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 BMWeBay logo of North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 713

 

Summary

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

 

Remedy

BMWeBay logo will notify owners, and dealers will inspect and, if necessary, replace the battery modules, free of charge. BMWeBay logo issued owners an interim notification on October 16, 2020. Although potentially affected BMWeBay logo owners received interim owner notification letters, all potentially affected BMWeBay logo owner vehicles have been remedied; therefore, BMWeBay logo Final owner notification letters will not be necessary. Owners may contact BMWeBay logo 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.safercar.gov.

 

Check if your BMW has a Recall

 


SIB 61 17 20
2020-09-11

RECALL 20V-490: HIGH-VOLTAGE BATTERY

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.

 

MODEL

E-SeriesModel DescriptionProduction Date
G01X3 xDrive30e Sports Activity Vehicle (SAV)July 8, 2020 – August 6, 2020
G20330e SedanJune 15, 2020

 

AFFECTED VEHICLES

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.

 

SITUATION

BMWeBay logo AG has issued a Delivery Stop (effective August 7, 2020) on certain Model Year 2020-2021 BMWeBay logo 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.

 

Attention!

 

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.

CAUSE

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.

 

CORRECTION

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

 

PROCEDURE

Refer to the attachment.

 

PARTS INFORMATION

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 CampaignPart Number for EPC for comparison 

Description

 

Quantity

61 27 8 843 41161 27 8 658 344High-voltage battery module (34AH NEG)As needed
61 27 8 843 41261 27 8 658 345High-voltage battery module (34AH POS)As needed
07 12 9 908 57007 12 9 908 570ISA screw (V-M6 GFX16)As needed
61 27 8 606 05761 27 8 606 057ISA screw (M6 GFX85-10.9- S)As needed
61 27 8 606 05861 27 8 606 058ISA threaded end screw (M6 GFX85-10.9-S)As needed
61 27 8 677 63861 27 8 677 638Hexagon bolt with inside Torx (M6x25mm)As needed
61 27 8 645 44661 27 8 645 446Hexagon bolt with inside TorxAs needed
See EPCSeal for high-voltage batterySeal for high-voltage batteryAs needed
83 19 2 468 44283 19 2 468 442BMWeBay logo HT-12 Antifreeze CoolantSublet 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 BMWeBay logo of North America (BMWeBay logo 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 BMWeBay logo 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.

 

WARRANTY INFORMATION

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:0061540500Gx Check PHEV high-voltage batteries

 

The vehicle is already in the workshop-

Work PkgLabor OperationDescription (Plus work)Labor Allowance
# 100 69 859Checking the charging history (if 100% SOC), no repair is necessary4 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 PkgLabor OperationDescription (Main work)Labor Allowance
# 200 69 318Checking the charging history (if 100% SOC), no repair is necessary6 FRU

 

Or:

The vehicle is already in the workshop

Work PkgLabor OperationDescription (Plus work)Labor Allowance
# 300 69 863Checking the charging history (if not 100% SOC), reading out serial numbers (Additional work is necessary, see below)5 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 PkgLabor OperationDescription (Main work)Labor Allowance
# 400 69 322Checking 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.

 

And:

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 OperationDescription (Additional/Associated work)Labor Allowance
00 69 864Additional work: removing and installing high-voltage battery, including removing and installing lid49 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 4Up to $40.00Reimbursement for the repair-related bulk material (Do not use the BMWeBay logo part numbers for claim submission)

 

Sublet reimbursement calculation for claiming the applicable repair-related bulk materials (BMWeBay logo part numbers) is at the dealer net price amount for the quantity used plus your center’s handling.

 

BMWeBay logo 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.

 

QUESTIONS REGARDING THIS BULLETIN

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

SAFETY RECALL NOTICE

 

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

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

BMWeBay logo AG has issued a Delivery Stop (effective August 7, 2020) on certain Model Year 2020-2021 BMWeBay logo 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

RECALL 20V-490: HIGH-VOLTAGE BATTERY

DO NOT ATTEMPT TO CHARGE VEHICLE!

 

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 BMWeBay logo repair instructions depending on the vehicle.

 

Note:

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.

 

Note:

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
BMWeBay logo 3 Series, X3 SAV, X5 SAV
MINIeBay logo Countryman
Issue Date: 08/14/2020
Last Update: 08/14/2020

 

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

Certain Plug-In Hybrid-Electric Vehicles (PHEV), specifically Model Year 2020-2021 BMWeBay logo 3 Series, X3 SAV, X5 SAV, and MINIeBay logo 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?

No.

 

Q6. How did BMWeBay logo Group become aware of the issue?

BMWeBay logo 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 BMWeBay logo center at www.bmwusa.com/dealer.

To ensure the BMWeBay logo Group has your most recent contact and vehicle information, please register your BMWeBay logo vehicle at www.bmwusa.com/myBMW.  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

DO NOT ATTEMPT TO CHARGE VEHICLE!

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

Vehicles

MAKEMODELYEAR
BMWeBay logo330E2021
BMWeBay logoX32020-2021
BMWeBay logoX52021
MINIeBay logoCOUNTRYMAN2020

 


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

 


Latest Recalls Documents

 


 

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  • [DESIGNED WITH J1772 Connector for All North America j1772 Connector EVs/PHEVs. Not fits for Tesla/Nacs Connector Cars(j1772 to Tesla adapter needed)]: Compatible with Tesla cars (Adapter needed, not included), Ford, GM, Audi, Kia, Honda, Kia, Hyundai, Gmc, Chevrolet Bolt, VW ID 4, Nissan Leaf, Ford Mustang Mach-E, IONIQ 5 2024 and before, BMW i3, i4, iX, Jeep Wrangler 4xe, etc. [Not fits for Nac connector cars-Kia EV6 2025/EV9,Ariya 2025&2025 loniq 5(J1772 to Tesla adapter needed)]
  • [Safety & Faster Charging with ETL, FCC, Energy Star Certified]: Meets the Safety Criteria Defined by: SAE J1772, UL2231-1/-2, UL 991, UL 2231, UL 2251, UL1998 and UL 2594. (ETL and FCC certified EV car charger with 3-year Warranty)
  • [Plug-play Mode(The Default Setting), Smart Touch Screen, No APP Needed]: Clearly show the charging amperage, charging speed, input voltage, delay time, etc. For the touch buttons: 1. Pull out the charging gun before press the buttons, otherwise no respond; 2. Long press "Ⓐ" or "Time" button to enter the setting interface, then you can adjust the amperage from 16A to 48A freely or Set the charging start time; 3. You can do "factory reset" if doesn't charging.
  • [Smart WIFI APP, You can Set the Charging Period]: By APP, you can wirelessly check the charging cost, history, fully-charged notification, track the charging status, during off-peak period, etc. [Wi-Fi Reset/Factory Reset Function, Add New Device Quickly]: If you can't find your device or you have replaced a new phone, just pull out the charging latches, simultaneously long press the Ⓐ button and time adjustment button on the product screen until it shows "Factory Reset", then wait 3-5 seconds and re-start your device.

This product presentation was made with AAWP plugin.

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