2022 BMW iX High-Voltage Battery Cell Module Replacement TSB

Why This Matters

High-voltage battery components are essential for the operation of electric vehicles like the 2022 BMW iX. Issues with the production process of these critical components can lead to potential safety concerns or affect the vehicle's performance and reliability. Furthermore, improper handling of high-voltage systems during repairs carries a significant risk of severe injury to personnel or damage to the vehicle itself.

What's Being Addressed

BMW has issued Service Action SIB 61 24 23 to address a manufacturing defect in certain 2022 BMW iX Sports Activity Vehicles. These affected vehicles were produced between March 29, 2022, and June 3, 2022. The underlying cause was identified during ongoing quality controls at the BMW Group, revealing that the production process for some high-voltage battery cells did not meet BMW's stringent standards. The remedy involves the precise removal and replacement of these specific affected high-voltage cell modules to ensure the vehicle's safety and proper function of the 2022 BMW iX high-voltage battery.

Important Warnings

Owners and technicians should be aware of several critical warnings related to this service action:

• Driving and Charging Advisory: BMW recommends NOT to drive the vehicle NOR charge the high-voltage battery until all necessary repair work, as outlined in Service Action SIB 61 24 23, has been completed to remedy the fault.
• High-Voltage System Safety: Only properly trained personnel who have successfully completed all applicable HV Technical Training Courses are authorized to perform repairs that involve disconnecting or removing high-voltage battery components on any Hybrid or Electric Vehicle. Work performed on high-voltage systems by unqualified individuals poses a significant risk of severe injury or damage to the vehicle. Additional safety information is found in Repair Instruction 61 00... “Observe safety instructions when handling electric vehicles”.
• Technician Certification: For Generation 5 vehicles, specific vehicle training is mandatory to diagnose, remove, and service any high-voltage component. It is explicitly 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. For example, to repair GEN4 HV battery of G05 PHEV, certification from Technical Training Course “ST2006 – SP44 HV Battery” or equivalent ST1825 – Alternative Drive Part 2 is required. For GEN5 HV battery, Technical Training Course “ST2205 Generation 5 High-voltage class” or equivalent “ST 2325 for High Voltage Battery Systems” is needed. For Generation 4 vehicles, once the HV system is disabled (indicated by the “Blitz” - lightning bolt icon displayed in the instrument cluster), a technician without HV Certification may remove HV components except for the High Voltage Battery.
• Part Return Process: Please DO NOT return these recalled High Voltage (HV) battery modules directly to the WPRC. Instead, technicians must follow the specific Gen 5 HV battery recall return process, which is detailed in Bulletin #: C-2-0323-0606 Gen 5 HV Battery Recall Return Process.pdf.

Repair Procedure Summary

The repair procedure for the 2022 BMW iX high-voltage battery, as detailed in Service Action SIB 61 24 23, involves a series of precise steps to be carried out by qualified technicians:

1. Cell Module Read Out Test Plan: Technicians must perform the cell module read out test plan using the ISTA diagnostic software. This determines the serial numbers and locations of the high-voltage cell modules. The diagnostic path within ISTA is: Vehicle management > Service function > Electric drive > High-voltage battery unit > "High-voltage battery unit: Read out stored serial numbers ABL". This test plan has been updated to identify affected modules and their location. A TSARA case titled "B61 24 23 HV Battery cell module ID process" must be submitted for assistance in identifying affected modules, attaching the module serial number read out to the case. Approval from TSARA is required before installing a new replacement cell module.
2. High-Voltage Battery Discharge: The high-voltage battery must be discharged to an average cell voltage of 3.51V using the ISTA test plan before opening the battery and removing defective modules. The "High-voltage battery unit discharged to a defined state of charge (SOC) ABL" service function is only available if the high-voltage battery temperature is between 59 to 95 °F (15°C and 35°C).
3. Module Replacement: Defective high-voltage cell modules are replaced using repair instructions 61 27 703 to 61 27 877, depending on the specific module location. An illustration is provided in the bulletin showing the SE10 HV Battery module locations for i20 xDrive50/xDrive60 models, depicting 11 numbered modules within the battery pack.

Required Parts

Only the applicable part numbers listed below should be used and invoiced. "As required" hardware should be ordered based on the module being replaced.

