMN-22V683-9776.pdf 159.439KB
Defect Notice 573 Report
RCLRPT-22V683-1483.PDF 242.772KB
Remedy Instructions and TSB
RCRIT-22V683-3858.pdf 137.396KB
Recall 573 Report – 10/5/22
RCLRPT-22V683-3950.PDF 215.724KB
Manufacturer Notices(to Dealers,etc) – Dealer Message re BMW Recall 22V-xxx: i3 (I01) High-Voltage Battery
RCMN-22V683-7965.pdf 266.386KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V683-8536.pdf 3079.206KB
Remedy Instructions and TSB
RCRIT-22V683-1876.pdf 273.07KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V683-3841.pdf 630.431KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-22V683-2248.pdf 631.586KB
Recall Quarterly Report #1, 2022-4
RCLQRT-22V683-1494.PDF 211.129KB
Recall Quarterly Report #2, 2023-1
RCLQRT-22V683-3367.PDF 211.231KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V683&docType=RCL
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SEOCONTENT-START
SAMPLE Company BMW of North America, LLC BMW Group Company Mailing Address PO Box 1227 Westwood NJ 07675- 1227 Telephone (855) 269-3361 Fax (201) 930-8362 E-mail CustomerRelations@ bmwusa.com Internet bmwusa.com BMW IMPORTANT SAFETY RECALL This notice applies to your vehicle, Recall Campaign No. 22V-683 High-Voltage Battery November 2022 Dear BMW Owner / Lessee: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. BMW AG has decided that a defect, which relates to motor vehicle safety, exists in certain Model Year 2019-2021 BMW i3 vehicles. Our records indicate that you are the owner of a potentially affected vehicle. Why are we contacting you? We are informing you of a safety recall on your vehicle although we are not able to perform the remedy at this time. We will notify you with a follow-up letter as soon as we are able to perform this safety recall. If you are not the only driver of this vehicle, please advise all other drivers and passengers of this important information. What could happen? The high voltage battery may have internal damage, which could cause an electrical short-circuit, and increase the risk of a fire. If the issue were to occur while driving, a warning message for HV Battery/Drivetrain malfunction may display. If you notice an unpleasant odor, or see smoke from the vehicle, 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 vehicle. All occupants should exit the vehicle and move to a safe location away from traffic. Dial 911 in the event of an emergency. If it is not an emergency, contact BMW Roadside Assistance at 1- 800-332-4269. What will BMW do? When the remedy is available, potentially affected high-voltage battery cells will be replaced for free. We will contact you with a follow-up letter when the remedy is available. What if I am not the current owner of this vehicle? If you changed your address or sold the vehicle, you can let us know by visiting www.bmwusa.com/mybmw or by contacting BMW Customer Relations (see left side of page for contact info). If you are a vehicle lessor, Federal Regulations require you to forward this notice to your lessee within ten days. What if I have additional questions? For the latest updates to this recall, please visit www.bmwusa.com/recall. Should you have any questions about this recall, please contact your authorized BMW center. If you need additional assistance, please contact BMW Customer Relations. If your BMW center is unable to remedy the defect without charge or within a reasonable period of time, you may notify the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or go to http://www.safercar.gov. Please be assured that your safety is important to us, and we sincerely apologize if this recall causes any inconvenience. We recommend that you and your passengers wear your safety belt at all times. Sincerely, BMW of North America, LLC Remedy is Unavailable 1 . November 2022
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© 2022 BMW of North America, LLC Service Information Bulletin September 26, 2022 Fuel Systems Please perform the procedure outlined in this Service Information on all affected vehicles before customer delivery. In the event the customer has already taken delivery of the vehicle, please perform the procedure the next time the vehicle is in the shop. RECALL 22V-683: REPLACING HIGH-VOLTAGE CELL MODULE MODEL E-Series Model Description G12 PHEV 745e xDrive AFFECTED VEHICLES Vehicles which require this 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 has issued a Recall on one Model Year 2021 BMW 745e xDrive vehicle that was produced on August 23, 2021. It was found in very rare cases that faults could have occurred in the winding of cell-internal foils of the high-voltage cell module. CAUSE Faults could have occurred in the winding of cell-internal foils of the high-voltage cell modules. CORRECTION Replacement of the affected cell module. 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 © 2022 BMW of North America, LLC 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). Perform Service Function “High-voltage battery unit: Read out stored series numbers”, this can be found in the following location in ISTA: Service Function / Power train / Hybrid car / High-voltage battery unit: read serial numbers stored on SME / High-voltage battery unit: Read out stored series numbers Once you have read the cell module serial numbers, replace the affected cell module with the Serial Number listed below per REP – “Replace cell module 1 (High-voltage battery unit removed) (high-voltage battery unit lid removed) (after vehicle diagnosis).” Note: The repair instruction listed above is an example for cell module 1 but the repair instruction name is the same for all cell modules and only the cell number is different (i.e.,1-6). Use the required