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

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. The one affected owner is expected to be contacted by phone and, if necessary, by First Class mail on November 7, 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

 


September 26, 2022

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 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) (highvoltage 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

 

 

 


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 is not aware of any accidents or injuries related to this issue.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
BMW 745E 2022

 


5 Associated Documents

Recall Acknowledgement

RCAK-22V683-7815.pdf 645.175KB

RCAK-22V683-7815

 


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

RCMN-22V683-9776.pdf 159.439KB

RCMN-22V683-9776

 


Defect Notice 573 Report

RCLRPT-22V683-1483.PDF 242.772KB

RCLRPT-22V683-1483

 


Remedy Instructions and TSB

RCRIT-22V683-3858.pdf 137.396KB

RCRIT-22V683-3858

 


Recall 573 Report – 10/5/22

RCLRPT-22V683-3950.PDF 215.724KB

RCLRPT-22V683-3950

 


Latest Recalls Documents

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

 


 

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