“This site contains affiliate links for which OEMDTC may be compensated” |
February 23, 2024 NHTSA CAMPAIGN NUMBER: 24V135000
High-Voltage Battery May Overheat
An overheated battery module increases the risk of a fire.
NHTSA Campaign Number: 24V135
Manufacturer BMW of North America, LLC
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 4
Summary
BMW of North America, LLC (BMW) is recalling certain 2024 i4 xDrive40, i4 M50 and i5 eDrive40 vehicles. The high-voltage battery module may contain insufficient weld seams, which can result in the battery overheating.
Remedy
Dealers will replace the high-voltage battery module, free of charge. 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
Service Information Bulletin | February 22, 2024 |
General Electrical Systems | B61 04 24 |
RECALL 24V-135: REPLACING THE CELL MODULE OF HIGH-VOLTAGE BATTERY
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 |
G26 | i4 xDrive40 |
G60 | i5 eDrive40 |
AFFECTED VEHICLES
Vehicles which require this Recall 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 Delivery Stop (effective February 14, 2024) on small number of Model Year 2024 BMW vehicles that were produced between September 23, 2023, and February 5, 2024.
As of February 19, 2024, this Delivery Stop has been upgraded to a Safety Recall.
Do not deliver to a customer, a New, Certified Pre-Owned or Used vehicle subject to a Delivery Stop, until the vehicle is repaired. Do not use or sell replacement equipment/parts subject to a Delivery Stop.
The Recall Notice and FAQ have been attached for additional information.
CAUSE
A manufacturing defect in the high-voltage battery can interrupt the electrical contact between the high-voltage cell terminal and the cell contacting system.
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”.
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 Highvoltage 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 high-voltage battery cell module position 6 per REP 61 27 721 – Replacing cell module 6 (After vehicle diagnosis) (Cover for high-voltage battery unit removed).
Module ID | Module ID ISTA | Position |
T588634480123B22930000762515271 | 8863448 01 62515271 17.08.23 00007 | 6 |
PARTS INFORMATION
Please enter a Recall IDS Ticket and the parts listed below will be ordered for you.
G26
Part number | Description | Quantity |
61 27 8 832 708 | Pad | 12 |
61 27 9 454 253 | Multi-purpose bolt | 14 |
61 25 8 833 846 | Hexagon bolt | 10 |
61 25 8 833 851 | Hexagon bolt | 4 |
07 14 6 899 140 | Cage nut | 4 |
39 10 6 865 725 | Multi-purpose bolt | 4 |
07 11 9 905 399 | Hexagon screw with washer | 4 |
33 30 6 861 221 | Torx bolt | 10 |
61 27 8 863 448 | Cell module, high-voltage battery | 1 |
61 27 9 454 854 | Screw | 20 |
61 27 8 677 639 | Screw | 6 |
61 27 9 884 703 | Gasket | 1 |
07 14 8 838 288 | Sealing bolt | 20 |
07 14 8 860 492 | Screw | 82 |
G60
Part number | Description | Quantity |
61 27 8 832 708 | Pad | 12 |
61 27 9 454 253 | Multi-purpose bolt | 14 |
61 25 8 833 846 | Hexagon bolt | 10 |
61 25 8 833 851 | Hexagon bolt | 4 |
07 14 6 899 140 | Cage nut | 4 |
39 10 6 865 725 | Multi-purpose bolt | 4 |
07 11 9 905 399 | Hexagon screw with washer | 4 |
33 30 6 861 221 | Torx bolt | 10 |
61 27 8 863 448 | Cell module, high-voltage battery | 1 |
61 27 9 454 854 | Screw | 20 |
61 27 8 677 639 | Screw | 6 |
61 27 9 884 703 | Gasket | 1 |
07 14 8 838 288 | Sealing bolt | 20 |
07 14 8 860 492 | Screw | 82 |
07 14 6 884 435 | Multi-purpose bolt ASA | 2 |
07 11 9 908 280 | Hexagon bolt | 4 |
07 14 7 283 812 | Speed nut | 2 |
31 11 6 899 302 | Multi-purpose bolt | 8 |
Bulk Material – Sublet
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.
