2024 BMW X5 Battery Failure Service Action SIB 61 22 24

BMW has issued Service Information Bulletin SIB 61 22 24 to address a manufacturing defect affecting the 12V and 48V batteries in certain 2024 BMW models. This service action aims to prevent premature battery failure by replacing the affected components. This is a critical service action to prevent a 2024 BMW X5 battery failure.

Why This Matters

A manufacturing defect in a limited number of 12V and 48V vehicle batteries can lead to premature battery failure. This issue could impact vehicle reliability and electrical system function. Addressing this proactively ensures the long-term performance and safety of your vehicle, preventing unexpected breakdowns due to a 2024 BMW X5 battery failure.

Cause of the Problem

The root cause of the premature battery failure is attributed to preliminary battery cell damage that occurred during the manufacturing process. This damage compromises the integrity and lifespan of both the 12V and 48V batteries.

Repair Procedure Summary

The correction involves replacing the affected battery or batteries, depending on the specific vehicle equipment. Technicians must follow detailed repair instructions and safety protocols during the replacement process as outlined in Service Information Bulletin SIB 61 22 24.

1. For vehicles with option code 1CE “48V Mild Hybrid system (AIR = 01CE Energy recovery system),” the 48V battery must be replaced according to repair instructions REP 61 21 007, titled "Replacing 48-V battery - with registering battery replacement - 61 21 007 | REP-REP-P-6121007”.
2. For F96, G05, and G07 vehicles equipped with a 12V Li-ion Auxiliary battery, the auxiliary battery is to be replaced following repair instructions REP 61 21 086, titled "Replacing 12-V lithium-ion auxiliary battery - registering with battery replacement - 61 21 086 | REP-REP-P-6121086".
3. For G2X vehicles equipped with a 12V Li-ion Dual Storage System (DSS) battery, the DSS battery replacement must adhere to repair instructions REP 61 21 004, titled "Replacing the 12V dual storage system - registering with battery change - 61 21 004 | REP-REP-P-6121004".

When renewing any battery, technicians must ensure that all procedures in the repair instructions are followed. This includes using a torque wrench and setting the tightening torque in accordance with repair instructions, using the battery size (capacity) installed standard upon battery replacement, cleaning contact surfaces, and having them checked by a second technician. Screws or nuts of the threaded connections must always be tightened to the specified torque. After diagnosis and battery replacement, any fault code entries associated with battery replacement must be deleted, and software on newly installed 48V vehicle batteries must be updated. Battery registrations must also be performed. ISTA will automatically reprogram and code all programmable control modules to the latest software.

Important Warnings for Owners and Technicians

BMW has issued several critical warnings to ensure proper handling and prevent further damage or safety risks:

• Battery Electronics Damage: “Damage to the 48 V Battery electronics can occur if it is disconnected from the on-board electrical system while active! Only activate the 48 V electrical system when the 48 V battery is fully installed (connected).”
• Programming Power Supply: “Always connect a BMW-approved battery charger/power supply (SI B04 23 10) when performing programming.”
• Terminal Handling: Technicians are instructed: “Do not pull on the ground cables” and “Do not place any tools under the terminal clip to lever (pry) off the terminal cover.”
• Threaded Connections: “In most cases, loose, corroded or improperly torqued threaded connections lead to component damage.”
• Recycling Prohibition: For removed parts, “Please DO NOT return batteries to the WPRC. You must use the “Normal End of Life" recycling return process in the aftersales bulletin below: Bulletin #: C-2-0824-0612 LITHIUM-ION BATTERY RECYCLING PROGRAM.”

Required Parts

Depending on the vehicle's equipment, the following part numbers may be used for replacement. Removed parts under warranty are the property of BMW NA and cannot be resold. They must be held in a secure retention area until claim payment notification.

Part Number	Description	Quantity
61 21 5 A38 DE3	48-V battery	1
61 21 5 A7E 839	12-V lithium-ion auxiliary battery	1
61 21 5 A8D 7F0	12-V lithium-ion auxiliary battery	1
61 21 5 A4A F23	12-V lithium dual storage system	1
61 21 5 A8D 7E0	12-V lithium dual storage system	1

Claim Information

Reimbursement for this service action, identified by repair code 0061790800 for “F96 G0x G2x Replace vehicle battery (12 V / 48 V),” is processed via normal claim entry. The bulletin specifies various labor operations and allowances:

