2022-2024 BMW i4 Combined Charging Unit Delivery Stop

BMW has issued Service Information Bulletin (SIB) 61 12 24, a Delivery Stop, for specific 2022-2024 BMW i4 Gran Coupe (G26) vehicles. These vehicles were produced between September 24, 2022, and December 14, 2023. This bulletin, Revision 1, replaces the earlier SI B61 12 24 dated March 21, 2024.

This Delivery Stop addresses a potential issue with the Combined Charging Unit (CCU) that requires immediate attention before vehicle delivery or continued use. The BMW i4 Combined Charging Unit is a critical component for the vehicle's high-voltage system.

Why This Matters

The Combined Charging Unit (CCU) in affected vehicles may not have been manufactured according to BMW's specifications. This defect can lead to an internal coolant leak, which could cause the CCU to fail. A failing CCU can severely impact the vehicle's high-voltage system and overall operation, posing a safety risk.

Symptoms of a Faulty Combined Charging Unit

Owners or technicians may observe several symptoms indicating a problem with the BMW i4 Combined Charging Unit. These include:

• "HV charging interruption"
• "No high-voltage readiness when starting up"
• "The high-voltage system switching off while driving, causing the vehicle to coast slowly to a stop"

These issues directly affect the vehicle's ability to charge and operate its high-voltage systems safely and reliably.

Important Warnings for Owners and Dealers

BMW has issued strict guidelines regarding vehicles affected by this Delivery Stop:

• "Do not deliver to a customer a New, Certified Pre-Owned or Used vehicle subject to a Delivery Stop, until the vehicle is repaired."
• "Do not use or sell replacement equipment/parts subject to a Delivery Stop."

Additionally, working on the high-voltage (HV) systems requires specialized training:

• "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"."
• Disabling the HV system (indicated by the "Blitz" lightning bolt icon in the instrument cluster) requires a technician trained to Technical Training Course ST1824 (Alternative Drive Part 1).
• High Voltage Battery removal and rework can only be performed by an HV Specialist Technician certified to Technical Training Course ST1825 (Alternative Drive Part 2), with specific certifications like ST2006 for GEN4 batteries or ST2205 for GEN5 batteries.

Repair Procedure Summary

The correction for this issue involves replacing the Combined Charging Unit (CCU). The repair procedure is detailed in BMW's internal repair instructions, specifically REP 61 42 501. This process includes removing the faulty CCU and installing a new, compliant unit. Following the physical replacement, the vehicle's control units will need programming and encoding to ensure proper function and updated software levels. Dealers will use Repair Code 0061460800 for this service.

Required Parts

To perform the repair for the BMW i4 Combined Charging Unit, the following parts are required:

• 61 44 5A73E28: Combined Charging Unit (CCU) - Quantity 1
• 12 90 9884545: Hexagon Bolt - Quantity 4

Additionally, bulk supply materials such as coolant are needed:

• 83 19 2 468 442: HT-12 Coolant (1 gallon concentrate) - Sublet as needed
• 83 19 5 A32 851: HT-12 Antifreeze RTU (Bulk 1/10 Liter) (Pre-mix) - Sublet as needed

Other small parts, fluids, and one-time use fasteners should be selected according to the Electronic Parts Catalog (ETK/AIR) and ISTA repair instructions.

Claim Information

For dealers, reimbursement for this action is handled via normal claim entry. The work package information includes labor operations such as 00 75 981, 00 75 982, 00 75 377, and 00 75 378, depending on whether the vehicle is being prepared for first delivery or is already in the workshop. Sublet Code 4 is used for bulk supply material reimbursement, and Sublet Code 2 is for Alternative Mobility Solution (AMS) expenses. Dealers should refer to SI B01 01 20, B01 07 20, and SI B01 29 16 for additional claim and documentation procedures.

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Source: NHTSA ID 10253351