B612323

10/19/23, 9:23 AM
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
SIB 61 23 23
SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGHVOLTAGE BATTERY
2023-10-12
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.
☐
THIS REPAIR IS MOBILE FRIENDLY
MODEL
E-Series
G26 BEV
Model Description
i4 Gran Coupe
Production Date
August 10, 2022 – September 2, 2022
AFFECTED VEHICLES
Vehicles which require this Service Action 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 Service Action on certain Model Year 2022 BMW i4 Gran Coupe vehicles that were
produced between August 10, 2022 – September 2, 2022.
CAUSE
As part of the quality controls carried out on an ongoing basis at the BMW Group, it was found that, in very
rare cases, the production process of cells of the high-voltage battery did not meet BMW standards.
CORRECTION
Removal and replacement of affected high-voltage cell modules.
Note: Only one of the vehicle’s high-voltage battery cells should be affected.
PROCEDURE
Important Warning for Working on the High-Voltage (HV) systems on BMW Group vehicles:
Only properly trained personnel, who passed all applicable HV Technical Training Courses, should
perform repairs which require disconnecting, or removal of High Voltage battery components on any
Hybrid or Electric Vehicle. Work performed on High Voltage systems by unqualified persons may
result in severe injury or damage to the vehicle. Additional safety information is found in Repair
Instruction 61 00… “Observe safety instructions when handling electric vehicles”.
Prior to disconnecting, or the removal of any HV component, the HV system needs to be disabled and
secured (by means of the HV Service Disconnect Switch and lock out) by a properly trained HV
technician, who has a minimum HV Qualification level after completing the Technical Training Course
“ST2324 High Voltage Drivetrain Systems” which as of 1/2023* includes ST1824 Alternative Drive Part
1.
* Note: As of January 2023, the HV component portion of the “ST2205 Generation 5 High-voltage
class” (except for the High Voltage Battery) has been merged into “ST2324 High Voltage Drivetrain
Systems”.
Up to Generation 4 Vehicles: Once the vehicle’s HV system is disabled (the “Blitz” - lightning bolt icon
is displayed in instrument cluster, see below), a technician without HV Certification may remove a HV
component (e.g., EH Heater, EKK Compressor, EME Control Unit, et.), except for the High Voltage
Battery.
Copyright ©2023 BMW of North America, Inc.
about:blank
1/8
10/19/23, 9:23 AM
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
For Generation 5 Vehicles however, the specific vehicle training is required to diagnose, remove and
service any HV component and it is NOT allowed for non HV certified technicians to work on the high
voltage system.
High Voltage Battery removal and rework can ONLY be performed by a High-voltage Certified
Technician with a HV Battery Certification level corresponding to a specific Electric or Hybrid vehicle,
for example:
To repair GEN4 HV battery of G05 PHEV a certification from Technical Training Course “ST2006 – SP44
HV Battery” or equivalent ST1825 – Alternative Drive Part 2 is required (or as of 1/2023 the equivalent
“ST 2325 for High Voltage Battery Systems”).
And
To repair A GEN5 HV battery the Technical Training Course “ST2205 Generation 5 High-voltage class”
is required or as of 1/2023* the equivalent “ST 2325 for High Voltage Battery Systems”.
BMW recommends NOT to drive the vehicle NOR charge the high-voltage battery until all repair work
below to remedy the fault has been completed.
Caution:
Please create a TSARA case for ALL vehicles prior to any disassembly.
The steps below must be followed precisely:
1. Please perform the cell module read out test plan in ISTA to determine the serial numbers and
locations of the high-voltage cell modules installed in the vehicle.
Diagnostic path:
Vehicle management > Service function > Electric drive > High-voltage battery unit >
High-voltage battery unit: Read out stored serial numbers ABL.
The “High-voltage battery unit: Read out stored serial numbers” test plan has been updated to identify the
high-voltage cell modules affected by this campaign and their location in the high-voltage battery.
Note:
Once the Cell module read out test plan has been performed, please submit a TSARA case titled “B61
23 23 HV Battery cell module ID process” for assistance in identifying the affected modules (attach the
module serial number read out to the case).