Chronology :
On February 12, 2024, during an internal quality check of the high-voltage battery modules, an inadequate weld was noticed. An engineering investigation was immediately initiated.
A review of the high-voltage battery assembly process, and vehicle production and logistics records, was performed. It was determined that the laser welding process, between the cell contacting system and a cell terminal, may not have been performed appropriately. Further reviews indicated that some modules with insufficient weld seams may not have been removed during the assembly process.
As a precaution, on February 14th, a vehicle stop ship at a vehicle assembly plant, and a corresponding dealer hold, was issued.
On February 15, 2024, BMW decided to conduct a voluntary safety recall.
BMW is not aware of any customer complaints, concerns, and/or instances, dealer field reports, or warranty claims that relate, or may relate, to the issue identified in this report.
BMW has not received any reports, nor is BMW otherwise aware, of any incidents, accidents or injuries that relate, or may relate, to the issue identified in this report.
3 Affected Products
Vehicles
MAKE | MODEL | YEAR |
BMW | I4 | 2024 |
BMW | I4 M50 | 2024 |
BMW | I5 | 2024 |
4 Associated Documents
Defect Notice 573 Report
RCLRPT-24V135-8404.PDF 215.499KB
Recall Acknowledgement
RCAK-24V135-6603.pdf 645.267KB
Manufacturer Notices(to Dealers,etc) – Service Information Bulletin re RECALL 24V-135: REPLACING THE CELL MODULE OF HIGHVOLTAGE BATTERY
Remedy Instructions and TSB – Service Information Bulletin re RECALL 24V-135: REPLACING THE CELL MODULE OF HIGHVOLTAGE BATTERY
RCRIT-24V135-9124.pdf 390.49KB
Latest Recalls Documents
For the Latest and Most recent Recall Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V135&docType=RCL
- Charge with confidence: ChargePoint builds reliable, flexible and innovative EV charging stations for home, business and fleets. Drivers have access to 24/7 support and hundreds of thousands of places to charge across North America via the ChargePoint app.
- Charge Smart: With the in-depth, user-friendly ChargePoint Mobile App, you can control your electric car charger, easily manage and set reminders, connect to your smart home devices, find stations, get valuable data and charging information, and get access to the app's latest features.
- Vast Network: ChargePoint’s extensive network includes 274k+ ChargePoint stations across North America and Europe, so you have peace of mind wherever life takes you. You can even charge up at plus 565k+ ChargePoint roaming partner stations for added flexibility and convenience when you’re on the go.
- Safe & Durable: Rely on this EV charger to provide safe charging at home, adhering to UL safety standards; The charger can be installed indoor or outdoor with a weatherproof NEMA outlet and includes a cable that stays pliable in very cold weather.
- Fast & Powerful: This charger charges up to 7 times faster than a 110V outlet, delivering an impressive 30 miles of range per hour. The plug is compatible with all EVs (Tesla requires adapter) and works with a 14-50 outlet. Requires 40A or 50A-rated circuit.
- Fast charging Speed: Experience quick and efficient EV charging with the Stylish 16A Level 2 portable EV charger, Charge your car 4x faster than traditional 8A Level 1 chargers, providing a rapid charging solution for your electric vehicle
- Universal Compatibility: Suitable for all EV cars and plug-in hybrids, it's compact, durable, and perfect for home use. Enjoy the convenience of a 23ft cable, ideal for most driveways or garages, The EV charger is perfect for multi-vehicle owners or buildings with EV charging docks. Enjoy the flexibility of charging different electric vehicles with one reliable charger.
- Excellent Protection:With an intelligent chip, the Level 2 EV charger offers comprehensive protection including lightning, leakage, grounding, over voltage, under voltage, over charge, over current, and overheat protection. CE certification, IP66 control box and EV connector ensure safe and secure charging.
- Portable & Convenient:Effortlessly carry and store the EV charger with the included portable bag. Simply plug into a NEMA 6-20 outlet, the NEMA 5-15 Outlet is included , and the compact size, along with the 23 ft extra-long charging cable, ensures compatibility with most driveways or garages
- EVDANCE 12 Months Warranty: EVDANCE covers a period of 12 months from the date of purchase. During this time, if you encounter any issues with your charger that are due to manufacturing defects or workmanship, Our dedicated team will assist you in resolving the matter promptly.
