High-Voltage Battery May Overheat – 2024 BMW i4 & i5

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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

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© 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

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