repair instruction for the cell module number that is being replaced. Cell Module Serial Number ISTA Cell Module ID Number 8658344136251527121071311015 5834413 62 11015 28/09/1951 10713 PARTS INFORMATION Please enter a Recall IDS Ticket and the parts listed below will be ordered for you. Part Number Part Description Quantity 61 27 8658344 Cell module of high-voltage battery (34AH NEG) 1 as required: 61 27 8658345 Cell module of high-voltage battery (34AH POS) 1 as required: 61 27 8 606 057 Torx socket 24 26 11 7 527 475 Hexagon bolt 3 26 12 7 536 563 Hexagon nut 3 18 30 5 A09 B63 V clip 1 07 11 9 904 024 Hexagon nut 4 18 30 9 909 376 Hexagon bolt 1 07 14 7 413 212 Combi-hexagon screw 6 07 12 9 908 570 Torx socket 4 61 27 8 620 917 Seal for high-voltage battery 1 61 27 8 677 638 Hexagon screw with internal Torx 49 61 25 8 632 010 Hexagon bolt 2 83 19 2 446 563 Refrigerant R1234yf Qty if/as needed Additionally, other small parts that are not specified above, such as one-time use screws, nuts, O-rings and seals, which must be replaced according to the ISTA repair instructions/ETK, must be © 2022 BMW of North America, LLC selected from the Electronic Parts Catalogue according to the respective vehicle type and invoiced under the special defect code. Recalled Part Retention Recalled parts that are removed from BMW vehicles cannot be used for resale! The recalled parts are the property of BMW NA. Your center is responsible for the proper identification, storage and documentation of these parts. They must be held in a secure retention area until notification of claim payment is made by BMW NA through DCSnet. Please DO NOT return these recalled High Voltage (HV) battery modules directly to the WPRC or through the current HV Battery return process. Please refer to the following document for the procedure that applies to returning these Recalled HV Battery Modules: • Bulletin #: C-2-0407-0603_HV-Battery_Recall_Return_Process And, for the latest related training, refer to: • Bulletin #: B-2-0322-0301_HV-Battery_Recall_Training For more information refer to CenterNet: “Menu>BMW>Aftersales>Business Development & Marketing Portal>Batteries>HV Training Module”. CLAIM INFORMATION Reimbursement for this Recall will be via normal claim entry utilizing the applicable work package information below with the additional repair-relate FRU allowances and the part numbers listed above that apply: Defect Code: 0061100700 Replacing high-voltage cell module(s) Plus work (+) Completion before the first vehicle delivery to a customer or the vehicle is already in the workshop Main work The vehicle arrives at your center and this Recall shows open (No other Main work will be performed or claimed during this workshop visit) 6-Module Configuration G12 Work Pkg Labor Operation Description Labor Allowance # 1 00 73 573 Checking the vehicle and removing and installing the high-voltage battery (Plus) 49 FRU # 2 00 73 035 Checking the vehicle and removing and installing the high-voltage battery (Main) 50 FRU Add the following FRU allowance to the labor above that applies (00 73 573 or 00 73 035) Description Labor Allowance Additional job/work to remove and attach the lid (includes High-voltage battery unit final test after repairing the high-voltage battery unit) 11 FRU © 2022 BMW of North America, LLC Then add FRU amount that applies to the cell module repair below that was performed (A, B, C, D or E) Description Labor Allowance Job/repair work time for replacing one or more of the 6 cell modules (top and/or bottom Additional FRU to claim (See below) A. Front Modules (up to 2) Labor Description Cell(s) FRU Replacing a cell module (# 5 POS) (Front Left); 1 4 Or: Replacing a cell module (# 2 NEG) (Front Right) 1 6 Or: Replacing a cell module (Both) (Front Left and Right) 2 10 Total Or: B. Top Rear Modules (up to 2) Labor Description Cell(s) FRU Replacing a cell module (# 4 POS) (Top Rear Left) 1 4 Or: Replacing a cell module (# 3 NEG) (Top Rear Right) 1 3 Or: Replacing a cell module (Both) (Top Rear Left and Right) 2 7 Total Or: C. Front and Top Rear Modules (All 4, A – 10 FRU plus B – 7 FRU) Labor Description Cell(s) FRU Replacing a cell module (All) (Front and Rear Top) 4 17 Total Or: D. Rear Bottom Modules (up to 2) Including the rear Top Modules as required (up to 2, for a total of 4) Labor Description Cell(s) FRU Replacing a cell module (# 6 POS/ # 4 Pos) (Bottom/Top, Rear Left) 1 up to 2 12 Or: Replacing a cell module (# 1 NEG/ # 3 NEG) (Bottom/Top, Rear Right) 1 up to 2 12 Or: Replacing a cell module (Both) (Bottom/Top Rear, Left and Right) 2 up to 4 24 Total Or: E. Front (All 2), Rear Bottom (All 2)/Top Modules (0 to 2) or All 6 Modules Labor Description Cell(s) FRU Replacing a cell module (Front, Rear Bottom/Top) 4 to 6 32 Total Claim Repair Comments © 2022 BMW of North America, LLC Only reference the Defect Code, work package (Pkg) number performed, and cell module replaced by their reference number in the RO technician notes and the claim comments (For example: 0061100700 WP 1, Cell modules 2, 4, 5), unless otherwise required by State law. Sublet – Bulk Materials (RO and Claim Comments Required) Sublet Code 4 Up to $100.00 Reimbursement for the repair-related bulk materials (Do not use the BMW part numbers for claim submission) Sublet reimbursement calculation for claiming the applicable repair-related bulk materials (BMW part numbers) is at the dealer net price amount for the quantities used plus your center’s handling. Enter this material cost in sublet and itemize the amount on the repair order and in claim comment section And, if applicable: Alternative Mobility Solution (AMS) for Vehicle Owners (RO and Claim Comments Required) This Recall repair qualifies for Alternative Mobility Solution (AMS) expense reimbursement, claim this item under the Defect Code noted above as follows: Sublet Code 2 – Itemize the AMS sublet amount on the repair order and in the claim comment section. Please refer to SI B01 29 16 for additional information. FEEDBACK REGARDING THIS BULLETIN Technical Feedback To submit feedback for the technical topics of this bulletin: Submit your feedback in the rating box at the top of this bulletin Warranty Feedback To submit feedback for the CLAIMS section of this bulletin: Submit an IDS ticket to the Warranty Department, or use the chat available in the Warranty Documentation Portal Parts Feedback To submit feedback for the PARTS section of this bulletin: Submit an IDS ticket to the Parts Department