- COMPATIBILITY: Wall Connector is compatible with all Tesla models: Model S, Model 3, Model X and Model Y.
- CHARGING SPEED: Up to 44 miles of range per hour of charge, with up to 11.5 kW / 48 amp output, depending on Tesla model and breaker size.
- CONVENIENCE: Indoor or outdoor installation (by your own electrician or one of the 1,400+ Tesla Certified Electricians) with variable amperage that allows max output to be customized to an existing power supply and supports any output up to 48A. Possible max output configurations include: 48A, 40A, 32A, 24A, 16A, 12A.
- CONNECTIVITY: Connecting the Wall Connector to a local Wi-Fi network enables over-the-air firmware updates for continual product improvements and remote access control.
- POWER-SHARE: Power-share is ideal for locations that need to charge more than one Tesla at the same time. This functionality allows up to six Wall Connectors to be linked for efficient power management.
- Faster Charging - Enjoy 6x faster charging with this charger with Level 2, 32Amp output power and NEMA 14-50 plug. 2-in-1 design, you can use mobile or wall-mounted.
- Adjustable Current & Delayed Start - Its adjustable current range is 10/16/24/32Amp, allowing you to customize the charging speed according to your specific needs.
- Smart APP control - EV Charge can monitor and specify the charging start time in real time. You can remotely control and monitor the charging status through the smart APP, view charging costs, history, full charge notification, track charging status, and adjust the current before charging.
- Excellent protection - This product is IP66 waterproof, which is higher than most IP55 waterproof levels on the market. It has passed international certification and has lightning protection, leakage, grounding, low voltage, overvoltage, overcharge, overheating, overcurrent and other protection functions, making it You can use it with more peace of mind.
- Universal Compatibility - EV Charge is compatible with most J1772 compliant electric vehicles and plug-in hybrid vehicles. Ideal for users with more than one electric vehicle or buildings with electric vehicle charging bases. When traveling or visiting relatives and friends, you no longer have to worry about charging.
- Grizzl-E Classic NEMA 14-50 Plug with 24 Feet Premium Cable is a simple, powerful, heavy-duty and portable Electric Vehicle Charging Station which is suitable for normal and cold weather. Compatible with all EVs and PHEVs sold in North America.
- UL Full Tested and Certified. Eligible for Federal rebate program. IP67 (Water resistant), Fire resistant. Over Current, Over Voltage , Under Voltage, Missing Diode, Ground Fault, and Over Temperature Protections. Self-Monitoring and Recovery, Power Outage Recovery. Built in GFCI.
- Fast charging and adjustable amperage: 40A, 32A, 24A, 16A. Maximum current output of 40 Amps for 50A circuit breaker, 32 Amps for 40A circuit breaker, 24 Amps for 30A circuit breaker, or 16 Amps for 20A circuit breaker. Charge Rate: 28-30 miles per hour at 40A, 22-25 miles per hour at 32A, 15-18 miles per hour at 24A and 10-12 miles per hour at 16A.
- Easy to install and use. Save hundreds of dollars on installation : just install a simple 14-50R outlet and you are ready to plug in your Grizzl-E. Easily transportable. Simple to remove from the mounting bracket and transport between different locations. NEMA-4 water and air tight metal enclosure. More power and output configurations for your money than any other charging station.
- 9X FASTER: EVIQO is electric vehicle charger for home providing 38 m/h (40 amp ev charger by default) and 46 m/h if hardwired and set as a 48A EV charger. Max output for EV charging station level 2 is set with a dip switch. Adjustable current: 1A increment in EVIQO app. Stay EVIPOWER-ful with live 24/7 post-sale customer support.
- SAFE, USA CERTIFIED: EVIQO electric car charger level 2 is UL compliant, Energy Star, ETL and FCC certified EV charging station with 2+1 year Extended Manufacturer Warranty. EVIQO level 2 home ev charger is weatherproof. This EV car charger level 2 is suitable for use as an indoor/ outdoor EV charger. EVIQO EV wall charger level 2 meets NEMA 4 and IP66 protection standards.
