B122818

5/5/2020
12 28 18_MALFUNCTION INDICATOR LAMP (MIL) MULTIPLE MOTOR POSITION SENSOR FAULTS STORED IN EME
SIB 12 28 18
2020-04-14
MALFUNCTION INDICATOR LAMP (MIL) MULTIPLE MOTOR POSITION
SENSOR FAULTS STORED IN EME
MODEL
This Service Information Bulletin (Revision 1) replaces SI B12 28 18 dated October 2018.
What’s New :
- Correction
- Parts Information
- Warranty
- Attachment
MODEL
E-Series
F15
Model Description
X5 40e PHEV Sports Activity Vehicle
Production Date
All
Engine
With N20 engine
SITUATION
The following check control messages are displayed:
CCM 34 "Malfunction indicator lamp (MIL)"
CCM 633 "Powertrain Malfunction!"
One or more of the following faults may be stored in the EME (electrical machine electronics):
222014 - Motor position sensor: Acquisition of measured values or tilt sensor angle faulty
222021 - Motor position sensor: Phase difference between sine input and cosine input greater
than threshold value
222022 - Motor position sensor: Engine speed exceeds threshold value
222029 - Motor position sensor: Offset of signal breakdown of amplitude difference between
sine input and cosine input greater than threshold value
2223B6 - Motor position sensor: Interrupt of sine coil or cosine coil or excitation coil
222724 - Longitudinal dynamics level 2: Group fault torque limits (collective error moment limits)
222725 - Longitudinal dynamics level 2: Angle sensor fault
CAUSE
1. Chafing damage on the wiring harness leading to the EME connector.
2. Contact resistance at the EME’s 58-pin signal connector A190*1B is too high.
3. The wires going to pins 41, 42, 43, 54, 55, and 56 in connector A190*1B are under tension. Vibrations
may sporadically increase the resistance values of these connections outside of the acceptable range,
leading to the activation of the Malfunction Indicator Lamp.
CORRECTION
1. Verify there is no chafing on the harness leading to EME connector A190*1B.
2. Change the harness routing and/or outer tape wrap to allow some slack, then release the tension at
the EME connector.
3. Install new bracket and screw onto EME to support harness (torque screw to 8.5 Nm).
4. Change the cable tie direction on EME connector.
This repair is the same repair that is outlined in SI B65 05 18 F15 PHEV – AIR BAG LAMP
ILLUMINATED- FAULT CODE 9309A0, it also addresses the issues identified in this bulletin
Replacing the EME will not provide a solution to this situation.
Only properly trained personnel, who have passed all applicable technical training courses, should perform
any maintenance or repairs on any Hybrid or Electric Vehicle. Work performed by unqualified persons may
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12 28 18_MALFUNCTION INDICATOR LAMP (MIL) MULTIPLE MOTOR POSITION SENSOR FAULTS STORED IN EME
result in severe injury or damage to the vehicle. Additional information is found in Repair Instruction 61 00…
Observe safety instructions when handling electric vehicles.
PROCEDURE
Refer to the enclosure.
Observe the note concerning handling the wiring harnesses and the lines. Refer to Repair
Operation REP 6100... Notes on handling wiring harnesses and cables.
Use a suitable tool for the repair wiring harness. Refer to Repair Operation REP 6113... Special
tools for wiring harness repairs.
PARTS INFORMATION
Only use and invoice the part numbers 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 claim.
Part Number
61 13 4 A03 DB3
61 25 7 621 147
61 13 8 383 722
Description
Angle Bracket
Screw
Cable Ties
Quantity
1
1
3
WARRANTY INFORMATION
During this workshop visit, the affected vehicle may also show one or more programming and encoding
Technical Campaign repairs also open, the programming and encoding procedure may only be invoiced one
time.
Modify the harness routing/taping, install the new bracket and wire ties as describe above and
update the vehicle to the required I-level by performing and submitting for this repair.