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11/3/22, 3:13 PM 61 21 22_RECALL 22V-683: REPLACING THE CELL MODULES OF THE HIGH-VOLTAGE BATTERY about:blank 1/4 SIB 61 21 22 RECALL 22V-683: REPLACING THE CELL MODULES OF THE HIGH-VOLTAGE BATTERY 2022-11-03 This Service Information Bulletin (Revision 1) replaces SI B61 21 22 dated October 2022. What’s New (Specific text highlighted): Recall # added to title Cause, Correction, Procedure, Parts, Claim sections added Please perform the procedure outlined in this Service Information on all affected vehicles before customer delivery. In the event the customer has already taken delivery of the vehicle, please perform the procedure the next time the vehicle is in the shop. MODEL E-Series Model Description Production Date I01 i3 and i3 Range Extender (REx) November 1, 2018 – May 26, 2021 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 October 5, 2022) on a small number of Model Year 2019 – 2021 BMW i3 vehicles that were produced between November 1, 2018 and May 26, 2021. As part of the quality controls carried out on an ongoing basis at the BMW Group, it was found that, in some cases, certain high-voltage battery cells may not have been produced to specifications. In very rare cases, this could lead to a short-circuit which may cause a thermal event. CAUSE Some high-voltage battery modules may not have been produced to specifications. CORRECTION 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. Copyright ©2022 BMW of North America, Inc. 11/3/22, 3:13 PM 61 21 22_RECALL 22V-683: REPLACING THE CELL MODULES OF THE HIGH-VOLTAGE BATTERY about:blank 2/4 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). 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 highvoltage cell modules installed in the vehicle. Diagnostic path: Vehicle management > Service function > Power train > 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 highvoltage cell modules affected by this campaign and their location in the high-voltage battery. The update will be included in ISTA version 4.38.2x, estimated available as of November 04, 2022 (pending verification). Only one (1) HV battery cell module should be identified as needing replacement. Note: If the test plan is not yet available at the time of the repair or the test plan was inconclusive in identifying the affected modules, please submit a TSARA case titled “i3 Battery cell module ID process” for assistance. 2. Replace the defective high-voltage cell module per REP 61 27 621 – Replacing a cell module (High-voltage battery unit removed) (after vehicle diagnosis). PARTS INFORMATION Only use and invoice the applicable part listed number below. Part Number Description Quantity 07 11 9 908 006 Torx screw with washer 26 61 27 8 626 650 Sealing bolt 4 61 27 7 644 532 Thread-tapping Torx screw 56 61 27 7 625 062 High voltage battery lid 1 07 12 9 907 467 Hexagon nut 4 64 53 8 375 742 Sealing ring 1 64 50 8 374 959 Sealing ring 1 61 27 7 933 747 Cell module of high-voltage battery (120AH) 1 Bulk Material (Top Up Quantity) – Sublet Part Number Description Quantity 83 1 9 2 446 563 BMW Group R-1234YF – (10 lb / 160 oz) (1 oz. unit) Qty in sublet needed Additionally, other small parts that are not specified above, such as one-time use screws, nuts, O-rings, and seals, which must be replaced according to the ISTA repair instructions/ETK, must be selected from the Electronic Parts Catalogue according to the respective vehicle type and invoiced under the special defect code. Recalled Part Retention The parts replaced to perform and submit for this Recall repair procedure are the property of BMW NA. Your center is responsible for the proper identification, storage, and documentation of these parts. They must be held in a secure retention area until notification of claim payment is made by BMW NA through DCSnet. Copyright ©2022 BMW of North America, Inc. 11/3/22, 3:13 PM 61 21 22_RECALL 22V-683: REPLACING THE CELL MODULES OF THE HIGH-VOLTAGE BATTERY about:blank 3/4 If these replaced parts are requested to be returned, a corresponding DCSnet Part Return tag will be generated. Refer to Aftersales Business Development & Marketing Bulletin #: B-2-0719-0603 for the high-voltage battery part return information that applies to this Service Action. Please DO NOT return the HV battery modules directly to the WPRC. Your center is responsible to follow any special rules and regulations that apply to returning these parts to BMW as instructed in the ABDM bulletin. For more information, refer to CenterNet: Menu>BMW>Aftersales>Business Development & Marketing Portal>Batteries. Any return requested parts that are not received by the within 60 days of the claim credit date may be subject to debit. CLAIM INFORMATION Reimbursement for this Recall will be via normal claim entry utilizing the applicable work package information below and the part numbers above. Plus work (+) Completion before the first