- SMART APP: EVIQO surveyed 1,800 EV owners to create EV home charger level 2 app. Set up to 3 schedules for cost savings during off-peak rates. Get smart tips and reminders, track power/costs live and monitor the charging history. Enjoy sleek intuitive interface of your electric car charger 240v. EVIQO level 2 car charger consistently enhances its firmware with remote OTA updates.
- COMPATIBLE WITH ALL EVs: EVIPOWER electric car home charging stations are equipped with heavy duty rubberized SAE J1772 connector compatible with all EVs / PHEVs in NA: all Tesla models, Chevrolet Bolt, VW ID 4, Nissan Leaf, Polestar 2, Ford Mustang Mach-E, IONIQ 5/6, BMW i3, i4, iX, Mercedes EQS, Audi, Rav4, VW ID 4, Jeep Wrangler 4xe level 2 charger (Tesla requires an adapter).
- FIRST-IN-CLASS: EVIQO electric vehicle charging stations offer the MARKET'S LONGEST 37" input cable with a NEMA 14-50 plug along with a 25' EXTRA LONG output cable.
- 【Makes For A Nice Setup】DAOLAR dock and hook combination is truly the perfect accessory for your EV charger. It is a simple addition that will have a huge impact to the outlook of your garage. The design concept is to keep your space organized and protect your charger from damage
- 【Heavy Duty and Durable】Heavy duty metal makes this charger holder extremely durable that can hold your EV Charger steady,and super easy to clean
- 【Perfect Fit All J1772 Plug】Highly recommend to anyone who want to mount standard J1772 type connector, indoors or outdoors
- 【Simple to Use】Simple insert and click the EV charging nozzle. The long charging cables can be easily coiled up and hung on the deep J hook
- 【No Cable Mess】Our cable organizer keeps your space clean by providing your wall ev charger with a safety storage holder - preventing kinking or tangling - so it stays ready for the next charge
- NOTE: It is necessary to use a J1772 to Tesla adapter in order to use Tesla vehicles.
- 8X FAST CHARGING: This fast charging car charger operates at Level 2 capacity, delivering an impressive 40Amp/240V, providing a formidable 9.6 KW charging capability. Experience unparalleled speed as it charges your electric vehicle up to 8 times quicker (at an impressive rate of 29~36 miles per hour) compared to a standard Level 1 charger.
- CHARGE ANY VEHICLE: This electric vehicle charger is universally compatible with all non-Tesla EVs and hybrids that utilize the standard J1772 plug connector, encompassing models.
- SMART CHARGING: Adjust the current limit (10A/16A/20A/24A/32A/40A) to match your home's circuit and with delay start, you can stagger the peak period of use to save electricity and reduce load
- Real-Time Charge Monitoring: Stay in the know with LED indicators and a vivid 1.77 nch TFT screen that provides instant updates on voltage, current, and power load, keeping you informed about the charging progress.
- UNIVERSAL COMPATIBILITY: Seamlessly transitions between NACS and J1772 connectors, accommodating all major North American EVs including Tesla Vehicles
- CHARGING SPEED: Up to 44 miles of range per hour of charge, with up to 11.5 kW / 48 amp output, depending on Tesla model and breaker size.
- CONVENIENCE: Indoor or outdoor installation (by your own electrician or one of the 1,400+ Tesla Certified Electricians) with variable amperage that allows max output to be customized to an existing power supply and supports any output up to 48A. Possible max output configurations include: 48A, 40A, 32A, 24A, 16A, 12A.
- CONNECTIVITY: Connecting the Wall Connector to a local Wi-Fi network enables over-the-air firmware updates for continual product improvements and remote access control via the app.
- POWER-SHARE: Power-share is ideal for locations that need to charge more than one Tesla at the same time. This functionality allows up to six Wall Connectors to be linked for efficient power management.
- ❤ [Working Voltage]: 👍Fits for: 110V-260V, suggest 220V or 240V(32A). 👍If your input voltage is under 220V, the safe current(Amperage) may be adjusted below 32A automatically. 👍If your input voltage is 110V, the default setting current is 15A, some cars may adjust to 12A because part of the electric cars such as Tesla will be adapted to the appropriate current according to the voltage change.❤ [Operating Regulations]: 👍Plug Socket: Only works with Nema 14-50 plug-in socket; 👍Doesn't charge or shows "No Plug error": Pull out the charging gun, long press "Ⓐ Button" until the screen shows "Plug-and-Play", then re-start and it will work well.