Part Number	Description	Quantity
61 27 8846469	Double cell module for high-voltage battery	Up to 5
61 27 8846470	Double cell module for high-voltage battery	Up to 6
07 14 9487466	Screw (12x1.5x50 10.9)	18
61 27 9487465	Screw (12x1.5x100 10.9)	10
31 11 6899302	Multi-purpose bolt (10x45 ZNS3)	14
61 27 9487464	Screw	8
51 16 1881149	Expanding rivet	6
61 27 9468425	Screw	94
07 14 8838288	Sealing screw (M8x28)	Order as required
61 27 9468423	Housing seal	1
61 27 9454855	Screw	Order as required
33 32 6775040	Hex bolt with washer (M14x1.5x148)	2
61 27 9893951	Screw (M8GFX46-10.9)	Order as required
61 27 9454854	Screw	Order as required
61 27 9893948	ASA combination bolt (M8x84-10.9)	Order as required

Additionally, other small parts not specified above, such as one-time use screws and nuts, may be required.

Claim Information

Reimbursement for this Service Action SIB 61 24 23 will be processed via normal claim entry. The Defect Code for this service action is 0061090800, labeled as "I20 Replacing cell module, high-voltage battery".

Work Packages and Labor Operations:

• Plus work (+): Completion before the first vehicle delivery or if the vehicle is already in the workshop.
• Main work: If the vehicle arrives at the service center with this service action open.

Flat Rate Labor Operation Codes:

• 00 75 566: Removing and installing high-voltage battery unit (Plusposition work) - 50 FRU.
• 00 75 049: Removing and installing high-voltage battery unit (Main work) - 52 FRU.
• 00 75 567: Perform the cell module read out test plan in ISTA, run HV battery discharge, and submit a TSARA case titled "Gen 5 HV Battery cell module ID process" - 5 FRU. This is an additional work labor operation, not a Main labor operation.

High-Voltage Cell Module Replacement Procedure:

• 00 75 567: Removing/installing lid for high-voltage battery unit (includes 61 27 900 - High-voltage battery unit final test, draining and topping up the coolant circuit) - 29 FRU.
• 00 75 567 - Cell Module 1 Only: Replacing cell module 1 - 11 FRU. Additional work with pressure test cooling system high-voltage battery unit and associated work (coolant drained) - 4 FRU. Total labor allowance (D) - 15 FRU.
• 00 75 567 - Cell Modules 1, 2, 11, 3, 10: Replacing cell module 1 - 11 FRU. Removing and installing cell module 1 - 10 FRU.
• Preliminary Work (Cell modules 2, 3, 10 and 11): Removing and installing the retaining frame for cell module 1 and SME (Associated work) (One-time) - 9 FRU.
• Cell module 2 / 11: Replace - 7 FRU each; LA - Both 14 FRU.
• Cell module 3 / 10: Replace - 9 FRU each; LA - Both 18 FRU.
• Additional after work (F): Pressure test cooling system and coolant drained - 4 FRU. Total labor allowance range (F) - 30 FRU to 58 FRU.
• 00 75 567 - Cell Modules 4, 9, 5, 8, 6, 7: Replace Cell module 4/9 - 14 FRU each; Both 28 FRU. Replace Cell module 5/8 - 15 FRU each; Both 29 FRU. Replace Cell module 6/7 - 14 FRU each; Both 28 FRU.
• Additional after work (G): Pressure test cooling system and coolant drained - 4 FRU. Total labor allowance range (G) - 18 FRU to 89 FRU.
• 00 75 567 - F and G, up to 10 Cell Modules: Claim sum of FRU amounts plus 4 FRU for Pressure Test (one-time) - As noted left (H).
• 00 75 567 - All Cell Modules (11): Replacing all cell modules - 104 FRU.
• Total labor allowance (I): Additional work with pressure test cooling system and coolant drained - 4 FRU. Total labor allowance (I) - 108 FRU.

Sublet - Bulk Materials: Sublet Code 4 allows for reimbursement of repair-related bulk materials up to $100.00. BMW part numbers should not be used for claim submission for bulk materials.

Alternative Mobility Solution (AMS): This repair qualifies for AMS expense reimbursement. Claim this item under Sublet Code 2. Refer to SI B01 29 16 for additional information.

NHTSA ID Number

NHTSA ID: 10244241