2022-2024 BMW i7 High-Voltage Cable Abrasion Protection

Overview of Service Action SIB 61 16 24

BMW has issued Service Information Bulletin SIB 61 16 24 (Revision 1), which supersedes the previous SI B61 16 24 dated August 2024. This service action addresses a potential issue with the rear high-voltage cable in certain 2022-2024 BMW i7 Sedan (Battery Electric Vehicle - BEV) models produced between August 4, 2021, and May 2, 2024. The bulletin includes an updated procedure and an added attachment with supporting images. This action aims to prevent chafing of the BMW i7 high-voltage cable for the electric drive unit.

Important Warnings for Owners and Technicians

BMW has issued several critical warnings regarding this service action, SIB 61 16 24, to ensure safety and proper procedure:

• "Do not deliver to a customer, a New, Certified Pre-Owned or Used vehicle subject to a Delivery Stop, until the vehicle is repaired." This means affected vehicles cannot be sold or delivered until the high-voltage cable issue is resolved.
• "Do not use or sell replacement equipment/parts subject to a Delivery Stop." This prevents potentially affected parts from being used.
• "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." This emphasizes the specialized training required for high-voltage system work.
• For Generation 5 Vehicles, specific vehicle training is mandatory to diagnose, remove, and service any high-voltage component. 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."

Symptoms

Owners of affected 2022-2024 BMW i7 vehicles may experience a specific warning message. The primary symptom is a "Drive faulty" Check Control message appearing in the instrument cluster. This indicates a problem with the electric drive unit's high-voltage cable.

Cause of the Problem

The root cause of this issue is chafing of the rear high-voltage cable that connects to the electric drive unit. Over time, this chafing can damage the cable, leading to the "Drive faulty" message.

Repair Procedure Summary

The correction involves inspecting the BMW i7 high-voltage cable and, if necessary, replacing it and/or installing abrasion protection. The procedure is detailed in repair instruction REP 61 12 477, titled "Removing and installing/replacing rear electrical machine high-voltage cable (Rear electrical machine)".

High-Voltage System Safety

Working on high-voltage (HV) systems requires specialized training. Technicians must have completed applicable HV Technical Training Courses, such as "ST2324 High Voltage Drivetrain Systems" or its predecessors like "ST1824 Alternative Drive Part 1", "ST2205 Generation 5 High-voltage class", "ST2006 – SP44 HV Battery", and "ST1825 – Alternative Drive Part 2". Before any HV component is disconnected or removed, the HV system must be disabled and secured using the HV Service Disconnect Switch and lock out. When the HV system is disabled, a "Blitz" (lightning bolt) icon will be displayed in the instrument cluster.

Inspection and Repair Steps

1. Removal: The high-voltage cable for the rear electrical machine is removed according to REP 61 12 477.
2. Inspection: The entire high-voltage cable is thoroughly inspected for any signs of chafing or damage.
3. Action based on inspection:
   • If chafing or damage is found, the high-voltage cable must be replaced, and retrofit abrasion protection installed. The installation of abrasion protection also follows REP 61 12 477.
   • If no chafing or damage is found, retrofit abrasion protection is still installed on the existing high-voltage cable, following REP 61 12 477.
4. Reinstallation: The high-voltage cable is reinstalled as per REP 61 12 477.

High-Voltage Cable AI Index Note

When replacing or installing a high-voltage cable, technicians must check its AI Index, which is a two-digit number following the part number on the cable's label (e.g., 5A37103-04, where '04' is the AI Index). If the cable has an AI Index of AI08 or below, abrasion protection must be retrofitted. If the cable has an AI Index of AI09 or higher, the abrasion protection is already integrated and does not need to be retrofitted.

Required Parts

When applicable, the following part numbers are used for this service action:

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

Additional materials and small parts, such as fluids, lubricants, one-time use screws, nuts, and seals, may be required and should be selected from the Electronic Parts Catalogue or other approved BMW Group resources.

Claim Information

Reimbursement for this Service Action is processed using Repair Code 0061610800, which covers "G70 BEV High-voltage cable abrasion protection, retrofit the eDrive motor." The following work packages and labor operations are available:

• Work Package #1 (00 76 815): Remove and install HV cable, check for damage (no repair necessary) - 10 FRU (Flat Rate Units)
• Work Package #2 (00 76 816): Check HV cable, replace - 10 FRU
• Work Package #3 (00 76 818): Vehicle already taken care of through another repair or Technical Campaign - 1 FRU
• Work Package #4 (00 76 202): (Main work) Remove and install HV cable, check for damage (no repair necessary) - 11 FRU
• Work Package #5 (00 76 203): (Main work) Check HV cable, replace - 11 FRU
• Work Package #6 (00 76 204): (Main work) Vehicle already taken care of through another repair or Technical Campaign - 1 FRU
• As needed for #2, #4, #5 (00 76 817): Additional work to retrofit abrasion protection - 2 FRU

Only one flat rate labor operation code can be used for claim submission, and only one Main work flat rate labor operation code can be claimed per workshop visit. Technicians must reference the SIB number and the work package number (e.g., B61 16 24 WP 1) in their repair order notes and claim comments.

Supporting Materials

The bulletin includes an attachment, B611624_Attachment.pdf, which provides additional pictures. These images show the high-voltage cable both before and after the abrasion protection is installed, helping technicians visualize the correct procedure. The attachment also illustrates the location of the AI Index on the high-voltage cable label.

NHTSA ID: 11008113