2022-2024 BMW i4, i5, i7, iX Drivetrain Malfunction & CCU Faults

BMW has issued Service Information Bulletin SIB 12 05 23 to address instances of a "Drivetrain Malfunction" message appearing in the instrument cluster of certain electric vehicles. This bulletin, which supersedes SI B12 05 23 dated February 2024, applies to 2022-2024 BMW i4, i5, i7, and iX models. The issue is typically accompanied by specific fault codes related to the high-voltage system's insulation. This document provides a detailed procedure for diagnosing and correcting the underlying cause of the "BMW i5 Drivetrain Malfunction" and similar issues in other affected models.

Symptoms of the Drivetrain Malfunction

Owners may observe a prominent "Drivetrain Malfunction message displayed in the instrument cluster." This warning indicates a problem with the vehicle's propulsion system. Alongside this visual alert, specific fault memory entries are saved in the Combined Charging Unit (CCU), pointing to high-voltage system anomalies. If you experience a "BMW i5 Drivetrain Malfunction," it's crucial to have your vehicle inspected promptly.

Associated Fault Codes (DTCs)

The Service Information Bulletin identifies two primary fault codes that may be stored in the CCU:

• 0317F2 - High-voltage system, insulation fault detected: when switch contactors are closed.
• 0317F1 - High-voltage system, insulation resistance below warning threshold: when switch contactors are closed.

These fault memory entries, often referred to as isolation faults, can occur individually or in combination. They must be accurately traced back to the eDrive motor using the ISTA test procedure to ensure proper diagnosis and repair.

Important Warnings for Owners and Technicians

BMW emphasizes several critical warnings to ensure safety and proper repair procedures:

• Procedure Execution: Technicians must ONLY PERFORM THIS PROCEDURE IF TEST PLAN DIAGNOSIS LEADS TO THE CLEANING PROCEDURE. This prevents unnecessary work and ensures the correct repair is applied.
• High-Voltage System Safety: Working on 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.”
• Certification Requirement: To perform this SIB 12 05 23, a GEN5 battery Certification is required from Technical Training Course “ST2205 Generation 5 High-voltage” class." This underscores the complexity and danger involved in HV system repairs.
• Transmission Fluid: Technicians are explicitly instructed: "NOTE: DO NOT DRAIN THE TRANSMISSION FLUID."
• Brush Module Replacement: "NOTE: DO NOT REPLACE BRUSH MODULE." The issue is typically resolved by cleaning, not replacement.
• Cleaning Tools: "Never use mechanical cleaning tools!" Only lint-free cloths and vacuuming should be used.
• Oil Leaks: "NOTE: If oil is found leaking from rotor seal and has contaminated brush module, please submit TC case to determine the condition of the copper rings before continuing with this procedure."
• Normal Wear: "NOTE: Black dust in the area of the brush module is normal abrasion of the carbon brushes and has no effect on the described cause." This helps differentiate normal wear from the specific contamination issue.

The Root Cause: Metal Chips and Contamination

The primary cause for the "Drivetrain Malfunction" and associated insulation faults is identified as a metal chip located behind the brush module, specifically between the brush module and the end shield of the electrical machine. Alternatively, contamination of the eDrive unit from the manufacturing process can also lead to this issue. This metal debris may not always be visible without disassembly. This problem affects vehicles built before November 2023.

Diagnosis and Trigger Conditions

Diagnosing the issue involves using the ISTA test procedure. If the ISTA test procedure indicates the presence of a metal chip or contamination as the possible cause, further repair steps are required. The fault memory entries (isolation faults) are traced back to the eDrive motor based on the ISTA test results. This systematic approach ensures that the correct repair is applied to resolve the "BMW i5 Drivetrain Malfunction."

Repair Procedure Summary

The repair procedure, as detailed in BMW Service Information Bulletin SIB 12 05 23, focuses on cleaning the affected eDrive motor components. It is a multi-step process that must be performed by certified technicians due to the high-voltage nature of the components:

1. High-Voltage System Preparation: Prior to any work, the high-voltage system must be disabled and secured by a properly trained technician with the necessary HV Qualification level, as per Technical Training Course ST1824 (Alternative Drive Part 1).
2. eDrive Motor Removal: Depending on the vehicle model and ISTA test results, either the rear or front eDrive motor is affected. The affected eDrive motor is removed according to ISTA test modules and specific repair instructions (e.g., 12 35 530/12 35 531 for rear, 12 35 520/12 35 521 for front).
3. Brush Module Removal: The brush module is then removed from the eDrive motor (referencing instructions like 12 37 902 for rear or 12 37 702 for front).
4. Cleaning: The area on the eDrive motor behind the brush module, and the brush module itself, are thoroughly vacuumed. Additionally, the slip rings on the rotor are cleaned with a lint-free cloth. Mechanical cleaning tools must not be used.
5. Reassembly and Testing: The brush module is reinstalled, and the eDrive unit is reassembled. An EoS (End of Series) test is performed on the drive unit. If this test fails, a technical case must be submitted. Finally, the drive unit is reinstalled in the vehicle.

This meticulous cleaning process is designed to eliminate the metal chips or contamination causing the "BMW i5 Drivetrain Malfunction."

Required Tools and Parts

For the eDrive removal and installation, and the cleaning procedure, specific materials are required:

• Antifreeze/Coolant:
  • Part Number: 83 19 5A32851 (HT-12 Antifreeze RTU, Bulk 1/10 liter, Pre-mix) - Sublet as needed.
  • Part Number: 83 19 2468442 (BMW Antifreeze/Coolant, 1 Gallon Concentrate, HT-12) - Sublet as needed.
• Lint-free cloth: NPN (Not Part Number) - Sourced locally, sublet as needed.

These items are essential for the proper execution of the repair and maintenance of the eDrive system.

Warranty and Claim Information

This repair is covered under the terms of the BMW New Vehicle Limited Warranty for Passenger Cars and Light Trucks. The specific Repair Code for this issue is 1233001500, labeled as "eDrive motor-permanent malfunction." Dealers should obtain flat rate unit (FRU) allowances for labor operations such as vehicle testing (00 00 006, 00 00 556), supporting voltage (61 21 528), diagnosis (61 00 006*, 00 58 500*), and the removal/installation of the eDrive unit and brush module (12 35 530, 12 37 902, 12 35 520, 12 37 702, 12 35 900). Additional labor for wheel alignment may also apply (32 00 595, 32 00 601, 32 00 650, 32 00 NNN). For detailed procedures on documenting and claiming, technicians should refer to SI B01 01 20 or B01 07 20.

NHTSA ID: 11012080