2023-2024 BMW i5/i7 HVAC Drumming Noise TSB

Owners of certain 2023-2024 BMW i5 and i7 models may experience a distinctive drumming noise emanating from the vehicle's air conditioning system during operation. This issue, specifically described as a "RYTHMIC DRUM NOISE HEARD FROM HVAC," is addressed by BMW Service Information Bulletin SIB 64 01 24, which supersedes SI B64 01 24 dated January 2024. The bulletin provides updated procedures and parts information for resolving this concern.

Symptoms

The primary symptom is a "drumming noise" heard when the air conditioning system is operating. This BMW i5 drumming noise can be noticeable and may vary in intensity depending on the conditions.

Cause of the Drumming Noise

The drumming noise originates from the air conditioning system's condensate drainage. Under conditions of warm temperatures and high air humidity, condensate forms within the blower housing. When the blower operates at high speeds, these condensate droplets are forcefully thrown vertically against the condensation drain opening.

The design of the long condensation drainage hose, combined with the geometry of the grommet and the heating and air conditioning unit, amplifies this impact. This creates an echoing effect heard from the condensate drain pipe, resulting in the characteristic BMW i5 drumming noise.

Important Warnings for Owners and Technicians

BMW emphasizes critical safety warnings when working on High-Voltage (HV) systems, which are present in the affected i5 and i7 models. Only properly trained personnel who have completed all applicable HV Technical Training Courses should perform repairs that require disconnecting or removing HV battery components. Unqualified individuals attempting such repairs risk severe injury or vehicle damage. Refer to Repair Instruction 61 00 for detailed safety instructions regarding electric vehicles.

Furthermore, technicians are explicitly warned: "DO NOT MODIFY the condensate drain pipe. This could allow water to collect upon the high voltage battery or back up into the HVAC box overflowing onto the vehicle floor." This highlights the importance of using the correct replacement part and following the specified procedure.

Repair Procedure Summary

To eliminate the BMW i5 drumming noise, the repair involves replacing the condensation water drain. An optimized condensation drain has been developed, which can be identified by a "WHITE DOT" or a revision "INDEX 02" or higher.

The general procedure includes:

1. High-Voltage Battery Unit Removal: The High Voltage Battery unit must be removed as per Repair Instruction 61 25 010. This step requires specialized training and certification due to the risks associated with HV systems. Only HV Specialist Technicians certified by Technical Training Course ST1825 (Alternative Drive Part 2) and with specific HV Battery Certification (e.g., ST2006 for GEN4 batteries) are authorized to perform HV battery removal and rework.
2. Condensation Water Drain Replacement: The existing condensation water drain is replaced with the optimized version. Before installing the new drain into the body from below, lubricant G14 (part number 83 23 2 360 412) must be applied to the top of the seal where it contacts the heater box.

It's important to note that while an image in the bulletin shows the HVAC box removed for clarity, technicians do not need to access the vehicle from inside the passenger compartment for this repair.

Required Parts and Materials

The following parts and materials are typically required for this repair:

• Condensation-water drain: Part Number 64 11 5 A43 278 (Quantity: 1)
• Lubricant G14 (900 ml / 30.43 ounces): Part Number 83 23 2 360 412 (Sublet as needed)
• BMW Group R-1234YF (10 lb / 160 oz, DN = 1 oz): Part Number 83 19 2 446 563 (Top-up quantity as needed)

Additional small parts and materials may be required based on the specific vehicle and should be selected from the Electronic Parts Catalogue (ETK) or AIR resources.

Claim Information

This repair is covered under the terms of the BMW New Vehicle Limited Warranty for Passenger Cars and Light Trucks. The repair code associated with this issue is 6411333200, described as "Moisture condensate drain hose on air conditioning Deformed / distorted / bent."

Applicable labor operations include:

• 61 25 010: Removing and installing the high-voltage battery unit (Main work)
• 61 25 510: Removing and installing the high-voltage battery unit (Plusposition)
• 51 00 001: Localizing body complaint(s) (Work time)
• 00 58 500: Diagnosis Worktime Flat Rate
• 64 99 000: Work time to replace the air conditioning system's condensation (water/moisture) drain hose

For detailed procedures on documenting and claiming diagnosis work time, refer to SI B01 01 20 or B01 07 20.

NHTSA ID: 10250603