Safety Recall 20V-490 – High-Voltage Battery Plug-In Hybrid-Electric Vehicle (PHEV) – 2020-2021 BMW 3 Series, X3 SAV, X5 SAV

August 18, 2020 NHTSA CAMPAIGN NUMBER: 20V490000

Hybrid Battery May Short-Circuit

A short-circuited hybrid battery may increase the risk of a fire.


NHTSA Campaign Number: 20V490

Manufacturer BMW of North America, LLC


Potential Number of Units Affected 713



BMW of North America, LLC (BMW) is recalling certain 2021 330e and X5 xDrive45e, 2020-2021 X3 xDrive30e, and 2020 MINI Countryman SE ALL4 vehicles. Loose welding beads may form a conductive path between the hybrid battery cells which could lead to a short-circuit.



BMW will notify owners, and dealers will inspect and, if necessary, replace the battery modules, free of charge. BMW issued owners an interim notification on October 16, 2020. Although potentially affected BMW owners received interim owner notification letters, all potentially affected BMW owner vehicles have been remedied; therefore, BMW Final owner notification letters will not be necessary. Owners may contact BMW customer service at 1-800-525-7417.



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


Check if your BMW has a Recall


SIB 61 17 20


This Service Information Bulletin (Revision 2) replaces SI B61 17 20 dated August 2020.


What’s New:

  • Parts Return information and attachments added
  • Warranty Information updated


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.



E-Series Model Description Production Date
G01 X3 xDrive30e Sports Activity Vehicle (SAV) July 8, 2020 – August 6, 2020
G20 330e Sedan June 15, 2020



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.



BMW AG has issued a Delivery Stop (effective August 7, 2020) on certain Model Year 2020-2021 BMW Hybrid-Electric vehicles that were produced between June 15, 2020 and August 6, 2020.


As of August 14, 2020, this Delivery Stop has been upgraded to a Recall.


Highlighted text below is for emphasis.




The vehicle’s high-voltage (HV) battery is not to be charged until you’ve completed the charging history test plan and confirmed that a prior charge has been successfully completed to 100% state of charge (SOC). 


If the vehicle has NOT had a charging process completed to 100% SOC; this vehicle must NOT BE RELEASED to the customer. Refer to the attachment procedure for more information.


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


On Plug-in Hybrid Electric Vehicle (PHEV) models, the HV battery may not have been produced to specifications.  When charging the battery to near its full state of charge, this could lead to a short-circuit and, in rare cases a thermal event.



The vehicle will be inspected and, if necessary, HV module(s) will be replaced.



Refer to the attachment.



Only use and invoice the Part Numbers for Technical Campaign below that apply.


Performing a part number look-up in ETK (EPC) by VIN or model in place of using/invoicing the following part numbers may result with the wrong part numbers being invoiced and installed, this could delay the payment of the claim.


Note: References to G05 have been deleted from this table.

Part Number for Technical Campaign Part Number for EPC for comparison  




61 27 8 843 411 61 27 8 658 344 High-voltage battery module (34AH NEG) As needed
61 27 8 843 412 61 27 8 658 345 High-voltage battery module (34AH POS) As needed
07 12 9 908 570 07 12 9 908 570 ISA screw (V-M6 GFX16) As needed
61 27 8 606 057 61 27 8 606 057 ISA screw (M6 GFX85-10.9- S) As needed
61 27 8 606 058 61 27 8 606 058 ISA threaded end screw (M6 GFX85-10.9-S) As needed
61 27 8 677 638 61 27 8 677 638 Hexagon bolt with inside Torx (M6x25mm) As needed
61 27 8 645 446 61 27 8 645 446 Hexagon bolt with inside Torx As needed
See EPC Seal for high-voltage battery Seal for high-voltage battery As needed
83 19 2 468 442 83 19 2 468 442 BMW HT-12 Antifreeze Coolant Sublet as needed


Additionally, other small parts that are not specified above, such as one-time use screws, nuts 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.


Parts Retention


The parts replaced to perform and submit for this Recall repair procedure are the property of BMW of North America (BMW NA).


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.


Upon claim payment, a DCSnet part return tag will be generated for the High-voltage (HV) battery modules.


Please DO NOT return these recalled HV battery modules directly to the WPRC.


HV battery modules are classified as dangerous goods by the Department of Transportation (DOT) and require special preparation, packing and labeling for transport.


Your center is responsible for following all rules and regulations that apply to shipping dangerous goods as described in the attachments.


Your center can use the Labelmaster® Dangerous Goods Information System (DGIS) for proper shipping procedures and guidelines (additional information for the DGIS can be found in SI B01 22 16).


Please also refer to the attachments for more information.


Any return requested Recall parts that are not received by the WPRC within 60 days of the claim credit date may be subject to debit.