It is imperative that once the new replacement cell module arrives, you attach that module serial
number to the TSARA case for approval.
Only when TSARA approves the replacement module you have clearance to install it in the HV battery
and continue the repair.
Please do not start the repair or submit a TSARA case if the status of the service action is NOT Green,
as there is not yet a “Remedy Available” for this vehicle.
2. The high-voltage battery must be discharged prior to removal to an average cell voltage of 3.51V
using the ISTA test plan below,
before the
high-voltage
batteryAmerica,
is opened
Copyright
©2023
BMW of North
Inc.and the defective modules
about:blank
2/8
10/19/23, 9:23 AM
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
are removed.
Diagnostic path:
Vehicle management > Service function > Electric drive > High-voltage battery unit >
High-voltage battery unit discharged to a defined state of charge (SOC) ABL.
Note:
The High-voltage battery unit discharged to a defined state of charge (ABL) service function is ONLY
available if the high-voltage battery temperature is between 59 to 95 ºF (15°C and 35°C).
3. Replace the defective high-voltage cell modules using repair instructions 61 27 703 to 61 27
877 depending on the affected cell module location.
G26 BEV SE27 HB Battery module locations shown below-
PARTS INFORMATION
Only use and invoice the applicable part listed number below.
Part Number
61 27 8863448
61 27 8863438
61 27 9454253
61 25 8833851
61 25 8833846
07 14 6884435
33 32 6760340
33 30 6861221
61 27 9884703
07 14 8860492
07 14 8838288
61 27 9454854
61 27 8677639
39 10 6865725
07 14 8835104
07 14 6899140
about:blank
Description
Quantity
Cell module, high-voltage battery
Up to 3
Double module for high-voltage battery
Up to 4
14
Multi-purpose bolt (M12x1.5x45)
Hexagon bolt (M12x5x130)
2
Hexagon bolt (5x105)
6
ASA Multi-purpose bolt (M10x35)
4
Torx bolt with washer (M12x127-10.9)
4
Torx bolt (ISA M12x35- 10.9)
10
Gasket
1
Screw (M5)
82
Sealing screw (M8x28)
20
Screw
as needed (max 63)
Screw (M6x18)
as needed (max. 22)
Multi-purpose bolt
4
Multi-purpose bolt (M12x1.5x72-10.9)
4
Copyright ©2023
Cage nut (M12x1.5-10ZNS3)BMW of North America, Inc.
4
3/8
10/19/23, 9:23 AM
61 27 8855826
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
High-voltage battery upper housing section
1 (If required)
Additionally, other small parts that are not specified above, such as one-time use screws, nuts,
O-rings and seals, which must be replaced according to the ISTA repair instructions/ETK, must be selected
from the Electronic Parts Catalog according to the respective vehicle type and invoiced under the special
defect code.
Part Retention
Parts that are removed from BMW vehicles cannot be used for resale! The parts are the property of
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.
Please DO NOT return these recalled High Voltage (HV) battery modules directly to the WPRC. You
must use the Gen 5 HV battery Recall return process.
The Gen 5 high-voltage cell module return process is different that the Gen 4, for the Gen 5 battery cell
module return process, refer to aftersales bulletin:
Bulletin #: C-2-0323-0606 Gen 5 HV Battery Recall Return Process.pdf
For more information refer to CenterNet: “Menu>BMW>Aftersales>Business Development & Marketing
Portal>Batteries>Bulletins”.
HV Battery Return Packaging - Bulk Payment
For this Service Action, to help offset the time to properly package the lithium-ion batteries for return, a bulk
payment of $20.00 per battery module will be made through monthly miscellaneous billing credit.
Payments will be identified as “Parts-$20 credit/HV battery recall returns to ITAP”.
Payment will not be issued for any lithium-ion batteries that were improperly packaged or shipped.
Hazardous materials or dangerous goods are defined as substances and articles that when offered for
transportation in commerce pose an unreasonable risk to health, safety, property, and the environment.
