2024 BMW iX High-Voltage Battery Defect Delivery Stop

BMW has issued a Delivery Stop, identified as Service Information Bulletin (SIB) 61 19 24 (Revision 1, dated September 24, 2024), for certain 2024 iX (I20 E-Series) vehicles. This bulletin replaces a previous version of SIB 61 19 24 dated August 2024. The Delivery Stop addresses a significant 2024 BMW iX battery defect concerning the high-voltage battery system.

The defect involves a manufacturing flaw in the high-voltage cells of the battery, which can lead to electrolyte leakage. This leakage might create a conductive connection with surrounding components. Depending on the contact resistance, owners may experience specific symptoms and the vehicle's charging capabilities will be affected.

Symptoms of the Battery Defect

Owners of affected 2024 BMW iX vehicles may observe the following indicators of the 2024 BMW iX battery defect:

• A "yellow or red Check Control message" displayed in the instrument cluster.
• A "charging interruption during charging" when attempting to power the vehicle.

BMW notes that while it is permitted to continue driving the vehicle if these messages appear, the charging interruption will persist.

Important Warnings for Owners and Dealers

BMW has issued several critical warnings related to this Delivery Stop and the handling of affected high-voltage battery components:

• "Do not deliver to a customer, a New, Certified Pre-Owned or Used vehicle subject to a Delivery Stop, until the vehicle is repaired."
• "Do not use or sell replacement equipment/parts subject to a Delivery Stop."
• "Please DO NOT return these replaced High Voltage (HV) battery modules directly to the WPRC." Instead, specific recycling procedures must be followed.
• "DO NOT DISPOSE OF THE BATTERY PACKAGING IN WHICH THE NEW BATTERY IS DELIVERED, AS IT IS REQUIRED FOR SHIPPING THE NORMAL END OF LIFE CORES (NOT RECALLED) BACK FOR RECYCLING."
• "DO NOT SEND ANY LITHIUM-ION BATTERIES TO THE WPRC. Lithium-ion batteries are strictly prohibited from being sent to any WPRC facility. Failure to comply with this directive could result in catastrophic consequences including fines and a partial or full claim debit."
• "It is critical that lithium-ion batteries are not co-mingled with lead acid or AGM battery cores."
• For recalled batteries, "Recall batteries – do NOT use original fiberboard box packaging, even if green condition! Recall batteries require special packaging provided by a 3rd party vendor contracted by BMW NA."

Cause of the Defect

The root cause of the 2024 BMW iX battery defect is a manufacturing flaw within the high-voltage cells of the high-voltage battery. This defect can lead to electrolyte leakage, which in turn may cause a conductive connection with adjacent components.

Repair Procedure Summary

To address the 2024 BMW iX battery defect, the following high-level procedure is outlined in SIB 61 19 24:

1. Serial Number Read Out: Technicians must perform a cell module serial number read out test plan using the ISTA diagnostic system. This step determines the serial numbers and locations of the high-voltage cell modules installed in the vehicle.
2. TSARA Case Submission: After the read-out, a TSARA (Technical Service and Repair Assistance) case must be submitted. This case should be titled "Delivery Stop: Replace Cell Modules – I20" and include the module serial number read-out for assistance in identifying the specific faulted module(s).
3. Module Replacement: The defective high-voltage cell modules are then replaced. This replacement procedure follows repair instructions 61 27 711 to 61 27 723, depending on the exact location of the affected cell module.

It is crucial that only properly trained personnel, who have passed all applicable High-Voltage Technical Training Courses, perform these repairs. Work on high-voltage systems by unqualified individuals can result in severe injury or vehicle damage. Specific training courses mentioned include "ST2324 High Voltage Drivetrain Systems", "ST1824 Alternative Drive Part 1", "ST2205 Generation 5 High-voltage class", "ST2006 – SP44 HV Battery", "ST1825 – Alternative Drive Part 2", and "ST2325 for High Voltage Battery Systems".

Required Tools or Parts

To perform the repair for the 2024 BMW iX battery defect, specific parts and materials are required. The following table lists the identified parts:

Part Number	Part Description	Quantity
07 14 9 487 466	Screw	18
61 27 9 487 465	Screw	6
61 27 9 487 464	Screw	8
33 32 6 775 040	Hexagon screw with washer	2
31 11 6 899 302	Multi-purpose bolt	14
61 27 8 846 469	Dual-cell module for high-voltage battery	As required
61 13 6 925 452	Abrasion-resistant fabric adhesive tape	1
61 27 8 846 470	Dual-cell module for high-voltage battery	As required
61 27 9 454 854	Screw	20
61 27 9 468 423	Housing gasket	1
07 14 8 860 492	Screw	94
07 14 8 838 288	Sealing bolt	24