Reimbursement for this Recall will be via normal claim entry utilizing the applicable work package information below, and when required, the part numbers listed above that apply:

Defect Code: 0061540500 Gx Check PHEV high-voltage batteries


The vehicle is already in the workshop-

Work Pkg Labor Operation Description (Plus work) Labor Allowance
# 1 00 69 859 Checking the charging history (if 100% SOC), no repair is necessary 4 FRU



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 69 318 Checking the charging history (if 100% SOC), no repair is necessary 6 FRU



The vehicle is already in the workshop

Work Pkg Labor Operation Description (Plus work) Labor Allowance
# 3 00 69 863 Checking the charging history (if not 100% SOC), reading out serial numbers (Additional work is necessary, see below) 5 FRU



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
# 4 00 69 322 Checking the charging history (if not 100% SOC), reading out serial numbers (Additional work is necessary, see below) 7 FRU


Only one of the flat rate labor operation codes listed above can be used for claim submission/reimbursement purposes.  Also, only one Main work flat rate labor operation code can be claimed per workshop visit.



Additional Work with performing WP # 3 or # 4 only

Note:  Job/repair work time labor operation 00 69 865 (below) will be available in the system for claim submission beginning on September 15, 2020.


Labor Operation Description (Additional/Associated work) Labor Allowance
00 69 864 Additional work: removing and installing high-voltage battery, including removing and installing lid 49 FRU (G01);

53 FRU G20 (330e xDrive);

59 FRU G20 (330e)

And, as required:
00 69 865 (estimated available date is Sept 15, 2020) 6-Module Configuration:  Job/repair work time (WT) for replacing one or more modules in addition to 00 69 864 (approximately 5 FRU additional per each module replaced) WT up to 32 FRU (G01 and G20, with/6-module configuration)


Claim Repair Comments


Only reference the SIB number and the work package (Pkg) number performed in the RO technician notes and the claim comments (For example: B61 17 20 WP 1), unless otherwise required by State law.


Additionally, for WP #3 or WP # 4, please also state the number of modules that required replacement.


As applicable to your center, please refer to SI B01 01 20 or B01 07 20 for claiming your job/repair work time (WT) and the repair-related explanation procedures.


And, as needed:

Sublet – Bulk Materials (RO and Claim Comments Required)

Sublet Code 4 Up to $40.00 Reimbursement for the repair-related bulk material (Do not use the BMW part numbers for claim submission)


Sublet reimbursement calculation for claiming the applicable repair-related bulk materials (BMW part numbers) is at the dealer net price amount for the 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 with 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.


And, as applicable:


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 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 receive a reimbursement request from a customer for a prior repair that may qualify, 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 review and respond to your inquiry accordingly.



Technical inquiries Submit feedback at the top of this bulletin
Warranty inquiries Submit an IDS ticket to the Warranty Department
Parts inquiries Submit an IDS ticket to the Parts Department


Supporting Materials

picture_as_pdf B611720 attachment Procedure_RECALL 20V_490 HIGH_VOLTAGE BATTERY_2.pdf
picture_as_pdf B611720_B-2-0719-0603 HV Batt core.pdf
picture_as_pdf B611720_2020-BMW-MINI-MY2020-2021-PHEV-Fxx-G0x-HV-Battery-FAQ- (14Aug2020).pdf
picture_as_pdf B611720 Recall Notice.pdf
picture_as_pdf B611720 Return Slip – Lithium Instructions.pdf

Attachment to B61 17 20

August 2020



To:  All Center Operators, Sales Managers, Service Manager, Parts Manager and Warranty Processor

RE: Recall 20V-xxx: High-Voltage Battery – B61 17 20

BMW AG has issued a Delivery Stop (effective August 7, 2020) on certain Model Year 2020-2021 BMW Hybrid-Electric vehicles that were produced between May 19, 2020 and August 6, 2020.  As of August 14, 2020, this Delivery Stop has been upgraded to a Recall.

Please be reminded that it is a violation of federal law (The Safety Act) for you to sell, lease or deliver any new motor vehicle covered by this notification until the recall repair has been performed.  This means that centers may not legally deliver new motor vehicles to consumers until they are fixed or use/sell replacement equipment/parts subject to this recall.  Note also that substantial civil penalties apply to violations of the Safety Act. 


Also, you should not sell, lease or deliver any Certified Pre-Owned or used vehicles subject to a safety recall until the repair is completed. 


Please follow any special instructions that we provide to you for the return or disposition of recall parts.


We appreciate all your assistance with this Recall.

Attachment 1 to SI B61 17 20
September 2020




Note: This attachment SI B61 17 20 is only valid for vehicles that have been retailed and in customer possession. This does not apply to vehicles in dealer inventory.  