- ❤ [6X Faster with ETL, FCC and CE Listed, Meets the Safety Criteria Defined by: SAE J1772, UL2231-1/-2, UL 991, UL 2231, UL 2251, UL1998 and UL 2594 & Compatible with all EVs and PHEVs Sold in North America]: Say goodbye to slow level 1 ev charger and enjoy 6X faster charging. Designed with J1772 TYPE 1 standard connector, compatible with Tesla (Adaptor Needed), Ford, GM, Nissan, Audi, Kia, Honda, BMW, Kia, Hyundai, Gmc, Chevy, etc.❤ [Up to 7.68kWh High Speed Charging & Adjustable Amperage from 16A to 32A]: Maximum current output of 32 Amps for 40A circuit breaker, 24 Amps for 30A circuit breaker, or 16 Amps for 20A circuit breaker.
- ❤ [2 Operating Modes: LED Screen Touch Control or APP Control, Real-time Monitor and Appoint The Charging Start Time, Save your Money]: The LED Screen Clearly show the Amperage, charging speed, input voltage, delay time, charge safely. For the touch buttons: 1. Pull out the charging gun, otherwise the touch buttons will no respond; 2. Long press "Ⓐ" to switch "Plug-and-Play" or "APP Start" charging modes; 3. Short press "Ⓐ" to adjust the amperage from 16A to 32A by needs.❤ The APP allows your vehicles to be charged during off-peak period by setting the delay start time, save the electricity bills. Check the charging cost, history, fully-charged notification, track the charging status.
- ❤ [Wi-Fi Reset Function, Add New Device Quickly]: If you can't find your device or you have replaced a new phone, you can use the Wi-Fi Reset Function, then you will find the device and connect quickly! (Pull out the charging gun, simultaneously long press the Ⓐ button and time adjustment button on the product screen until it shows "WIFI Reset", then re-start your device.) ❤ [Nema Type 4 Protection Degree & 25ft Long Bold Cable]: Approved by NEMA Type 4, the Aimiler ev charger can be used indoor or outdoor. Equipped with 25 feet military grade charging cable, the drop-resistant plug endures over 10,000 charges, up to 2 tons of pressure, and offers a 20-year lifespan.
- ❤ [Question & Answer 1: Why can't find the device on app? or Can't find the device after changing phones]: Solutions: 1. Confirm your phone to connect with the 2.4Ghz wifi, not connect the wifi whose name has 5G suffix; 2. Turn on the wifi and bluetooth of the phone; 3. Wifi reset: Pull out the charging gun, simultaneously long press the Ⓐ button and time button on the product screen until it shows "WIFI Reset". 4. Re-start and add your device.
Last update on 2024-04-22 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.
SEOCONTENT-START
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-135
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
BMW of North America, LLC FEB 23, 2024 NHTSA Recall No. : 24V-135 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 : 4
Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2024-2024 BMW i4 xDrive40, i4 M50 Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC
Descriptive Information : Approximately 3 vehicles were manufactured with a high-voltage battery module(s) that may not have been assembled according to specifications. Basis for recall population determination:
Vehicle manufacturing information and component assembly records were reviewed to determine the number and production date range of potentially affected vehicles. Recall component difference to non-recall component:
The high-voltage battery module(s) may not have been assembled according to specifications. Production Dates : SEP 23, 2023 – FEB 05, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-135 Page 2 Vehicle 2 : 2024-2024 BMW i5 eDrive40 Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC
Descriptive Information : Approximately 1 vehicle was manufactured with a high-voltage battery module(s) that may not have been assembled according to specifications. Basis for recall population determination:
Vehicle manufacturing information and component assembly records were reviewed to determine the number and production date range of potentially affected vehicles. Recall component difference to non-recall component:
The high-voltage battery module(s) may not have been assembled according to specifications. Production Dates : DEC 07, 2023 – DEC 07, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The high-voltage battery module(s) may not have been assembled according to specifications. The laser welding process, which connects the cell contacting system to a cell terminal, may not have been performed appropriately. This could result in an insufficient weld seam at that location, and could cause a disconnection between the cell contact system and the terminal. During the module assembly process, some modules which contained insufficient weld seams may not have been removed from the process.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : This could lead to an overheating of the module and, in a rare case, a thermal event.