For the other open campaign repairs, please be sure to also perform any additional work (before
and/or after) these repairs require and/or close the remaining programming and encoding Technical
Campaign repairs as outlined in the corresponding Service Information Bulletin.
The repair procedure in this bulletin is covered under the terms of the BMW New Vehicle Limited Warranty
for Passenger Cars and Light Trucks or the BMW Certified Pre-Owned Program.
Defect
Code:
F15 PHEV restraint system CC message (wiring harness
to electrical machine electronics)
6112900100
Vehicle is already in the workshop
Work Pkg
Labor Operation
#1
00 66 548
Description (Plus Work)
Performing vehicle test (with vehicle
diagnosis system – checking faults)
perform repair to EME, clear faults,
program and encode the vehicle (Plus
work – Vehicle is already in the
workshop)
Labor Allowance
18 FRU
Or:
The vehicle arrives at your center and this repair is needed and performed (No other Main work will
be performed/claimed during this workshop visit)
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12 28 18_MALFUNCTION INDICATOR LAMP (MIL) MULTIPLE MOTOR POSITION SENSOR FAULTS STORED IN EME
Work Pkg
#2
Labor
Operation
Description (Main work)
Labor Allowance
00 66 034
Performing vehicle test (with vehicle
diagnosis system – checking faults)
perform repair to EME, clear faults,
program and encode the vehicle (Main
work)
20 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.
Claim Repair Comments
Only reference the SIB number and the work package (Pkg) number performed in the RO technician notes
and in the claim comments (For example: B12 28 18 WP 1), unless otherwise required by State law.
And, as needed:
Sublet – Bulk Materials (RO and Claim Comments Required)
Sublet Code 4 Up to $5.00
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 materials (BMW part
numbers) is at the dealer net price amount for the quantities used plus your center’s handling.
Enter this material cost in sublet and itemize the amount on the repair order and in claim comment section.
Consequential Repair
When additional work and/or parts are required as a direct result of the issue described in this Service
Information bulletin, claim these items under the under the defect code listed above together with the
corresponding labor operations (including any additional diagnosis) listed in AIR if applicable.
Please explain the reason for this consequential repair work (the why and what) on the repair order and in
the claim comments section.
Programming and Encoding - Vehicle Control Units (RO and Claim Comments Required)
The programming procedure automatically reprograms and encodes all vehicle control modules which do
not have the latest software I-level. If one or more control module failures occur during this programming
procedure:
Please claim this consequential control module-related repair work (including performing the
IRAP Control Unit Recovery procedure first as required, refer to the SIB in AIR) under the
defect code listed in this bulletin with the applicable AIR labor operations.
Please explain this additional work (The why and what) on the repair order and in the claim comments
section
For control module failures that occurred prior to performing this programming procedure:
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12 28 18_MALFUNCTION INDICATOR LAMP (MIL) MULTIPLE MOTOR POSITION SENSOR FAULTS STORED IN EME
When covered under an applicable limited warranty, claim the applicable test plan and the
corresponding control module-related repair work using the applicable defect code and labor
operations in AIR (including diagnosis with separate punch times).
Supporting Materials
picture_as_pdf B122818 Attachment 1 Procedure to inspect and repair the EME connector wiring
harness 2.pdf
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Attachment to SI B12 28 18
March 2020
MALFUNCTION INDICATOR LAMP (MIL) MULTIPLE MOTOR
POSITION SENSOR FAULTS STORED IN EME
PROCEDURE
Inspect and repair the EME connector wiring harness: F15 PHEV
Important warning for working on the high-voltage systems on the F15 PHEV:
Only properly trained personnel, who have passed all applicable technical training courses,
should perform any maintenance or repairs on any Hybrid or Electric Vehicle. Work performed
by unqualified persons may result in severe injury or damage to the vehicle. Additional
information is found in Repair Instruction 61 00… Observe safety instructions when handling
electric vehicles.