Connect the vehicle to ISTA diagnostics.  After Short Test is completed; follow the path below:


1. Service Function


2. Hybrid Vehicle


3. High Voltage Battery unit


4. Charging of High Voltage Battery


5. Select:

“Read History of last charging procedures” ABL (test plan)


6. Select:

“State of Charge of the High Voltage Battery at the end of Charging Procedure” (#2 in example)


7. Select:

“Statistics of All Charging Procedures “(#5 in example)


8.  Read out the State Of Charge from the displayed histogram (see illustration).


Note: The SOC ranges are displayed in the bar graph, with a number of occurrences of when a particular SOC level has been achieved (e.g. SOC shows above 80% was reached 13 times in our example, column #6)


9. Using the displayed data on column #6, verify if the vehicle has ever been charged to a SOC greater than 80%.

Proceed to step 10 below


10.  Check the successfully completed charging processes of the high-voltage battery.


11.  Select:

“Reasons for Stopping Charging Procedure” (#3 in example)


Note: There you can access the test module history of the previous charging processes and the causes for the end of the charging processes are displayed.


See example, the charging process was successfully completed with 57 previous charging processes (column 2).


Note: The frequency of the various causes for the stopping of the charging process is displayed on top of the column.


12. See column 2: Charging process completed successfully


13.  Using the displayed data on column 2, verify if the vehicle has, at least one, successfully completed (100% SOC) charging process.


14.  Interpret the findings:


If the charging history test module (in step 9) displays at least one charging process where the SOC reached higher than 80%, AND at least one charging process successfully completed to 100% SOC (in step13); NO MORE ACTION is required, and vehicle can be released to a customer, with the Campaign Recall closed.


If however, the charging history test module (in step 9) does NOT show a charging process higher than 80%, AND NO charging process that was successfully completed to 100% SOC (in step13); then the vehicle must NOT be released back to the customer.

In this case, continue diagnosing with step 15 – Checking the cell modules


Display of serial numbers installed with “Read out saved serial numbers” ABL in ISTA.


15.   Check the HV battery cell module serial numbers with ISTA, using the “Read out saved serial numbers” ABL (Test Plan).


16.   Follow the diagnostic path below:

-> “Vehicle management”

-> “Service functions”

->”High-voltage battery unit”

->”High-voltage battery unit”

-> “Read out saved serial numbers”.


17.   Refer to the example (in the illustration) of the serial numbers installed and proceed as follows.


18.   Review the saved serial numbers of the cell modules installed.


19.   Check the marked position of the serial number for each cell module (5th position from the last).


20.   For numbers 0, 1, 2, the cell module is OK.


21.   For numbers 3, 4, 5, the respective cell module must be replaced.


Note: See bulletin for part information. Replace the affected cell modules using the appropriate BMW repair instructions depending on the vehicle.



The vehicle’s high-voltage (HV) battery is NOT to be charged until you’ve completed the test plan and confirmed that the vehicle has been successfully charged at least once to 100% SOC.



If the vehicle has NEVER had a charging process completed to 100% SOC; this vehicle must NOT be charged and must NOT BE RELEASED (or retailed to a customer) as further repairs are necessary. See procedure above.


Attachment to B61 17 20
August 2020

Safety Recall 20V-xyz
High-Voltage Battery
Plug-In Hybrid-Electric Vehicle (PHEV)
Model Year 2020-2021
BMW 3 Series, X3 SAV, X5 SAV
MINI Countryman
Issue Date: 08/14/2020
Last Update: 08/14/2020


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

Certain Plug-In Hybrid-Electric Vehicles (PHEV), specifically Model Year 2020-2021 BMW 3 Series, X3 SAV, X5 SAV, and MINI Countryman models in the US, produced between March and August 2020, are potentially affected.


Q2. What is the specific issue?

On PHEV models, the high-voltage battery may not have been produced to specifications.  When charging the battery to near its full state of charge, this could lead to a short-circuit and, in rare cases a thermal event.


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

Other models have been produced with a High-Voltage battery that has been produced to specifications.


Q4. Can I continue to drive my vehicle?

Yes.  However, drive in standard mode only, do not use sport mode.

If you are not the only driver of this vehicle, please advise all other drivers of this important information.


Q5. Can I charge my vehicle?



Q6. How did BMW Group become aware of the issue?

BMW Group became aware of the issue through our quality control procedures.


Q7. How will I be informed of this Safety Recall?

Potentially affected customers are being contacted by phone, and arrangements are being made for the Safety Recall to be performed.  Alternate transportation will be accommodated.  You can locate your nearest authorized BMW center at

To ensure the BMW Group has your most recent contact and vehicle information, please register your BMW vehicle at  Registration is free, and will give you access to factory-initiated campaigns and other information specific to your vehicle.


Q8. How will my vehicle be repaired?

Your vehicle will be checked, and if necessary, HV battery module(s) will be replaced.


