High Voltage Battery Damage from Water Intrusion – 2021-2023 MINI Hardtop 2 Door (Cooper SE)

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-302
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
BMW of North America, LLC APR 29, 2024 NHTSA Recall No. : 24V-302 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 : 128 Estimated percentage with defect : 10 %
Vehicle Information : Vehicle 1 : 2021-2023 MINI Hardtop 2 Door (Cooper SE) Vehicle Type : LIGHT VEHICLES Body Style : 2-DOOR Power Train : HYBRID ELECTRIC
Descriptive Information : Approximately 128 vehicles were manufactured with a high voltage battery housing 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 housing may not have been assembled according to specifications. Production Dates : JUN 12, 2020 – NOV 30, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : Potentially affected high voltage battery housings may not have been produced according to specification.
On certain production dates, there was an insufficient application of the sealing compound around the sealing surface of the two housing halves of the high voltage battery module, which could lead to water ingress in the high voltage battery.
If water ingress enters the housing of the high voltage battery, an isolation fault will be set, and the vehicle will display a warning message. Over time, water
ingress can lead to further isolation faults. Part 573 Safety Recall Report 24V-302 Page 2 FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If a significant amount of water were to enter the high voltage battery,
multiple isolation failures could occur. The vehicle may stall. If multiple isolation faults were to occur, this could, over long periods of inactivity, lead to an overheating of the high voltage battery and, in rare cases, a thermal event, even when the vehicle is not in operation.
Description of the Cause : NR Identification of Any Warning
that can Occur : If an isolation fault occurs, the vehicle will display a warning message to the driver, warning them of the fault and advising the vehicle be inspected by a MINI service center. Involved Components : Component Name 1 : High voltage battery housing Component Description : High voltage battery housing Component Part Number : N/A Supplier Identification : Component Manufacturer
Name : BMW Plant Dingolfing Address : NR
Foreign States
Country : Germany Chronology :
In October 2023, BMW became aware of a field incident in the U.S. involving a MINI Hardtop 2 Door (Cooper SE) in which the vehicle experienced a thermal event. An engineering analysis of this vehicle was initiated. In January 2024 BMW AG was informed of an additional field incident in Germany. Engineering analysis of the vehicle identified isolation faults within the high voltage battery. Additional analysis was started to further understand the root cause of the isolation fault. In March 2024, root cause analysis continued, which indicated that it was likely that the thermal events were triggered by multiple isolation faults in the high voltage battery system. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-302
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The information contained in this report was submitted pursuant to 49 CFR §573
In April 2024, supplier production and process records were examined, as well as further review of the field situation regarding isolation faults in the high voltage battery. An insufficient sealing process of the high voltage battery during production, for specific and limited time periods, was identified. Vehicle assembly information and supplier production and process records were reviewed to determine the potentially affected vehicles. On April 22, 2024, BMW decided to conduct a voluntary safety recall for certain vehicles produced with an insufficient sealing of the high voltage battery. Additional field monitoring of isolation faults is planned.
Description of Remedy :
Description of Remedy Program : The high voltage battery will be leak tested and inspected for isolation
faults within the high voltage battery housing. If water ingress is present, the high voltage battery will be repaired. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
Owners will be notified by First Class mail advising them of the recall and to schedule an appointment with an authorized MINI center to have the remedy performed for free. If this condition were to occur to a potentially affected vehicle prior to this recall, the remedy would be covered by the MINI New Vehicle Limited Warranty program. Therefore, reimbursement for a pre-notification remedy re Part 573.13 and Part 577.11 is not necessary.
High voltage battery housing, p/n – N/A. NR Recall Schedule :
Description of Recall Schedule : Dealer notification is expected to begin and end on April 29, 2024.
Owner notification is expected to begin and end on June 21, 2024.
Planned Dealer Notification Date : APR 29, 2024 – APR 29, 2024
Planned Owner Notification Date : JUN 21, 2024 – JUN 21, 2024
* NR – Not Reported

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