2022-2023 BMW i4 High-Voltage Battery Cell Module SIB 61 23 23

BMW has released Service Information Bulletin (SIB) 61 23 23 concerning the high-voltage battery cell module in specific 2022-2023 BMW i4 Gran Coupe vehicles. This service action aims to correct a manufacturing deviation found in the production process of these battery cells.

Situation

This Service Action, SIB 61 23 23, applies to certain Model Year 2022 BMW i4 Gran Coupe (G26 BEV) vehicles that were produced between August 10, 2022, and September 2, 2022. Vehicles requiring this service will show an "Open" status when checked in AIR, the "Service Menu" of DCSnet (Dealer Communication System), ISPA Next, or Warranty Vehicle Inquiry.

Cause of the Issue

As part of ongoing quality controls at the BMW Group, it was discovered that in very rare instances, the production process for cells within the high-voltage battery did not meet BMW's stringent standards. This can lead to a faulty BMW i4 high-voltage battery cell module.

Correction

The prescribed correction involves the removal and replacement of the affected high-voltage cell modules. Typically, only one of the vehicle's high-voltage battery cells should be affected by this issue.

Important Warnings for Owners

BMW has issued several critical warnings regarding this service action and working with high-voltage systems:

• Do Not Drive or Charge: BMW recommends NOT to drive the vehicle NOR charge the high-voltage battery until all repair work to remedy the fault has been completed.
• Qualified Personnel Only: Repairs requiring disconnection or removal of High Voltage battery components on any Hybrid or Electric Vehicle must ONLY be performed by properly trained personnel who have passed all applicable HV Technical Training Courses. Work performed by unqualified persons may result in severe injury or damage to the vehicle. Additional safety information can be found in Repair Instruction 61 00... "Observe safety instructions when handling electric vehicles".
• Generation 5 Vehicles: For Generation 5 vehicles, specific training is required to diagnose, remove, and service any HV component. It is NOT allowed for non-HV certified technicians to work on the high-voltage system.
• No Repair Without Remedy: Technicians are instructed NOT to start the repair or submit a TSARA case if the status of the service action is NOT Green, as there is not yet a "Remedy Available" for this vehicle.

Repair Procedure Summary

The repair procedure for the BMW i4 high-voltage battery cell module involves several precise steps:

1. Cell Module Identification: Technicians must perform the cell module read-out test plan in ISTA to determine the serial numbers and locations of the high-voltage cell modules installed in the vehicle. The diagnostic path 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.
2. TSARA Case Submission: After performing the read-out, a TSARA case titled "B61 23 23 HV Battery cell module ID process" must be submitted for assistance in identifying the affected modules, attaching the module serial number read-out to the case.
3. Approval for Replacement: It is crucial that once the new replacement cell module arrives, its serial number is attached to the TSARA case for approval. Installation is only permitted once TSARA approves the replacement module.
4. Battery Discharge: The high-voltage battery must be discharged prior to removal to an average cell voltage of 3.51V. The diagnostic path for this is: Vehicle management > Service function > Electric drive > High-voltage battery unit > "High-voltage battery unit discharged to a defined state of charge (SOC) ABL". This service function is only available if the high-voltage battery temperature is between 59 to 95 °F (15°C and 35°C).
5. Module Replacement: The defective high-voltage cell modules are then replaced using repair instructions 61 27 703 to 61 27 877, depending on the specific location of the affected cell module. A diagram is provided in the bulletin showing G26 BEV SE27 HB Battery module locations.

Required Parts

Only specific, applicable part numbers should be used for this repair. These include:

Part Number	Description	Quantity
61 27 8863448	Cell module, high-voltage battery	Up to 3
61 27 8863438	Double module for high-voltage battery	Up to 4
61 27 9454253	Multi-purpose bolt (M12x1.5x45)	14
61 25 8833851	Hexagon bolt (M12x5x130)	2
61 25 8833846	Hexagon bolt (5x105)	6
07 14 6884435	ASA Multi-purpose bolt (M10x35)	4
33 32 6760340	Torx bolt with washer (M12x127-10.9)	4
33 30 6861221	Torx bolt (ISA M12x35- 10.9)	10
61 27 9884703	Gasket	1
07 14 8860492	Screw (M5)	82
07 14 8838288	Sealing screw (M8x28)	20
61 27 9454854	Screw	as needed (max 63)
61 27 8677639	Screw (M6x18)	as needed (max. 22)
39 10 6865725	Multi-purpose bolt	4
07 14 8835104	Multi-purpose bolt (M12x1.5x72-10.9)	4

Additional small parts not specified above, such as one-time use screws, nuts, O-rings, and seals, must be selected from the Electronic Parts Catalog according to ISTA repair instructions/ETK and invoiced under the special defect code.

Claim Information and Warranty

Reimbursement for this Service Action will be processed via normal claim entry using work package (WP 1 or WP 2) and the additional work labor operation code 00 75 565. The defect code for this action is 0061080800, described as "G26 BEV Replacing high-voltage battery cell module".

Labor operations include:

• 00 75 564: Removing and installing high-voltage battery unit (Plusposition work) - 86 FRU
• 00 75 048: Removing and installing high-voltage battery unit (Main work) - 87 FRU
• 00 75 565: Perform cell module read-out test plan, HV battery discharge, and TSARA case submission - 5 FRU
• 00 75 565: Removing/installing lid for high-voltage battery unit (includes 61 27 900) - 27 FRU
• 00 75 565: Replacing single cell modules 6 or/and 7 - 14 FRU each (28 FRU total)
• Various FRU allowances are detailed for replacing single, dual, and triple cell modules, depending on their location.
• Additional work for pressure testing the cooling system of the high-voltage battery unit - 4 FRU.

Sublet Code 4 allows for reimbursement of repair-related bulk materials up to $100.00. For Alternative Mobility Solution (AMS) expenses, Sublet Code 2 applies, with reference to SI B01 29 16 for further information.

Part Retention and Return

Parts removed from BMW vehicles cannot be resold and remain the property of BMW NA. Centers are responsible for proper identification, storage, and documentation of these parts in a secure retention area until claim payment notification. Technicians are instructed: "Please DO NOT return these recalled High Voltage (HV) battery modules directly to the WPRC. You must use the Gen 5 HV battery Recall return process."

For Generation 5 vehicles, the return process differs from Generation 4. Refer to aftersales bulletin C-2-0323-0606 Gen 5 HV Battery Recall Return Process.pdf for details. A bulk payment of $20.00 per battery module will be made for packaging lithium-ion batteries for return, identified as "Parts-$20 credit/HV battery recall returns to ITAP". Payment will not be issued for improperly packaged or shipped batteries. All applicable regulatory requirements for transporting hazardous materials must be followed.

Feedback Regarding This Bulletin

BMW encourages feedback on this bulletin:

• Technical Feedback: Submit feedback in the rating box at the top of the bulletin.
• Warranty Feedback: Submit an IDS ticket to the Warranty Department or use the chat in the Warranty Documentation Portal.
• Parts Feedback: Submit an IDS ticket to the Parts Department.

NHTSA ID: 10244240