RECALL 23V-295: CELL MONITORING CIRCUIT – 2022-2024 BMW iX & 2023 I4

April 26, 2023 NHTSA CAMPAIGN NUMBER: 23V295000

HV Battery Cell Monitoring Circuit Not Secured

An engine stall increases the risk of a crash.

 

NHTSA Campaign Number: 23V295

Manufacturer BMW of North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 31

 

Summary

BMW of North America, LLC (BMW) is recalling certain 2022-2024 iX xDrive50 and 2023 i4 eDrive35, i4 eDrive40, and i4 M50 Hybrid Electric vehicles. The high voltage battery cell monitoring circuit may have improperly secured electrical connections which can result in an engine stall.

 

Remedy

Dealers will replace the high voltage battery cell monitoring circuit, free of charge. Owner notification letters are expected to be mailed June 16, 2023. 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 10 23
2023-05-04

RECALL 23V-295: CELL MONITORING CIRCUIT

This Service Information Bulletin (Revision 1) replaces SI B61 10 23 dated April, 2023.

 

What’s New:

  • Recall number updated in SIB title and attachments
  • Added Cause, Correction, Parts, Claim

 

MODEL

E-Series Model Description Production Date
G26 i4 Gran Coupe August 5, 2022 – March 28, 2023

 

AFFECTED VEHICLES

Vehicles which require this campaign to be completed will show it as “Open” when checked either in AIR, AWP, Campaign Summary or Warranty Vehicle Inquiry.

Please make sure you check your dealer inventory as soon as possible.  As of April 21, 2023, you can see a list of affected vehicles in Inventory Campaign Details (ICD) under ROSS.

 

SITUATION

BMW AG is conducting a Voluntary Safety Recall (effective April 20, 2023) on a small number of Model Year 2023 BMW i4 vehicles that were produced between August 5, 2022, and March 28, 2023.

An electrical plug connection may not have been assembled to specifications and, while driving, could result in stalling.

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

The bulletin will be updated when additional information becomes available.

 

CAUSE

Faulty connectors in the production of the cell supervisory circuit (CSC).

 

CORRECTION

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”.

*Note: As of January 2023, the “ST2205 Generation 5 High-voltage stand-alone class” has been merged into “ST2324 for High Voltage Drivetrain Systems” and “ST2325 for High Voltage Battery Systems”

Replace CSC per REP 61 27 539 – Replacing CSC (After vehicle diagnosis) (lid for the high-voltage energy storage system removed).

 

PARTS INFORMATION

Please enter a BMW/MINI Recall IDS ticket and parts will be ordered on your behalf. The replacement parts must be installed in the VIN listed in the PO.

Part Number Description Quantity
61 27 8 841 837 Cell monitoring circuit 1
61 27 9 884 703 Seal 1
07 14 8 860 492 Screw (M5) 82
07 14 8 838 288 Seal screw (M8x28) 20
61 27 9 454 253 Mufti-purpose bolt (M12x1.5×45) 14
61 25 8 833 846 Hex bolt (5×105) 6
61 25 8 833 851 Hex bolt (M12x5x130) 2
07 11 9 905 399 Hex bolt with washer (M6x18-U1) 4
33 30 6 861 221 Torx-bolt (ISA M12x35-10.9) 10

 

Bulk Material

Part Number Description Quantity
83 19 2 468 442 BMW Antifreeze/Coolant (1 gallon concentrate) – HT-12 Sublet as needed
Or:
83 19 5 A32 851 HT-12 Antifreeze RTU (Bulk 1/10 Liter) (Pre-mix) Sublet 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 selected from the Electronic Parts Catalogue according to the respective vehicle type and invoiced under the special defect code.

 


SIB 61 11 23
2023-05-04

RECALL 23V-295: CELL MONITORING CIRCUIT

This Service Information Bulletin (Revision 1) replaces SI B61 11 23 dated April, 2023.

 

What’s New:

  • Recall number added to SIB title and Attachments
  • Added Cause, Correction, Parts, Claim

 

MODEL

E-Series Model Description Production Date
I20 iX Sports Activity Vehicle June 13, 2022 – March 23, 2023

 

AFFECTED VEHICLES

Vehicles which require this campaign to be completed will show it as “Open” when checked either in AIR, AWP, Campaign Summary or Warranty Vehicle Inquiry.

Please make sure you check your dealer inventory as soon as possible.  On April 21st you can see a list of affected vehicles in Inventory Campaign Details (ICD) under ROSS.

 

SITUATION

BMW AG is conducting a Voluntary Safety Recall (effective April 20, 2023) on a small number of Model Year 2022 – 2024 BMW iX vehicles that were produced between June 13, 2022, and March 23, 2023.

