2023-2024 BMW i7 High-Voltage Cable Chafing Delivery Stop

BMW has issued Service Information Bulletin SIB 61 14 24, Revision 3, which replaces the August 2024 version of the same bulletin. This bulletin details a delivery stop for certain 2023-2024 BMW i7 Sedan (G70) Battery Electric Vehicles (BEV).

The delivery stop, effective June 14, 2024, is necessary to address a potential issue with the rear high-voltage cable for the electric drive unit.

Symptoms

Owners of affected 2023-2024 BMW i7 vehicles may experience a Check Control message displaying "Drive faulty". This warning indicates a problem with the vehicle's drive system, specifically linked to the high-voltage cable.

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 remedy is completed."
• "Do not use or sell replacement equipment/parts subject to a Delivery Stop."

Furthermore, repairs involving high-voltage (HV) systems require specialized training:

• Only properly trained personnel who have passed applicable HV Technical Training Courses should perform repairs that involve disconnecting or removing High Voltage battery components. Unqualified persons performing such work 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".
• Specific certifications, such as ST2324 High Voltage Drivetrain Systems or ST2325 for High Voltage Battery Systems, are required depending on the vehicle generation and component being serviced.

Cause

The root cause of the "Drive faulty" message in the 2023-2024 BMW i7 is identified as chafing of the rear high-voltage cable that supplies power to the electric drive unit. This chafing can lead to damage and system malfunctions.

Repair Procedure Summary

The correction involves inspecting and potentially replacing the high-voltage cable, along with installing abrasion protection. This procedure is outlined in Repair Instruction REP 61 12 477, titled "Removing and installing/replacing rear electrical machine high-voltage cable (Rear electrical machine)".

Technicians will first remove the high-voltage cable for the rear electrical machine. A thorough inspection of the entire high-voltage cable will then be performed to check for any signs of chafing or damage.

If chafing or damage is found, the high-voltage cable must be replaced, and retrofit abrasion protection installed. If no chafing or damage is present, only the retrofit abrasion protection needs to be installed. The abrasion protection acts as an additional layer of defense against future chafing.

Finally, the high-voltage cable for the rear electrical machine is reinstalled according to REP 61 12 477. It's important to note that if a replacement cable with an AI index of AI08 or below is used, abrasion protection must be retrofitted. Cables with an AI index of AI09 or higher already include this protection.

Required Tools or Parts

Specific parts may be required for this repair:

• 61 29 5 B5B BE9: Repair cable (Quantity 1)
• 61 12 5 A37 103: High voltage wiring harness (Quantity 1, if required)

Additionally, other small components such as one-time use screws, nuts, O-rings, and seals must be selected from the Electronic Parts Catalogue (ETK) based on the specific vehicle type and invoiced under the special repair code.

Warranty Claim Information

Reimbursement for this action is processed through normal claim entry using the applicable work package information. The primary Repair Code for this service is 0061590800, described as "G70 BEV Retrofitting abrasion protection for high-voltage cable of rear electric drive unit."

Several labor operations are associated with this service, including:

• 00 76 805 or 00 76 193: Remove and install high-voltage cable and check for damage (no repair needed) – 10-11 FRU.
• 00 76 806 or 00 76 194: Check high-voltage cable for damage and replace – 10-11 FRU.
• 00 76 807: Additional work to retrofit abrasion protection (when applicable) – 2 FRU.

Source: NHTSA ID 11008112