Bulk Supply Material - Sublet

Part Number	Description	Quantity
83 19 5A32851	HT-12 Antifreeze RTU (Bulk DN = 1/10 Liter) (Pre-mix)	As needed
83 19 2468442	BMW Antifreeze/Coolant (DN = 1 Gallon Concentrate) - HT-12	As needed

Claim Information

Reimbursement for this action will be processed through normal claim entry. The relevant Repair Code is 0061770800, described as "I20 cell modules, replace high-voltage battery." Various work packages and labor operations are detailed for different stages of the repair, including initial diagnosis, top cell module replacement, and bottom cell module replacement. Alternative Mobility Solution (AMS) expenses are also reimbursable under Sublet Code 2.

High-Voltage Battery Recycling Program

BMW of North America has implemented a Lithium-Ion Battery Recycling Program (Bulletin #: C-2-0824-0612) to ensure proper and safe disposal of high-voltage batteries. This program supersedes previous bulletins C-2-0407-0602, C-2-0407-0603, and C-2-0323-0606. This is particularly relevant for the 2024 BMW iX battery defect as it involves high-voltage battery components.

Battery Core Credit Process

Starting September 1, 2024, all Li-Batteries (12V, 48V, and high voltage) will have a core charge ranging from $150 to $600, depending on battery size and capacity. For warranty and non-warranty Li-Batteries purchased after this date, a YRE5 parts return code is required to initiate the recycling request and generate core credit. Batteries purchased prior to September 1, 2024, will not qualify for a core credit.

Normal End of Life Li-Batteries (Non-Recalled or Damaged)

For low and high voltage lithium-ion batteries replaced under normal diagnosis or repairs, the battery/module should be placed in the returnable packaging received with the replacement part. If the original packaging is unusable, DDR shipping crates will be provided. The return process is managed through the Redwood Materials portal.

Recalled or Damaged Li-Batteries

Special procedures apply to recalled or damaged batteries, classified as DDR (Damaged, Defective, or Recalled) under Department of Transportation (DOT) 49 CFR regulations, which require special packaging. Redwood Materials facilitates these returns. The process involves a specific assessment by a GEN 5 high voltage battery Certified Technician ("HV certified technician") before contacting Redwood Materials.

Electrical Assessment

The electrical assessment determines the module category based on ISTA vehicle tests for critical faults. The categories are:

Module category	Description
GREEN	"Not critical" fault codes stored according to the diagnosis procedure as per recall bulletin.
YELLOW	Electrical fault in the module. "Not critical" according to the diagnosis, procedure as per recall bulletin.
RED	Module damaged or "critical" according to the diagnosis or no assessment possible via the diagnosis, procedure can't be completed as per recall bulletin.

Visual Assessment

This assessment classifies the battery based on physical condition:

Assessment Category	Green	Yellow	Red
Smoke			X
Evidence of Fire			X
Heat Development			X
Crack or opening on the housing *		X	X
Dents/bulges in the housing, deformations, changes**	X	X
Parts/components weakened due to corrosion		X
Slack, lose or damaged connections		X
Serial number/Safety Instructions sticker not legible***	X
Suspected water damage or leakage			X

• *Size of the crack determines the module transport category.
• **Dent/bulge up to a depth of 0.5 mm or a length of 5 cm is permitted and rated as green.
• ***The serial number must be clearly identifiable. If the nameplate can no longer be read, the housing of the high-voltage battery unit must be clearly marked with the serial number.

Transportation Measures Based on Assessment

Module Category	Explanation	Transportation Measures
Green Transport	The cell module does not show any damage or fault. It can be considered safe.	Recall batteries – do NOT use original fiberboard box packaging, even if green condition! Recall batteries require special packaging provided by a 3rd party vendor contracted by BMW NA.
Yellow Transport	The cell module shows damage or faults, but it is not liable to rapidly disassemble or react dangerously when transported.	Special packaging provided by a 3rd party vendor contracted by BMW NA.
Red Transport	The cell module shows damage or faults, and it is known or is suspected to be capable of rapid disassembly or dangerous reaction when transported.	Submit a TSARA case for additional instructions and procedures From BMW NA.

If there is any uncertainty regarding the assessment results, BMW Technical Support should be contacted immediately. Until resolved, the removed high-voltage battery unit or cell module must be identified with warning sign 6 and cordoned off.

Owner Action

If you own a 2024 BMW iX and experience a "yellow or red Check Control message" or "charging interruption during charging," it is important to contact your authorized BMW dealer. They will be able to check if your vehicle is affected by SIB 61 19 24 and perform the necessary diagnostic and repair procedures. Do not attempt to repair high-voltage components yourself.

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Source: NHTSA ID: 11008115