vehicle delivery to a customer or the vehicle is already in the workshop Main work The vehicle arrives at your center and this Recall shows open (No other Main work will be performed or claimed during this workshop visit) Defect Code: 0061150700 I01 Replace cell module of high-voltage battery Only one of the flat rate labor operation codes listed above can be used for claim submission and reimbursement. Also, only one Main work flat rate labor operation code can be claimed per workshop visit. Work Pkg Labor Operation Description Labor Allowance # 1 00 73 615 Replacing affected high-voltage cell module (one) (Plus work) (Includes 00 00 556/61 21 519/test plan, extract, evacuate and fill the air condition system, removing and replacing the HV battery cover and 61 27 900) 45 FRU Or: # 2 00 73 073 Replacing affected high-voltage cell module (one) (Main work) (Includes 00 00 006/61 21 519/test plan, extract, evacuate and fill the air condition system, removing and replacing the HV battery cover and 61 27 900) 46 FRU Claim Repair Comments Only reference the SIB number, the work package (Pkg) number performed, and the cell module replaced in the RO technician notes and the claim comments (For example: B61 21 22 WP 1, Cell module position 5), unless otherwise required by State law. And: Sublet – Bulk Materials (RO and Claim Comments Required) Sublet Code 4 See the sublet reimbursement calculation below Reimbursement for the repair-related bulk material (Do not use the BMW part number for claim submission) Sublet reimbursement calculation for claiming the applicable repair-related bulk material (BMW part number) is at the dealer net price amount for the quantity used plus your center’s handling. Enter this material cost in sublet and itemize the amount on the repair order and in claim comment section. And, if applicable: Copyright ©2022 BMW of North America, Inc. 11/3/22, 3:13 PM 61 21 22_RECALL 22V-683: REPLACING THE CELL MODULES OF THE HIGH-VOLTAGE BATTERY about:blank 4/4 Alternative Mobility Solution (AMS) for Vehicle Owners (RO and Claim Comments Required) This Recall repair qualifies for Alternative Mobility Solution (AMS) expense reimbursement, claim this item under the Defect Code noted above as follows: Sublet Code 2 – Itemize the AMS sublet amount on the repair order and in the claim comment section. Please refer to SI B01 29 16 for additional information. Reimbursement of Prior Customer-Pay Repairs (TREAD Act) Based on the issue and the age of the Affected Vehicles being addressed by this Safety Recall Campaign, a reimbursement request for a qualifying prior customer-pay repair is not likely. However, if you do receive a reimbursement request from a customer for a prior repair that may qualify, please contact the Warranty department (include a legible copy of the invoice) through IDS by selecting Coverage, Policy, Coding Questions and Mileage Corrections. The Warranty department will review and respond to your inquiry accordingly. FEEDBACK REGARDING THIS BULLETIN Technical Feedback To submit feedback for the technical topics of this bulletin: Submit your feedback in the rating box at the top of this bulletin Warranty Feedback To submit feedback for the CLAIMS section of this bulletin: Submit an IDS ticket to the Warranty Department, or use the chat available in the Warranty Documentation Portal Parts Feedback To submit feedback for the PARTS section of this bulletin: Submit an IDS ticket to the Parts Department Supporting Materials picture_as_pdf B612122 Recall Notice 03Nov2022.pdf picture_as_pdf B612122_2022-MY2022-2023-I01-HV-Battery-FAQ-(03Nov2022).pdf Copyright ©2022 BMW of North America, Inc. Attachment to B61 21 22 November 2022 SAFETY RECALL NOTICE To: All Center Operators, Sales Managers, Service Manager, Parts Manager and Warranty Processor RE: Recall 22V-683: High-Voltage Battery – B61 21 22 BMW AG is conducting a Voluntary Safety Recall (effective October 5, 2022) on a small number of Model Year 2019 – 2021 BMW i3 vehicles that were produced between November 1, 2018 and May 26, 2021. Please be reminded that it is a violation of federal law (The Safety Act) for you to sell, lease or deliver any new motor vehicle covered by this notification until the recall repair has been performed. This means that centers may not legally deliver new motor vehicles to consumers until they are fixed or use/sell replacement equipment/parts subject to this recall. Note also that substantial civil penalties apply to violations of the Safety Act. Also, you should not sell, lease or deliver any Certified Pre-Owned or used vehicles subject to a safety recall until the repair is completed. Please follow any special instructions that we provide to you for the return or disposition of recall parts. We appreciate all your assistance with this Recall. Attachment to B61 21 22 November 2022 Safety Recall 22V-683 High-Voltage Battery Model Year 2019-2021 BMW i3 BEV, i3 Rex Issue Date: 10/05/2022 Q1. Which BMW Group models in the US are potentially affected by this Safety Recall? A small number of Model Year 2019-2021 BMW i3 BEV and i3 Rex models in the US, 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? Yes. Q6. Can I charge my vehicle? Yes. Q7. How will I be informed of this Safety Recall? Owners of potentially affected vehicles will be notified via First Class mail and requested to schedule an appointment with an authorized BMW center to have the remedy performed. Owners can locate their 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. Q8. How and when will my vehicle be repaired? When the remedy is available, the affected battery cell module will be replaced. Owners will be notified again as soon as the remedy is available.