• For G2X vehicles with a 12V Li-ion Dual Storage System (DSS) battery:
  • Work Package #1: Labor Operation 00 77 520, Description: Replace (12 V) dual battery (Plusposition). Labor Allowance: As applicable.
  • Work Package #2: Labor Operation 00 77 014, Description: Replace (12 V) dual battery (Main work). Labor Allowance: As applicable.
• For vehicles with option code 1CE “48V Mild Hybrid system (AIR = 01CE Energy recovery system)”:
  • Work Package #3: Labor Operation 00 77 521, Description: Replace battery (48 V) (Plusposition). Labor Allowance: 29 FRU (G23 MC 53AT); 32 FRU (G22 MC 13AR, G05 All).
  • Work Package #4: Labor Operation 00 77 015, Description: Replace battery (48 V) (Main work). Labor Allowance: 31 FRU (G23 MC 53AT); 34 FRU (G22 MC 13AR, G05 All).
• For F96, G07, G22, and G23 vehicles:
  • Work Package #5: Labor Operation 00 77 521, Description: Replace battery (48 V) (Plusposition). Labor Allowance: 31 FRU (G07, G22 MC 83AP); 33 FRU (G23 MC 63AT, G05 All); 41 (F96 MC 23ET).
  • Work Package #6: Labor Operation 00 77 015, Description: Replace battery (48 V) (Main work). Labor Allowance: 32 FRU (G07, G22 MC 83AP); 35 FRU (G23 MC 63AT, G05 All); 43 (F96 MC 23ET).

Additional work for programming and encoding is required after part replacement. This includes Expanded Work Package A (Labor Operation 00 77 522) for additional work/programming-encoding (Associated work), which includes 8 FRU for carrying out vehicle test (00 00 006/61 21 528). Labor Operation 00 77 520 for replacing the 12V battery (Associated work) has an allowance of 11 FRU. During the workshop visit, if the affected vehicle also has other open programming and encoding Technical Campaign repairs, only one programming and encoding procedure may be invoiced. For detailed procedures on documenting and claiming diagnosis work time, refer to SI B01 01 20 or B01 07 20. This service action qualifies for Alternative Mobility Solution (AMS) expense reimbursement; refer to SI B01 29 16 for additional information.

Lithium-Ion Battery Recycling Program

BMW of North America has implemented a comprehensive Li-Battery recycling program (Bulletin #: C-2-0824-0612) to ensure the proper disposal of lithium-ion batteries. This program covers normal end-of-life warranty replacements and recalled batteries at no cost to the dealer network, emphasizing sustainability and compliance.

Key Recycling Program Directives:

• Packaging Retention: “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.”
• WPRC Prohibition: “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.”
• No Co-mingling: “It is critical that lithium-ion batteries are not co-mingled with lead acid or AGM battery cores.”

Battery Core Credit Process

Starting September 1, 2024, a core charge ranging from $150 to $600 will apply to all 12V, 48V, and high voltage lithium-ion batteries, depending on their size and capacity. For warranty and non-warranty batteries purchased after this date, a YRE5 parts return code is required to initiate the recycling request through Redwood's portal and generate core credit back to the dealer. Batteries purchased before September 1, 2024, do not qualify for core credit and do not require a YRE5 code. Allow 30 days for credits to appear in your statement after pickup.

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

For batteries replaced under normal diagnosis or repairs, they should be placed in the returnable packaging from the replacement part. If the packaging is unusable due to damage, DDR shipping crates will be provided. The return process is managed through the Redwood Materials portal at https://portal.redwoodmaterials.com/bmw. A Certified HazMat Shipper must be on site to execute the return, along with an Emergency Response Phone Number.

Recalled or Damaged Li-Batteries

Special procedures apply to recalled or damaged batteries. The condition certification form is not necessary for normal end-of-life replacements. High voltage battery recalls require special packaging for transport, classified as DDR (Damaged, Defective, or Recalled) by the Department of Transportation 49 CFR. Redwood Materials facilitates these returns. The process for requesting a pickup for recalled batteries is identical to the steps for normal end-of-life batteries, but additional information is required in step 3, which triggers special packaging to be shipped by Redwood Materials.

Crucial Warning: “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.”

An assessment of the HV Cell Module must be performed by a GEN 5 high voltage battery Certified Technician (“HV certified technician”) prior to contacting Redwood Materials, as per Air Document REH-HIN-P-6125-32 - V.1. This assessment includes both electrical and visual checks to classify the battery's condition. If your center has not completed the required supplemental HV Battery recall training, reference bulletin C-2-0824-0302 prior to arranging for recalled HV battery returns.

The battery recall process is divided into three parts: Transport assessment, Transport preparation, and Performing the transport.

Battery Assessment Categories:

Assessment Category	Green	Yellow	Red
Electrical Assessment	"Not critical" fault codes stored according to the diagnosis procedure as per recall bulletin.	Electrical fault in the module. "Not critical" according to the diagnosis, procedure as per recall bulletin.	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
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, loose 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.

If there is any uncertainty regarding the assessment results, BMW Technical Support should be contacted immediately for additional guidance. Until uncertainties are resolved, the removed high-voltage battery unit or cell module must be identified with warning sign 6 and cordoned off with high-voltage barrier tape. If the high-voltage battery unit is still in the vehicle, it must also be identified with warning sign 6 and cordoned off.

Owner Action

If you own a 2024 BMW X5, X7, 430i, X6, or 330i manufactured within the specified dates (January 25, 2024 – May 8, 2024), it is recommended to contact your authorized BMW dealer. They can check if your vehicle is affected by Service Information Bulletin SIB 61 22 24 and schedule the necessary battery replacement. This repair will be performed under warranty at no cost to you, addressing any potential 2024 BMW X5 battery failure.

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Source: NHTSA ID: 11008118