Recall 22V-683: High-Voltage Battery – 2022 BMW 7 Series

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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:

  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.

 

  1. 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

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Manufacturer Notices(to Dealers,etc) – Dealer Notification re BMW Recall 22V-xxx: High-Voltage Battery

RCMN-22V683-9776.pdf 159.439KB

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Defect Notice 573 Report

RCLRPT-22V683-1483.PDF 242.772KB

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Remedy Instructions and TSB

RCRIT-22V683-3858.pdf 137.396KB

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Recall 573 Report – 10/5/22

RCLRPT-22V683-3950.PDF 215.724KB

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Manufacturer Notices(to Dealers,etc) – Dealer Message re BMW Recall 22V-xxx: i3 (I01) High-Voltage Battery

RCMN-22V683-7965.pdf 266.386KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V683-8536.pdf 3079.206KB

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Remedy Instructions and TSB

RCRIT-22V683-1876.pdf 273.07KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V683-3841.pdf 630.431KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V683-2248.pdf 631.586KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V683-1494.PDF 211.129KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V683-3367.PDF 211.231KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V683&docType=RCL

 


 

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Last update on 2024-04-22 / Affiliate links / Images from Amazon Product Advertising API

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