NHTSA ID Number: 10146649
Manufacturer Communication Number: B611817
TSB/Document Date: 2018-11-05
Summary
"SME FAULT CODE 21F02A. Upon starting the vehicle, the following CC message is displayed to the customer: "Powertrain malfunction!" (CCM-ID: 633) In addition, one or several of the following CC message(s) may be displayed: "Charging not possible" (CCM-ID: 804), "Hybrid
system malfunctioning!" (CCM-ID: 585), "Drive. No restart" (CCM-ID: 586) or "Engine fault! Power loss" (CCM-ID: 29). Possible hardware defect of the safety box."
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SI B61 18 17
General Electrical Systems
April 2017
Technical Service
SME FAULT CODE 21F02A
MODEL
G12 PHEV (740e xDrive
iPerformance)
F15 PHEV (X5 xDrive40e)
G30 PHEV (530e
iPerformance)
F30 PHEV (330e
iPerformance)
SITUATION
Upon starting the vehicle, the following CC message is displayed to the customer:
z
"Powertrain malfunction!" (CCM-ID: 633)
In addition, one or several of the following CC message(s) may be displayed:
z
"Charging not possible" (CCM-ID: 804), "Hybrid system malfunctioning!" (CCM-ID: 585),
z
"Drive. No restart" (CCM-ID: 586) or "Engine fault! Power loss" (CCM-ID: 29).
CAUSE
Possible hardware defect of the safety box.
CORRECTION
Replace the safety box (S-Box) or program the vehicle.
PROCEDURE
Note: Always connect a BMW approved battery charger/power supply (SI B04 23
10).
1. Perform diagnosis with the latest version of ISTA.
2. Read out the fault memory of the vehicle.
Is fault code “21F02A - High-voltage battery unit, safety box: Fault, voltage and
current sensor (multiple fault)” stored in the battery management electronics (SME).
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Note: Subsequently, the following fault code will also be entered:
z
21F1F6 - High-voltage battery, switch contactors: Switch-off after a fault
YES — Go to next step.
NO — Continue diagnosis with ISTA.
3. Count the number of fault code 21F02A occurrences.
Was the code entered more than three (3) times?
YES — Replace safety box according to repair instruction.
NO — Ignore the fault code and reprogram/recode the vehicle with the most current version
of ISTA/P or ISTA Next.
PARTS INFORMATION
F15 PHEV (X5 xDrive40e)
Part number
Description
Quantity
61 27 8 686 893
Safety Box
1
07 12 9 908 570
ISA screw
13
07 11 9 909 322
Self-locking hex nut
4
61 27 8 614 090
Seal for HV battery
1
61 27 7 643 663
28
61 27 8 614 091
Seal, service cover, HV
battery
1
Part number
Description
Quantity
61 27 8 686 893
Safety box
1
07 11 9 909 322
Self-locking hex nut
6
07 12 9 908 570
ISA screw
4
61 27 8 626 650
Sealing screw
6
61 27 8 626 643
1
F30 PHEV (330e)
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unit
61 27 8 625 078
Hexagon screw with torx
socket
36
G12 PHEV (740e xDrive iPerformance)
Part number
Description
Quantity
61 27 8 686 893
Safety box
1
07 11 9 909 322
Self-locking hex nut
4
07 12 9 908 570
ISA screw
4
61 27 8 620 917
Seal, high-voltage battery
unit
1
61 27 7 643 663
51
G30 PHEV (530e iPerformance)
Part number
Description
Quantity
61 27 8 686 893
Safety box
1
07 11 9 909 322
Self-locking hex nut
4
07 12 9 908 570
ISA screw
4
61 27 8 620 917
Seal, high-voltage battery
unit
1
61 27 7 643 663
49
83 19 2 221 349
R134a (Gas 1 oz units)
As needed
83 19 2 287 039
R1234YF (Gas 1 oz units)
As needed
Bulk Materials
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty for Passenger Cars and Light
Trucks or the BMW Certified Pre-Owned Program.
Defect Code
6127040200
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Labor Operation:
00 00 006
Labor Allowance:
Description:
Refer to KSD2
Performing “vehicle
test” (with vehicle
diagnosis system –
checking faults) (Main
work)
Refer to KSD2
Performing “vehicle
test” (with vehicle
diagnosis system –
checking faults) (Plus
work)
Refer to KSD2
Connect an approved
battery charger/power
supply (indicated in KSD
2 as Charging battery)
Or:
00 00 556
And:
61 21 528
If you are using a Main labor code for another repair, use the Plus code labor operation 00 00 556
instead.
And, if necessary:
Replacing the Safety Box per the procedure (excluding the 530e iP and 530e xDrive)
Labor Operation:
61 25 510
Labor Allowance:
Description:
Refer to KSD2
Removing and installing the
high voltage battery unit
(Includes discharging,
evacuating and filling-back
air conditioner)
Refer to KSD2
Replace the contactor
(safety) box (High-voltage
battery unit remove)
And:
61 27 551
Or, for the:
G30 (530e iP and 530e xDrive, until the labor operations below are listed in the KDS2
Labor Operation
61 25 510*
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Type No.
Series
Model
Labor
Allowance
JA03
G30
XB1H
530e
iPerformance
45 FRU
JB23
G30
XB1H
530e xDrive
41 FRU
Type No.
Series
Model
Labor
Allowance
JA03
G30
XB1H
530e
iPerformance
16 FRU
JB23
G30
XB1H
530e xDrive
16 FRU
And:
Labor Operation
61 27 551*
*See the section above for the corresponding Flat Rate Labor Operation “Description” information.
And/or:
Vehicle Programming and Coding
Labor Operation:
Labor Allowance:
Description:
61 00 730
Refer to KSD2
Programming / encoding control
unit(s)
Refer to KSD2 for the corresponding flat rate unit (FRU) allowances.
When ISTA/P automatically reprograms and codes all the vehicle’s control modules that “currently
do not have” the latest software and if one or more control module failures occur “during” this
programming procedure:
z
Please claim this “consequential” control module-related repair work under the defect code
listed in this bulletin with the applicable KSD2/AIR labor operations.
Other Repairs
Control module failures that occurred “prior” to performing this programming procedure:
z
When “covered” under an applicable limited warranty, claim this control module-related
repair work using the applicable defect code and labor operations in KSD2/AIR.
And, as necessary:
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Sublet – Bulk Materials (excluding R134a or R1234YF)
Sublet Code 4
See sublet
reimbursement
calculation below
Reimbursement for the repairrelated bulk materials (Please do
not use the part numbers for claim
submission)
Sublet reimbursement calculation for claiming the “used quantities” of repair-related bulk materials
(BMW part numbers) is at dealer net plus your center’s handling.
Enter this material cost in sublet and itemize the amount in the claim comment section.
Overlapping Labor Procedure – Other Repairs
If invoicing the KSD2 flat rate labor operation codes for other repair work results in overlapping
labor, for those flat rate labor operations that are affected, you can now:
z
Replace the stated KSD2 “FRU allowance” with a “reduced FRU value” to eliminate the
overlapping labor.
For help in identifying the overlapping labor, please refer to the AIR FRU Plausibility Check
(Overlapping Labor Tool) that is located in the AIR Client.
Eligible other repair work being claimed under a different defect code will require separate punch
times.
On the repair order and in the claim comment section, please identify and itemize those labor
operations being claimed with a “reduced FRU value.”
[ Copyright ©2017 BMW of North America, Inc. ]
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TSB/Document ID: B611817
Replacement Service Bulletin Number:
MFR Communication Date: 2017-04-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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