An electrical plug connection may not have been assembled to specifications and, while driving, could result in stalling.

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

The bulletin will be updated when additional information becomes available.

 

CAUSE

Faulty connectors in the production of the cell supervisory circuit (CSC).

 

CORRECTION

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”.

*Note: As of January 2023, the “ST2205 Generation 5 High-voltage stand-alone class” has been merged into “ST2324 for High Voltage Drivetrain Systems” and “ST2325 for High Voltage Battery Systems”

Replace CSC per REP 61 27 539 – Replacing CSC (After vehicle diagnosis) (lid for the high-voltage energy storage system removed).

 

PARTS INFORMATION

Please enter a BMW/MINI Recall IDS ticket and parts will be ordered on your behalf. The replacement parts must be installed in the VIN listed in the PO.

Part Number Description Quantity
61 27 8 841 837 Cell monitoring circuit 1
07 14 8 860 492 Screw 94
07 14 8 838 288 Seal screw 28
61 27 9 468 423 Gasket, housing 1
07 14 9 487 466 Screw 18
61 27 9 487 467 Hex Bolt 6
31 11 6 899 302 Multi-purpose bolt 14
33 32 6 775 040 Hex bolt with washer 2
61 27 9 487 464 Screw 4
51 16 1 881 149 Expanding rivet 6

 

Bulk Material

Or:
83 19 5 A32 851 HT-12 Antifreeze RTU (Bulk 1/10 Liter) (Pre-mix) Sublet 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 selected from the Electronic Parts Catalog according to the respective vehicle type and invoiced under the special defect code.

 


Safety Recall 23V-295
Plug Connection
Model Year 2022-2024
BMW iX, i4
Issue Date: 4/20/2023

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

Certain Model Year 2022-2024 BMW iX and i4 models in the US are potentially affected.

 

Q2. What is the specific issue?

An electrical plug connection for the High Voltage Battery may not have been assembled to specifications and, while driving, could result in stalling.

 

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

Other models have been manufactured 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 are being contacted by phone and will also be notified via First Class mail requesting them to schedule an appointment with an authorized BMW center to have the remedy performed. Owners can locate their nearest authorized BMW center at 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?

The plug connection will be replaced for free and should take about one hour.

 

Q9. Do I have to wait for BMW to contact me to have the remedy performed?

No.  Please contact an authorized BMW center as soon as possible to have the remedy performed.  For the latest updates to this Safety Recall, please visit www.bmwusa.com/recall.

 


Chronology :

On March 14, 2023, BMW became aware of a vehicle quality check anomaly involving its electrical system during an end-of-line test at a vehicle assembly plant. A vehicle hold was issued, and an investigation was initiated.

Preliminary information indicated that the test anomaly involved the vehicle’s high-voltage battery Cell Monitoring Circuit (CSC). The high-voltage battery supplier was contacted, and information was reviewed including production process records and images.

Further reviews indicated that an electrical connection within the CSC may not have been assembled to specifications, as certain connectors may not have been properly secured. It was suggested that this could lead to an interruption of electrical power.

By April 6th, the complete review of the supplier production process images from start-of-production was completed. Additional testing including test bench and dynamic shaker tests were performed. On April 14th, the analysis of the test data suggested that the interruption of electrical power could occur while driving.

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

On April 19, 2023, BMW decided to conduct a voluntary safety recall.

In late April, a vehicle quality check during an end-of-line test at a vehicle assembly plant identified an electrical system anomaly. It was suggested that this could be similar to the issue that had been identified earlier. Additional analyses were conducted and, on May 20, 2023, BMW decided to add additional potentially affected vehicles to the voluntary safety recall.

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

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
BMW I4 2023
BMW IX 2022-2024

 


6 Associated Documents

Manufacturer Notices(to Dealers,etc) – Dealer Message re BMW Recall 23V-xxx: Cell Monitoring Circuit

RCMN-23V295-6980.pdf 399.462KB

RCMN-23V295-6980

 


Remedy Instructions and TSB

RCRIT-23V295-7435.pdf 401.215KB

RCRIT-23V295-7435

 


Recall Acknowledgement

RCAK-23V295-4363.pdf 645.262KB

RCAK-23V295-4363

 


Defect Notice 573 Report

RCLRPT-23V295-5283.PDF 215.63KB

RCLRPT-23V295-5283

 


Recall 573 Report – 5/17/23

RCLRPT-23V295-3564.PDF 215.738KB

RCLRPT-23V295-3564

 


Recall 573 Report – 5/17/23

RCLRPT-23V295-5154.PDF 215.736KB

RCLRPT-23V295-5154

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V295&docType=RCL

 


 

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