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SAMPLE Company BMW of North America, LLC BMW Group Company Mailing Address PO Box 1227 Westwood NJ 07675- 1227 Telephone (888) 269-8362 Fax (201) 930-8362 E-mail CustomerRelations@ bmwusa.com Internet bmwusa.com BMW IMPORTANT SAFETY RECALL This notice applies to your vehicle, Recall Campaign No. 22V-683: High-Voltage Battery November 2022 Dear BMW Owner / Lessee: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. BMW AG has decided that a defect, which relates to motor vehicle safety, exists in certain Model Year 2022 BMW 745e xDrive vehicles. Our records indicate that you are the owner of a potentially affected vehicle. Why are we contacting you? We are pleased to inform you that we are ready to perform this recall. If you have not had this recall performed, please contact your authorized BMW center immediately to schedule an appointment. Please visit www.bmwusa.com/dealer to locate your nearest BMW center. If you are not the only driver of this vehicle, please advise all other drivers and passengers of this important information. What could happen? The high voltage battery may have internal damage, which could cause an electrical short-circuit, and increase the risk of a fire. If the issue were to occur while driving, a warningmessage for HV Battery/Drivetrainmalfunctionmay display. If you notice an unpleasant odor, or see smoke from the vehicle, 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 vehicle. All occupants should exit the vehicle and move to a safe location away from traffic. Dial 911 in the event of an emergency. If it is not an emergency, contact BMW Roadside Assistance at 1-800-332-4269. What will BMW do? Potentially affected high-voltage battery cells will be replaced for free, and could take a few days. What if I am not the current owner of this vehicle? If you changed your address or sold the vehicle, you can let us know by visiting www.bmwusa.com/mybmw or by contacting BMW Customer Relations (see left side of page for contact info). If you are a vehicle lessor, Federal Regulations require you to forward this notice to your lessee within ten days. What if I have additional questions? For the latest updates to this recall, please visit www.bmwusa.com/recall. Should you have any questions about this recall, please contact your authorized BMW center. If you need additional assistance, please contact BMW Customer Relations. If your BMW center is unable to remedy the defect without charge or within a reasonable period of time, you may notify the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or go to http://www.safercar.gov. Please be assured that your safety is important to us, and we sincerely apologize if this recall causes any inconvenience. We recommend that you and your passengers wear your safety belt at all times. Sincerely, BMW of North America, LLC Remedy is Available 1
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SAMPLE Company BMW of North America, LLC BMW Group Company Mailing Address PO Box 1227 Westwood NJ 07675- 1227 Telephone (888) 269-8362 Fax (201) 930-8362 E-mail CustomerRelations@ bmwusa.com Internet bmwusa.com BMW IMPORTANT SAFETY RECALL This notice applies to your vehicle, Recall Campaign No. 22V-683: High-Voltage Battery November 2022 Dear BMW Owner / Lessee: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. BMW AG has decided that a defect, which relates to motor vehicle safety, exists in certain Model Year 2019-2021 BMW i3 vehicles. Our records indicate that you are the owner of a potentially affected vehicle. Why are we contacting you? Weare pleased to inform you that we are ready to perform this recall. If you have not had this recall performed, please contact your authorized BMW center immediately to schedule an appointment. Please visit www.bmwusa.com/dealer to locate your nearest BMW center. If you are not the only driver of this vehicle, please advise all other drivers and passengers of this important information. What could happen? The high voltage battery may have internal damage, which could cause an electrical short-circuit, and increase the risk of a fire. If the issue were to occur while driving, a warning message for HV Battery/Drivetrain malfunction may display. If you notice an unpleasant odor, or see smoke from the vehicle, 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 vehicle. All occupants should exit the vehicle and move to a safe location away from traffic. Dial 911 in the event of an emergency. If it is not an emergency, contact BMW Roadside Assistance at 1- 800-332-4269. What will BMW do? Potentially affected high-voltage battery cells will be replaced for free, and could take a few days. What if I am not the current owner of this vehicle? If you changed your address or sold the vehicle, you can let us know by visiting www.bmwusa.com/mybmw or by contacting BMW Customer Relations (see left side of page for contact info). If you are a vehicle lessor, Federal Regulations require you to forward this notice to your lessee within ten days. What if I have additional questions? For the latest updates to this recall, please visit www.bmwusa.com/recall. Should you have any questions about this recall, please contact your authorized BMW center. If you need additional assistance, please contact BMW Customer Relations. If your BMW center is unable to remedy the defect without charge or within a reasonable period of time, you may notify the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or go to http://www.safercar.gov. Please be assured that your safety is important to us, and we sincerely apologize if this recall causes any inconvenience. We recommend that you and your passengers wear your safety belt at all times. Sincerely, BMW of North America, LLC Remedy is Available 1 . November 2022