Description of the Cause : NR Identification of Any Warning NR
that can Occur : Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-135 Page 3 Component Name 1 : High-Voltage Battery Module Component Description : High-Voltage Battery Module Component Part Number : 8863448 Supplier Identification : Component Manufacturer
Name : BMW AG Address : NR
NR
Country : NR Chronology :
On February 12, 2024, during an internal quality check of the high-voltage battery modules, an inadequate weld was noticed. An engineering investigation was immediately initiated. A review of the high-voltage battery assembly process, and vehicle production and logistics records, was performed. It was determined that the laser welding process, between the cell contacting system and a cell terminal, may not have been performed appropriately. Further reviews indicated that some modules with insufficient weld seams may not have been removed during the assembly process. As a precaution, on February 14th, a vehicle stop ship at a vehicle assembly plant, and a corresponding dealer hold, was issued. On February 15, 2024, BMW decided to conduct a voluntary safety recall. BMW is not aware of any customer complaints, concerns, and/or instances, dealer field reports, or warranty claims that relate, or may relate, to the issue identified in this report. BMW has not received any reports, nor is BMW otherwise aware, of any incidents, accidents or injuries that relate, or may relate, to the issue identified in this report. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-135
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy : Description of Remedy Program : The affected high-voltage battery module will be replaced.
Owner notification letters are not required, as the one potentially affected owner was contacted on February 16th, and their vehicle was immediately brought to an authorized BMW center to have the remedy performed. As there was only one potentially affected owner, and this owner has not replaced the module at their own expense, reimbursement for a pre- notification remedy re Part 573.13 and Part 577.11 is not necessary.
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
High-Voltage Battery Module – part number: 8863448 NR Recall Schedule : Description of Recall Schedule : Dealer notification is expected to begin and end on February 23, 2024.
Owner notification letters are not required, as the one potentially affected owner was contacted on February 16th, and their vehicle was immediately brought to an authorized BMW center to have the remedy performed.
Planned Dealer Notification Date : FEB 23, 2024 – FEB 23, 2024 Planned Owner Notification Date : NR – NR
* NR – Not Reported
**************************************************************************************************************
© 2024 BMW of North America, LLC
Service Information Bulletin February 22, 2024
General Electrical Systems B61 04 24
RECALL 24V-135: REPLACING THE CELL MODULE OF HIGHVOLTAGE
BATTERY
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
G26 i4 xDrive40
G60 i5 eDrive40
AFFECTED VEHICLES
Vehicles which require this Recall 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 Delivery Stop (effective February 14, 2024) on small number of Model Year
2024 BMW vehicles that were produced between September 23, 2023, and February 5, 2024.
As of February 19, 2024, this Delivery Stop has been upgraded to a Safety Recall.
Do not deliver to a customer, a New, Certified Pre-Owned or Used vehicle subject to a Delivery Stop,
until the vehicle is repaired. Do not use or sell replacement equipment/parts subject to a Delivery
Stop.
The Recall Notice and FAQ have been attached for additional information.
CAUSE
A manufacturing defect in the high-voltage battery can interrupt the electrical contact between the
high-voltage cell terminal and the cell contacting system.
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”.
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
© 2024 BMW of North America, LLC
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 Highvoltage
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 high-voltage battery cell module position 6 per REP 61 27 721 – Replacing cell module 6
(After vehicle diagnosis) (Cover for high-voltage battery unit removed).
Module ID Module ID ISTA Position
T588634480123B22930000762515271 8863448 01 62515271 17.08.23 00007 6
PARTS INFORMATION
Please enter a Recall IDS Ticket and the parts listed below will be ordered for you.