Therefore, BMW of North America would like to remind you all applicable regulatory requirements must be
followed when transporting hazardous materials. Your center is responsible for ensuring that your procedures
are in compliance with all current D.O.T. regulations.
CLAIM INFORMATION
Reimbursement for this Service Action will be via normal claim entry utilizing the relevant work package (WP 1
or WP 2), the additional work labor operation code (00 75 565) for the applicable total FRU allowance, and the
part numbers listed above that apply.
Plus work
(+)
The vehicle is already in the workshop
Main work
The vehicle arrives for this Service Action, no other Main work will be performed/
claimed during this workshop visit
Defect Code:
0061080800
G26 BEV Replacing high-voltage battery cell module
Below are the special flat rate labor operation code choices
A.
for this action.
about:blank
Copyright ©2023 BMW of North America, Inc.
4/8
10/19/23, 9:23 AM
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
Work Pkg
Labor
Operation
Description
Labor
Allowance
#1
00 75 564
Removing and installing high-voltage
battery unit (Plusposition work)
86 FRU
00 75 048
Removing and installing high-voltage
battery unit (Main work)
87 FRU
Or:
#2
Only one Main work flat rate labor operation code can be claimed per workshop visit.
Note for 00 75 565: Claim labor operation code 00 75 565 one-time only for the applicable
total FRU allowance that applies. Itemize the total work time (WT) FRU allowanced claimed
on the RO and in the claim comments.
Work time labor operation code 00 75 565 is not considered a Main labor operation.
1.
00 75 565:
Additional Work with Labor Operation 00 75 564 (WP 1) or 00 75 048
(WP 2)
00 75 565
Perform the cell module read out test plan in ISTA to
determine the serial numbers and locations of the highvoltage cell modules affected by this Service Action (Includes
00 00 556/61 21 528), run the HV battery discharge
procedure, and submit a TSARA case titled “Gen 5 HV
Battery cell module ID process” for the final confirmation of
the high-voltage cell location.
Labor
Allowance
5 FRU
Note: The following HV cell module replacement procedure includes completing and attaching the
required Battery Condition Certification form for each HV cell module replaced.
And for access to perform the repair as instructed by the above (B):
Removing/installing lid for high-
1.
voltage battery unit
00 75 565
Removing/installing lid for high-voltage battery unit
(Includes 61 27 900 - High-voltage battery unit final test,
draining and topping up the coolant circuit)
27 FRU
With B and C, together with the repair item below that applies:
00 75 565 – Replacing
1.
Single Cell Modules 6 or/and 7
Replacing cell module 6
Or/and:
Replacing cell module 7
Total
Labor
Allowance
14 FRU
14 FRU
28 FRU
Additional Work (E) FRU Allowance is included as noted below in the F to K Work Procedures.
1.
Preliminary
Access (Cell Module 1, 2/11, 3/10, 4/9, 5/8)
Remove and install intermediate level (For access to cell module 1, minus Labor operation
codes 61 27 010/501 and 61 27 900 that is included in item C)
Or:
about:blank
for Labor
Allowance
11 FRU
Copyright ©2023 BMW of North America, Inc.
5/8
10/19/23, 9:23 AM
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
1.
00 75 565 – Replacing Single Cell
Labor
Allowance
12 FRU
23 FRU
00 75 565 – Replacing Single Cell
Labor
Allowance
37 FRU
51 FRU
Module 1
Replacing cell module 1
Total with E (11 FRU included)
Or:
1.
Modules (6 and/or 7 and 1)
D (14 FRU), E (11 FRU included) and F for 2 cell modules (6 or 7 and 1)
D (28 FRU), E (11 FRU included) and F for 3 cell modules (6 and 7 and 1)
Or:
00 75 565 – Replacing Dual-Cell Modules
1.