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From: Broadcast Messaging System To: DL-BMS_Message_Monitors Subject: BMW Recall 22V-xxx: High-Voltage Battery Date: Wednesday, September 7, 2022 11:55:27 AM Publish Date: From: Expiration Date: September 7, 2022 Technical Service September 21, 2022 DCSnet Message Urgent Subject: BMW Recall 22V-xxx: High-Voltage Battery BMW AG is conducting a Voluntary Safety Recall (effective September 7, 2022) on one Model Year 2022 BMW 745e xDrive vehicle that was produced on August 23, 2021. The high-voltage battery may not have been produced to specifications by the supplier. VIN: WBA7W4C06NCH89356 (retailed) Defect Code: 0061100700 The Recall Notice has been attached for further information. We will update you when additional information becomes available. Sincerely, Technical Service Attachments: Recall Notice_0061100700[1662565343762].pdf Recall Notice_0061100700[1662565343762].pdf Recipients: All, 75784, BMW of Fort Lauderdale/Lauderdale MINI, All Departments, All Personnel All, 51106, BMW of Bloomfield Hills, All Departments, All Personnel SAFETY RECALL NOTICE To: All Center Operators, Sales Managers, Service Manager, Parts Manager and Warranty Processor RE: Recall 22V-xxx: High-Voltage Battery BMW AG is conducting a Voluntary Safety Recall (effective September 7, 2022) on one Model Year 2022 BMW 745e xDrive vehicle that was produced on August 23, 2021. VIN: WBA7W4C06NCH89356 (retailed) Please be reminded that it is a violation of federal law (The Safety Act) for you to sell, lease or deliver any new motor vehicle covered by this notification until the recall repair has been performed. This means that centers may not legally deliver new motor vehicles to consumers until they are fixed or use/sell replacement equipment/parts subject to this recall. Note also that substantial civil penalties apply to violations of the Safety Act. Also, you should not sell, lease or deliver any Certified Pre-Owned or used vehicles subject to a safety recall until the repair is completed. Please follow any special instructions that we provide to you for the return or disposition of recall parts. We appreciate all your assistance with this Recall.
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From: Broadcast Messaging System To: DL-BMS_Message_Monitors Subject: BMW Recall 22V-xxx: i3 (I01) High-Voltage Battery Date: Wednesday, October 5, 2022 12:54:57 PM Publish Date: From: Expiration Date: October 5, 2022 Technical Service October 19, 2022 DCSnet Message Urgent Subject: BMW Recall 22V-xxx: i3 (I01) High-Voltage Battery BMW AG is conducting a Voluntary Safety Recall (effective October 5, 2022) on a small number of Model Year 2019 – 2021 BMW i3 vehicles that were produced between November 1, 2018 and May 26, 2021. 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. The Recall Notice and Q&A have been attached for further information. The bulletin will be updated when additional information becomes available. Sincerely, Technical Service Attachments: B612122 Recall Notice[1664981864546].pdf B612122[1664981864546].pdf B612122_2022-MY2022-2023-I01-HV-Battery-FAQ-(05Octl2022) [1664981864546].pdf B612122 Recall Notice[1664981864546].pdf B612122[1664981864546].pdf B612122_2022-MY2022-2023-I01-HV-Battery-FAQ-(05Octl2022) [1664981864546].pdf Recipients: BMW Passenger Cars, All Offering, All Region, All Areas, All Departments, All Personnel BMW i, All Offering, All Region, All Areas, All Departments, All Personnel BMW Passenger Cars, CC-All 10/7/22, 11:53 AM 61 21 22_RECALL 22V-XXX: HIGH-VOLTAGE BATTERY about:blank 1/1 SIB 61 21 22 RECALL 22V-XXX: HIGH-VOLTAGE BATTERY 2022-10-05 MODEL E-Series Model Description Production Date I01 i3 November 1, 2018 – May 26, 2021 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 October 5, 2022) on a small number of Model Year 2019 – 2021 BMW i3 vehicles that were produced between November 1, 2018 and May 26, 2021. During supplier production, the high-voltage battery may not have been produced to specifications. A shortcircuit could occur which could lead to a thermal event. The affected high-voltage battery cell module will be replaced. The Recall Notice and Q&A have been attached for further information. The bulletin will be updated when additional information becomes available. Supporting Materials picture_as_pdf B612122 Recall Notice.pdf picture_as_pdf B612122_2022-MY2022-2023-I01-HV-Battery-FAQ-(05Octl2022).pdf Copyright ©2022 BMW of North America, Inc. Attachment to B61 21 22 October 2022 SAFETY RECALL NOTICE To: All Center Operators, Sales Managers, Service Manager, Parts Manager and Warranty Processor RE: Recall 22V-xxx: High-Voltage Battery – B61 21 22 BMW AG is conducting a Voluntary Safety Recall (effective October 5, 2022) on a small number of Model Year 2019 – 2021 BMW i3 vehicles that were produced between November 1, 2018 and May 26, 2021. Please be reminded that it is a violation of federal law (The Safety Act) for you to sell, lease or deliver any new motor vehicle covered by this notification until the recall repair has been performed. This means that centers may not legally deliver new motor vehicles to consumers until they are fixed or use/sell replacement equipment/parts subject to this recall. Note also that substantial civil penalties apply to violations of the Safety Act. Also, you should not sell, lease or deliver any Certified Pre-Owned or used vehicles subject to a safety recall until the repair is completed. Please follow any special instructions that we provide to you for the return or disposition of recall parts. We appreciate all your assistance with this Recall. Attachment to B61 21 22 