August 2020

Attachment Procedure to SI M61 04 20


Connect a vehicle to ISTA diagnostic. After Short Test is completed, follow the path:

1. Service Function

2. Hybrid Vehicle

3. High Voltage Battery unit

4. Charging of High Voltage Battery

5. Read History of last charging procedures

6. State of Charge of the High Voltage Battery at the of Charging Procedure (selection #2)

7. Statistics of All Charging Procedures (selection #5)

8. Read out the State of Charge (SOC) from the displayed histogram (see the last picture below). The SOC ranges are displayed, with a number of occurrences when a particular SOC level was achieved shown above the bar graph (e.g. SOC above 80% was reached 13 times in our example, column #6)

9. In case the SOC above 80% was reached at least once, NO FURTHER ACTION is required, and vehicle can be released to a customer, with the Campaign Recall closed.

10. In case State Of Charge did not reach 80%, vehicle SHOULD NOT BE RELEASED. More information on how to repair HV Battery will be available shortly. Make sure that customer is offered a loaner vehicle.




5 Affected Products


BMW 330E 2021
BMW X3 2020-2021
BMW X5 2021


16 Associated Documents

Recall Quarterly Report #1, 2020-4

RCLQRT-20V490-2765.PDF 211.127KB



Remedy Instructions and TSB

RCRIT-20V490-4271.pdf 1955.58KB



Miscellaneous Document Bulletin re HV Battery Recall Return Process

RMISC-20V490-1263.pdf 2021.352KB



Recall 573 Report

RCLRPT-20V490-4884.PDF 216.786KB



Manufacturer Notices(to Dealers,etc) – Subject: BMW High-Voltage Battery – Recall 20V-490 Stop-Sale Compensation and Recall 20V-601 AMP Subsidy Information Date: Thursday, October 8, 2020

RCMN-20V490-7982.pdf 89.477KB



Remedy Instructions and TSB

RCRIT-20V490-9032.pdf 483.222KB



Remedy Instructions and TSB

RCRIT-20V490-5604.pdf 483.07KB



Remedy Instructions and TSB

RCRIT-20V490-5292.pdf 574.721KB



Manufacturer Notices(to Dealers,etc) – Dealer Notification re BMW Delivery Stop: High-Voltage Battery – Update

RCMN-20V490-6473.pdf 418.849KB



Defect Notice 573 Report

RCLRPT-20V490-5778.PDF 216.849KB



Manufacturer Notices(to Dealers,etc) – Dealer Notification re MINI Delivery Stop: High-Voltage Battery – Update

RCMN-20V490-0149.pdf 456.047KB



Remedy Instructions and TSB

RCRIT-20V490-7455.pdf 456.047KB



Recall Acknowledgement

RCAK-20V490-3506.pdf 244.219KB



Recall 573 Report

RCLRPT-20V490-3441.PDF 216.774KB



Remedy Instructions and TSB

RCRIT-20V490-7951.pdf 418.849KB



Interim Owner Notification Letter(Part 577)

RIONL-20V490-8834.pdf 709.804KB



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  • 416 Pages - 02/19/2013 (Publication Date) - McGraw Hill TAB (Publisher)
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NOCO Boost Plus GB40 1000 Amp 12-Volt UltraSafe Lithium Jump Starter Box, Car Battery Booster Pack, Portable Power Bank Charger, and Jumper Cables for up to 6-Liter Gasoline and 3-Liter Diesel Engines
  • Start Dead Batteries - Safely jump start a dead battery in seconds with this compact, yet powerful, 1000-amp portable lithium car battery jump starter pack - up to 20 jump starts on a single charge - and rated for gasoline engines up to 6 liters and diesel engines up to 3 liters.
  • UltraSafe - Safe and easy to use car battery jump starter pack without the worry of incorrect connections or sparks. Safely connect to any 12-volt automotive car battery with our mistake-proof design featuring spark-proof technology and reverse polarity protection.
  • Multi-Function - It's a car jump starter, portable power bank, and LED flashlight. Recharge smartphones, tablets, and other USB devices. It's easily rechargeable from any powered USB port in 3 hours at 2.1-amps. Plus, an integrated 100-lumen LED flashlight with seven light modes, including emergency strobe and SOS.
  • Advanced Design - Our most advanced portable car battery jump starter ever. Featuring high-discharge lithium technology for safe operation in any climate. A rugged and water-resistant enclosure rated at IP65. A rubberized over-molded casing to prevent scratching or marring of surfaces. And an ultra-compact and lightweight design weighing just 2.4 pounds.
  • In The Box - GB40 UltraSafe Portable Lithium Car Battery Jump Starter Pack, Heavy-Duty Battery Clamps, 12-Volt Car Charger, Micro USB Charging Cable, Microfiber Storage Bag, User Guide, 1-Year Warranty, and Designed in the USA.

Last update on 2023-05-27 / Affiliate links / Images from Amazon Product Advertising API

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