Safety Recall 20V-490 – High-Voltage Battery Plug-In Hybrid-Electric Vehicle (PHEV) – 2020 MINI Countryman

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

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 713

 

Summary

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.

 

Remedy

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.

 

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

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SIM 61 04 20
2020-09-04

RECALL 20V-490: HIGH-VOLTAGE BATTERY

This Service Information Bulletin (Revision 2) replaces SI M61 04 20 dated August 2020.

 

What’s New:

• Entire Bulletin

• This Delivery Stop has been upgraded to a Recall

 

Please perform the procedure outlined in this Service Information on all affected vehicles before customer delivery. All the vehicles affected in this defect code are dealer inventory vehicles.

 

MODEL

 

 

AFFECTED VEHICLES

Vehicles which require this Recall 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

BMW AG has issued a Delivery Stop (effective August 11, 2020) on a small number of Model Year 20202021 MINI Countryman (PHEV) vehicles that were produced between June 19, 2020 and June 22, 2020.

 

As of August 14, 2020, this Delivery Stop has been upgraded to a Recall.  Please re-check your dealer inventory as the VIN list has changed.

 

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 (or retailed to a customer), see attachment procedure for more information; No parts are to be replaced by the dealer and the vehicle will need to be temporarily returned to BMW of North America, LLC (BMW NA) for further testing.

 

BMW NA is currently working on the Instructions for the transport of the vehicle and will be provided in the next bulletin update.

 

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

 

The bulletin will be updated when additional information becomes available.

 

CAUSE

On Plug-in Hybrid Electric Vehicle (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.

 

CORRECTION

The vehicle will be inspected and, if necessary, temporarily returned to BMW NA for further testing.

 

PROCEDURE

Refer to the attachment.

 

PARTS INFORMATION

No parts are required.

 

WARRANTY INFORMATION

Reimbursement for this Recall will be via normal claim entry utilizing the applicable work package information below that applies:

 

 

Only one of the flat rate labor operation codes listed above can be used for claim submission/reimbursement purposes.

 

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: M61 04 20 WP 1), unless otherwise required by State law.

 

QUESTIONS REGARDING THIS BULLETIN

 

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Supporting Materials

picture_as_pdf M610420_2020-BMW-MINI-MY2020-2021-PHEV-Fxx-G0x-HV-Battery-FAQ-(14Aug2020).pdf
picture_as_pdf M610420 attachment Procedure_RECALL 20V_490 HIGH_VOLTAGE BATTERY_2.pdf
picture_as_pdf M610420 Recall Notice.pdf

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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

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.

 

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Attachment 1 to SI M61 04 20
September 2020

RECALL 20V-490: HIGH-VOLTAGE BATTERY

DO NOT ATTEMPT TO CHARGE VEHICLE!

 

Note: This attachment SI M61 04 20 is only valid for vehicles that are in dealer inventory and have NOT been retailed to customers.

 

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”

 

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 at least one charging process higher than 80%, AND NO charging process that was successfully completed to 100% SOC (in step13); then this vehicle must NOT BE RELEASED (Do not retail to customer).

 

This vehicle must be sent back to BMW NA for further testing.

 

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). No parts are to be replaced by the dealer and the vehicle will need to be brought back to BMW NA for further testing.

 

Note: 

Instructions for the transport of the vehicle are currently being worked out and will be provided in the next bulletin update. 

 

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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?

No.

 

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 www.bmwusa.com/dealer.

To ensure the BMW Group has your most recent contact and vehicle information, please register your BMW 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.

 

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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.

 

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5 Affected Products

Vehicles

 

 

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16 Associated Documents

Recall Quarterly Report #1, 2020-4

RCLQRT-20V490-2765.PDF 211.127KB

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Remedy Instructions and TSB

RCRIT-20V490-4271.pdf 1955.58KB

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Miscellaneous Document Bulletin re HV Battery Recall Return Process

RMISC-20V490-1263.pdf 2021.352KB

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Recall 573 Report

RCLRPT-20V490-4884.PDF 216.786KB

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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

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Remedy Instructions and TSB

RCRIT-20V490-9032.pdf 483.222KB

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Remedy Instructions and TSB

RCRIT-20V490-5604.pdf 483.07KB

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Remedy Instructions and TSB

RCRIT-20V490-5292.pdf 574.721KB

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

RCMN-20V490-6473.pdf 418.849KB

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Defect Notice 573 Report

RCLRPT-20V490-5778.PDF 216.849KB

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

RCMN-20V490-0149.pdf 456.047KB

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Remedy Instructions and TSB

RCRIT-20V490-7455.pdf 456.047KB

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Recall Acknowledgement

RCAK-20V490-3506.pdf 244.219KB

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Recall 573 Report

RCLRPT-20V490-3441.PDF 216.774KB

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Remedy Instructions and TSB

RCRIT-20V490-7951.pdf 418.849KB

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Interim Owner Notification Letter(Part 577)

RIONL-20V490-8834.pdf 709.804KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V490&docType=RCL

 

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