October 2022 Safety Recall 22V-xyz High-Voltage Battery Model Year 2019-2021 BMW i3 BEV, i3 Rex Issue Date: 10/05/2022 Q1. Which BMW Group models in the US are potentially affected by this Safety Recall? A small number of Model Year 2019-2021 BMW i3 BEV and i3 Rex models in the US, 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? Yes. Q6. Can I charge my vehicle? Yes. Q7. How will I be informed of this Safety Recall? Owners of potentially affected vehicles will be notified via First Class mail and requested to schedule an appointment with an authorized BMW center to have the remedy performed. Owners can locate their 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. Q8. How and when will my vehicle be repaired? When the remedy is available, the affected battery cell module will be replaced. Owners will be notified again as soon as the remedy is available.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-683 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : BMW of North America, LLC Submission Date : OCT 05, 2022 NHTSA Recall No. : 22V-683 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : BMW of North America, LLC Address : P.O. Box 1227 Westwood NJ 07675-1227 Company phone : 18005257417 Population : Number of potentially involved : 16 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 BMW 745e xDrive Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : Approximately 1 vehicle was manufactured with a high voltage battery that may not have been produced by the supplier according to specifications. Basis for recall population determination: Vehicle manufacturing information and supplier production records were reviewed to determine the potentially affected vehicle population. Recall component difference to non-recall component: One or more battery cells may not have been produced by the supplier according to specifications. Production Dates : AUG 23, 2021 – AUG 23, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 22V-683 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2019-2022 BMW i3 BEV, i3 Rex Vehicle Type : LIGHT VEHICLES Body Style : 2-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : Approximately 15 vehicle was manufactured with a high voltage battery that may not have been produced by the supplier according to specifications. Basis for recall population determination: Vehicle manufacturing information and supplier production records were reviewed to determine the potentially affected vehicle population. Recall component difference to non-recall component: One or more battery cells may not have been produced by the supplier according to specifications. Production Dates : NOV 01, 2018 – MAY 26, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The high voltage battery may not have been produced by the supplier according to specifications. During the production and assembly process of the battery cell, an electrode may not have been properly sized during the laser cutting process. If a battery cell was assembled with a miscut electrode, this could lead to a short-circuit. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : In rare cases, a short-circuit could lead to a thermal event which could increase the risk of an injury. Description of the Cause : NR Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : High Voltage Battery Component Description : High Voltage Battery Component Part Number : 8658-344/-345, 88408-38/-41 Part 573 Safety Recall Report 22V-683 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Supplier Identification : Component Manufacturer Name : Samsun Address : 150-20 Gongse-ro-Giheung-gu Yongin-si Foreign States 17084 Country : Korea, Republic of Chronology : On May 25, 2022, a 2021 BMW 320e xDrive Touring experienced a thermal event in Finland. An engineering investigation was initiated. Preliminary information suggested that the issue might be related to 20V-601, in which debris was able to enter a battery cell during supplier production, but further information and analyses were necessary. In order to accurately determine the root cause of the incident, access to the vehicle and the battery would be needed. In June and July, BMW contacted the vehicle owner and the insurance company in an attempt to gain access to the vehicle. However, it was not until mid-July that the vehicle was made available. In mid-July, the vehicle analysis was able to commence in Finland. Initial analyses of the vehicle did not result in an identification of the root cause, and therefore, analyses of the battery would also be necessary. In mid-August, the battery was shipped to BMW for analysis. Analyses consisted of CT scans of battery cells, and battery module and cell disassembly in conjunction with the battery supplier. Analyses of CT scan data and disassembled components were performed. In early September, it was finally determined that the root cause of the field incident was a damaged electrode within a cell, which was further confirmed by reviews of supplier production records in which certain electrodes may not have been properly sized during the laser cutting process. On September 6, 2022, BMW decided to conduct a voluntary safety recall. BMW continued to analyze the issue with the high-voltage battery supplier. It was determined that additional battery cells may not have been produced to specifications. Parts tracing was performed to correlate battery cells to battery modules, and battery modules to potentially affected vehicles. On September 28, 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 regarding this issue. Part 573 Safety Recall Report 22V-683 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : The affected battery cell module will be replaced. Potentially affected owners are being