2/11, 3/10, 4/9, 5/8 (Includes cell modules 6 and 7)
Only One (1) Dual-Cell Module (with F when
applicable)
Replacing dual-cell module 2 (Includes cell 11)
Or:
Replacing dual-cell module 3 (Includes cell 10)
Or:
Replacing dual-cell module 4 (Includes cell 9)
Or:
Replacing dual-cell module 5 (Includes cell 8)
Labor Allowance with E (11
FRU included in the below)
26 FRU
Total with Cell
Module 1 (F)
38 FRU
24 FRU
36 FRU
24 FRU
36 FRU
22 FRU
34 FRU
Or:
Only Two (2) Dual-Cell Modules (with F
I.
when applicable)
Dual-cell modules
Pre-work (E)
2 (Includes cell 11)
3 (Includes cell 10)
4 (Includes cell 9)
5 (Includes cell 8)
Totals
Cell module 1 (F)
Totals
2/3 (2)
11 FRU
15 FRU
13 FRU
2/4 (2)
11 FRU
15 FRU
2/5 (2)
11 FRU
15 FRU
13 FRU
39 FRU
12 FRU
51 FRU
39 FRU
12 FRU
51 FRU
11 FRU
37 FRU
12 FRU
49 FRU
3/4 (2)
11 FRU
3/5 (2)
11 FRU
13 FRU
13 FRU
13 FRU
37 FRU
12 FRU
49 FRU
11 FRU
35 FRU
12 FRU
47 FRU
4/5 (2)
11 FRU
13 FRU
11 FRU
35 FRU
12 FRU
47 FRU
Or:
Only Three (3) Dual-Cell Modules (with
1.
F when applicable)
Dual-cell modules
Pre-work (E)
2 (Includes cell 11)
3 (Includes cell 10)
4 (Includes cell 9)
5 (Includes cell 8)
Totals
Cell module 1 (F)
Totals
about:blank
2/3/4 (3)
11 FRU
15 FRU
13 FRU
13 FRU
2/3/5 (3)
11 FRU
15 FRU
13 FRU
3/4/5 (3)
11 FRU
2/4/5 (3)
11 FRU
15 FRU
13 FRU
13 FRU
13 FRU
11 FRU
11 FRU
11 FRU
52 FRU
50 FRU
48 FRU
50 FRU
12 FRU
12 FRU
12 FRU
12 FRU
64
FRU
62
FRU
60
FRU
62 FRU
Copyright ©2023 BMW of North America, Inc.
All (4)
11 FRU
15 FRU
13 FRU
13 FRU
11 FRU
63 FRU
12 FRU
75 FRU
6/8
10/19/23, 9:23 AM
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
Or:
00 75 565 – All Single
1.
Labor Allowance
Cell (3) and Dual-Cell (4) Modules
Replacing all cell modules
99 FRU
And, with any of the above:
Labor Description
Additional work with pressure test cooling system high-voltage battery unit
Associated work (coolant drained) (to high-voltage battery unit)
Labor Allowance
4 FRU
Claim Repair Comments
Only reference this SIB number, the work package (Pkg) number performed, and cell modules replaced by
their reference number in the RO technician notes and the claim comments (For example: B61 23 23 WP 1,
Cell module 4), unless otherwise required by State law.
Sublet – Bulk Materials (RO and Claim Comments Required)
Sublet
Code 4
Up to $100.00
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.
Alternative Mobility Solution (AMS) for Vehicle Owners (RO and Claim Comments Required)
This Service Action 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.
FEEDBACK REGARDING THIS BULLETIN
Technical Feedback
Warranty Feedback
Parts Feedback
To submit feedback for the technical topics of this bulletin: Submit your
feedback in the rating box at the top of this bulletin
To submit feedback for the CLAIMS section of this bulletin: Submit an IDS
ticket to the Warranty Department, or use the chat available in the Warranty
Documentation Portal
To submit feedback for the PARTS section of this bulletin: Submit an IDS
ticket to the Parts Department
Copyright ©2023 BMW of North America, Inc.
about:blank
7/8
10/19/23, 9:23 AM
61 23 23_SERVICE ACTION: REPLACING THE CELL MODULE OF THE HIGH-VOLTAGE BATTERY
Copyright ©2023 BMW of North America, Inc.
about:blank
8/8