2024-2025 BMW X5, X6, X7 Power Control Unit Delivery Stop

BMW has issued a Delivery Stop, identified as Service Information Bulletin (SIB) 61 02 25, for specific 2024-2025 BMW X5, X6, and X7 vehicles. This bulletin, a revision of SI B61 02 25 dated February 14, 2025, addresses a critical issue with the vehicle's 12V Power Control Unit (PCU).

The 2024 BMW X5 Power Control Unit and similar units in other affected models may exhibit unfavorable tolerances, leading to potential system failures. Owners of these vehicles should be aware of the symptoms and the necessary repair steps.

Important Warnings for Owners and Dealers

BMW has issued strict instructions 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 vehicle is repaired."
• "Do not use or sell replacement equipment/parts subject to a Delivery Stop."
• "The exchanged PCU should not be discarded and is required for analysis purposes." Dealers are instructed to store the removed PCU as a special damage part and return it promptly for analysis upon request.
• "Always connect a BMW-approved battery charger/power supply (SI B04 23 10)" during programming procedures.

Symptoms of a Failing Power Control Unit

The primary issue stems from unfavorable tolerances within the 12V PCU module. This can lead to the Power Control Unit (PCU) switching off when the vehicle is under heavy electrical loads. When this occurs, the PCU will no longer charge the Lithium-Ion (Li-Ion) Auxiliary (AUX) battery.

This failure to charge the auxiliary battery can result in several critical symptoms:

• Failure of the vehicle's roll stabilization system.
• Loss of communication to the EARS modules, specifically S 0421 and S 0422.

Cause of the Issue

The root cause of this problem is an unfavorable tolerance within the 12V PCU module itself. This manufacturing deviation can prevent the unit from functioning correctly, particularly under demanding conditions, leading to the auxiliary battery not receiving a charge.

Repair Procedure Summary

The correction for this issue involves replacing the faulty 12V PCU and inspecting the auxiliary battery. The repair process, detailed in SIB 61 02 25, includes several key steps:

1. PCU Replacement: The Power Control Unit is replaced following specific repair instructions titled "Removing and installing the voltage transformer/Power Control Unit (PCU) 61 42 050 | REP-REP-P-6142050-G07”.
2. Vehicle Programming: After PCU replacement, the vehicle must be programmed using the latest ISTA software. This involves connecting a BMW-approved battery charger, connecting to ISTA, determining and executing the measures plan, and performing a vehicle test to clear any fault memory.
3. Auxiliary Battery Evaluation: The additional Li-Ion AUX battery is evaluated using the ISTA test module "ABL-DIT-AT6121_DSSLTO_EARS". This diagnostic step checks the battery's condition and charging capability.
4. Auxiliary Battery Replacement (If Needed): If the Li-Ion AUX battery is found to be defective or cannot be recovered, it will be replaced according to repair instructions "Replacing 12-V lithium-ion auxiliary battery - registering with battery replacement - 61 21 086 | REP-REP-P-6121086-G07_EMARS - V.4".
5. Fault Code Deletion: All fault codes are deleted, and a sleep cycle is performed to ensure the registered battery characteristics are saved in the vehicle's memory.

This comprehensive approach ensures that both the faulty 12V PCU is replaced and any affected auxiliary battery is addressed, restoring proper function to the vehicle's electrical and stability systems. The 2024 BMW X5 Power Control Unit replacement is a critical part of this process.

Required Parts

For this repair, the primary part required is:

• Power Control Unit PCU control unit: Part Number 61 42 5 B62 A38 (Quantity: 1)

If the inspection determines that the 12V lithium-ion auxiliary battery is also defective, the following part will be required:

• 12V lithium-ion auxiliary battery: Part Number 61 21 5 B3F 328 (Quantity: 1)

Other materials and small parts, such as fluids, lubricants, one-time use screws, nuts, and seals, may also be required based on the ISTA repair instructions and Electronic Parts Catalog.

Owner Action

If you own a 2024-2025 BMW X5, X6, or X7, your vehicle may be subject to this Delivery Stop. BMW is notifying dealers, and vehicles requiring this campaign will show as “Open” when checked in AIR, AWP, Campaign Summary, or Warranty Vehicle Inquiry. Dealers are checking their inventory for affected vehicles.

It is recommended to contact your authorized BMW dealer to determine if your vehicle is affected by SIB 61 02 25. The repair will be performed free of charge under the terms of the Delivery Stop.

NHTSA ID: 11016442