contacted by phone and will also be notified by First Class mail advising them of the recall and to schedule an appointment with an authorized BMW dealer to have the remedy performed for free. If this condition were to occur to a potentially affected vehicle prior to this recall, the remedy would be covered by the BMW New Vehicle Limited Warranty program. Therefore, reimbursement for a prenotification remedy re Part 573.13 and Part 577.11 is not necessary. How Remedy Component Differs from Recalled Component : Recall component: High Voltage Battery – part number: 8658-344/-345, 88408-38/-41 Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Dealer notification is expected to begin and end on October 5, 2022. Owner notification is expected to begin and end on November 28, 2022 Planned Dealer Notification Date : OCT 05, 2022 – OCT 05, 2022 Planned Owner Notification Date : NOV 28, 2022 – NOV 28, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-683 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : BMW of North America, LLC Submission Date : SEP 13, 2022 NHTSA Recall No. : 22V-683 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : BMW of North America, LLC Address : P.O. Box 1227 Westwood NJ 07675-1227 Company phone : 18005257417 Population : Number of potentially involved : 1 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 BMW 745e xDrive Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : Approximately 1 vehicle was manufactured with a high voltage battery that may not have been produced by the supplier according to specifications. Basis for recall population determination: Vehicle manufacturing information and supplier production records were reviewed to determine the potentially affected vehicle population. Recall component difference to non-recall component: One or more battery cells may not have been produced by the supplier according to specifications. Production Dates : AUG 23, 2021 – AUG 23, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The high voltage battery may not have been produced by the supplier according to specifications. During the production and assembly process of the battery cell, an electrode may not have been properly sized during the laser cutting process. If a battery cell was assembled with a miscut electrode, this could lead to a short-circuit. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : In rare cases, a short-circuit could lead to a thermal event which could increase the risk of an injury. Part 573 Safety Recall Report 22V-683 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of the Cause : NR Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : High Voltage Battery Component Description : High Voltage Battery Component Part Number : 8658-344/-345, 88408-38/-41 Supplier Identification : Component Manufacturer Name : Samsun Address : 150-20 Gongse-ro-Giheung-gu Yongin-si Foreign States 17084 Country : Korea, Republic of Chronology : On May 25, 2022, a 2021 BMW 320e xDrive Touring experienced a thermal event in Finland. An engineering investigation was initiated. Preliminary information suggested that the issue might be related to 20V-601, in which debris was able to enter a battery cell during supplier production, but further information and analyses were necessary. In order to accurately determine the root cause of the incident, access to the vehicle and the battery would be needed. In June and July, BMW contacted the vehicle owner and the insurance company in an attempt to gain access to the vehicle. However, it was not until mid-July that the vehicle was made available. In mid-July, the vehicle analysis was able to commence in Finland. Initial analyses of the vehicle did not result in an identification of the root cause, and therefore, analyses of the battery would also be necessary. In mid-August, the battery was shipped to BMW for analysis. Analyses consisted of CT scans of battery cells, and battery module and cell disassembly in conjunction with the battery supplier. Analyses of CT scan data and disassembled components were performed. In early September, it was finally determined that the root cause of the field incident was a damaged electrode Part 573 Safety Recall Report 22V-683 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 within a cell, which was further confirmed by reviews of supplier production records in which certain electrodes may not have been properly sized during the laser cutting process. On September 6, 2022, BMW decided to conduct a voluntary safety recall. BMW is not aware of any accidents or injuries related to this issue. Description of Remedy : Description of Remedy Program : The affected battery cell module will be replaced. The one affected owner is being contacted by phone. If necessary, the one owner will also be notified by First Class mail advising them of the recall and to schedule an appointment with an authorized BMW dealer to have the remedy performed for free. If this condition were to occur to a potentially affected vehicle prior to this recall, the remedy would be covered by the BMW New Vehicle Limited Warranty program. Therefore, reimbursement for a pre-notification remedy re Part 573.13 and Part 577.11 is not necessary. How Remedy Component Differs from Recalled Component : Recall component: High Voltage Battery – part number: 8658-344/-345, 88408-38/-41 Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Dealer notification is expected to begin and end on September 13, 2022. Owner notification is expected to begin and end on November 7, 2022 Planned Dealer Notification Date : SEP 13, 2022 – SEP 13, 2022 Planned Owner Notification Date : NOV 07, 2022 – NOV 07, 2022 * NR – Not Reported
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