G26
Part number Description Quantity
61 27 8 832 708 Pad 12
61 27 9 454 253 Multi-purpose bolt 14
61 25 8 833 846 Hexagon bolt 10
61 25 8 833 851 Hexagon bolt 4
© 2024 BMW of North America, LLC
07 14 6 899 140 Cage nut 4
39 10 6 865 725 Multi-purpose bolt 4
07 11 9 905 399 Hexagon screw with washer 4
33 30 6 861 221 Torx bolt 10
61 27 8 863 448 Cell module, high-voltage battery 1
61 27 9 454 854 Screw 20
61 27 8 677 639 Screw 6
61 27 9 884 703 Gasket 1
07 14 8 838 288 Sealing bolt 20
07 14 8 860 492 Screw 82
G60
Part number Description Quantity
61 27 8 832 708 Pad 12
61 27 9 454 253 Multi-purpose bolt 14
61 25 8 833 846 Hexagon bolt 10
61 25 8 833 851 Hexagon bolt 4
07 14 6 899 140 Cage nut 4
39 10 6 865 725 Multi-purpose bolt 4
07 11 9 905 399 Hexagon screw with washer 4
33 30 6 861 221 Torx bolt 10
61 27 8 863 448 Cell module, high-voltage battery 1
61 27 9 454 854 Screw 20
61 27 8 677 639 Screw 6
61 27 9 884 703 Gasket 1
07 14 8 838 288 Sealing bolt 20
07 14 8 860 492 Screw 82
07 14 6 884 435 Multi-purpose bolt ASA 2
07 11 9 908 280 Hexagon bolt 4
07 14 7 283 812 Speed nut 2
31 11 6 899 302 Multi-purpose bolt 8
Bulk Material – Sublet
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.
Part Retention
The parts replaced to perform and submit for this Service Action repair procedure are the property of
BMW NA.
© 2024 BMW of North America, LLC
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.
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 to replace Cell Module Position Six (6) will be via normal claim entry
utilizing the applicable work package information below and the part numbers listed above that apply.
Repair Code: 0061360800 —
Below are the special flat rate labor operation code choices for this action.
Completion before the first vehicle delivery to a customer or the vehicle is already in the
workshop.
Work Pkg Labor Operation Description (Plusposition work) Labor Allowance
# 1 00 75 877*
Removing and installing high-voltage
battery, including removing and installing
lid
101 FRU (G60);
105 FRU (G26)
And: 00 75 879*
Replace identified high-voltage cell
module (module position 6)
19 FRU
Or:
The vehicle arrives at your center and this Recall shows open (No other Main work will be
performed or claimed during this workshop visit)
Work Pkg Labor Operation Description (Main work) Labor Allowance
# 2 00 75 289*
Removing and installing high-voltage
battery, including removing and installing
lid
103 FRU (G60)
107 FRU (G26)
And: 00 75 879*
Replace identified high-voltage cell
module (module position 6)
19 FRU
Only one Main work flat rate labor operation code can be claimed per workshop visit.
(*) Also included in the special flat rate operation codes provided above:
61 27 700 Charging cell module (Associated work, cell module removed)
© 2024 BMW of North America, LLC
61 27 900 Performing EoS test for high-voltage battery unit (Associated work, (after having
repaired the high-voltage battery unit)
61 27 901 Additional work with pressure test cooling system high-voltage battery unit
Claim Repair Comments
Only reference the SIB number and the work package (Pkg) number performed in the technician’s RO
notes and in the claim comments (For example: B61 04 24 WP 1), unless otherwise required by State
law.
And:
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 material (BMW part
number) is at the dealer net price amount for the proportional quantity used plus your center’s
handling.
BMW Antifreeze/Coolant: Claim the corresponding sublet dollar amount for the quantity needed to
replace what was drained. The one-gallon concentrate part number quantity for a 50/50 coolant/water
solution.
Enter this material cost in sublet and itemize the amount on the repair order and in claim comment
section.
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 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 should receive a reimbursement request from a customer for a repair that may qualify
because it addressed the issue described in this bulletin, and it was performed prior to the notification
of Recall, 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 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
© 2024 BMW of North America, LLC
Parts Feedback
To submit feedback for the PARTS section of this bulletin: Submit an IDS
ticket to the Parts Department
**************************************************************************************************************
**************************************************************************************************************
**************************************************************************************************************
**************************************************************************************************************
**************************************************************************************************************
SEOCONTENT-END