Note: This repair overlaps with SI B65 05 18 F15 PHEV – AIR BAG LAMP ILLUMINATED
FAULT CODE 9309A0.
1. Position the vehicle on a lift.
2. Visually inspect the EME wiring harness for chafe marks throughout entire visible area.
If there are chafe marks on the wiring harness (arrows) per the examples below, the harness
must be repaired. Go to Step 3.
3. De-energize high-voltage system. Refer to Repair Instructions 61 25 900.
4. Disconnect the 12V battery. Refer to Repair Instructions 61 20 900
5. Remove the underbody paneling on the right side. Refer to Repair Instructions 51 71 016.
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6. Perform a visual inspection of connector
A190*1B on the bottom of the EME.
If there are noticeable problems (e.g. damage,
traces of water, etc.) contact BMW of North
America’s Technical Service Department by
submitting a TSARA case.
7. Remove connector A190*1B from the EME.
Cut the cable tie holding the harness to the EME
connector (circled).
Note:
• Observe the note concerning handling the
wiring harnesses and the lines. Refer to
Repair Operation REP 6100... Notes on
handling wiring harnesses and cables.
• Use a suitable tool for the repair wiring
harness. Refer to Repair Operation REP
6113... Special tools for wiring harness
repairs.
8. Remove the wiring harness tape wrapping
from the connector (arrow).
9. Release the connector cover.
• Examine pins 41, 42, 43, 54, 55, and 56 at the
EME connector (outlined in yellow)
• Also examine pins 7 and 20 (outlined in red)
which are for the ACSM signal
• Notify technical support via a TSARA case if
there is visual/water damage to these pins.
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10. Remove the last 8" of tape from the harness
at the EME connector to reduce the pull tension
of this connection at the EME.
Note: The two wires white and yellow are under
strong tension, thus are entering the connector at
a tight angle (arrow).
11. The wires between the cable tie location
and the EME electrical connector/pins should
NOT be under tension!
The white and yellow wires have been reformed
in a larger radius (arrows) to enable a partial
relief bend. This eliminates tension on the
electrical pins.
12. If more slack is needed at the connector to
enable the larger radius relief bend, locate the
last body tie down approx. 6” back from this EME
connector. Slightly pull on the harness carefully.
13. Wrap Fabric-tape (P/N 61 13 6 902 588)
twice around the wiring harness at the location
where the cable tie will be fastened.
There should be a 2” or larger gap (circled)
between this wrap for the cable tie, and where
the harness’ main wrap begins.
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14. When reinstalling the cable tie
(P/N 61 13 8 383 722) on the end of the EME
connector, point the end of the tie upwards so it
can’t rub on the underbody panel of the vehicle
(right circle).
Also check to make certain there is minimal
tension on the harness so that it won’t droop and
contact the tip of the underbody panel hold down
screw (left circle).
15. Remove bolt from EME. Install the new angle
bracket and screw into the EME as shown here.
•
•
61 13 4 A03 DB3
61 25 7 621 147
Angle Bracket
Screw
The screw must be torqued to 8.5 Nm.
If the heat shield blocks access to this screw,
gently bend it out of the way, and then after
screw and bracket are installed, bend it back into
position.
16. The wiring harness is then laid onto the new
angle bracket and secured with two new cable
ties as shown here.
•
61 13 8 383 722
Cable Ties
There must be some slack between the angle
bracket and the EME electrical connector.
This slack functions as strain relief and prevents
vibrations in the harness/underbody from being
transmitted to the EME electrical connector.
17. Reinstall the underbody paneling on the right side (refer to Repair Operation 51 71 016).
18. Reconnect the vehicle battery (refer to Repair Operation 61 20 900).
19. Reconnect the high-voltage system (refer to Repair Operation 61 25 900).
20. Clear the fault memory.
21. Briefly drive the vehicle in electric mode to verify that the MIL no longer illuminates.
22. Fully charge the high-voltage battery as a courtesy to the customer.
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