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SI B61 06 16
General Electrical Systems

March 2016
Technical Service

SUBJECT

CCM “Engine fault! Power loss" and/or "Battery charging fault!"
MODEL

F15 PHEV (X5 xDrive40e)
F30 PHEV (330e)
Produced up to 11/10/2015
SITUATION

Upon unlocking or starting the vehicle, one or both of the following Check Control messages
(CCM) are displayed to the customer:
z

“Engine fault! Power loss" (CCM-ID: 29)

z

"Battery charging fault!" (CCM-ID: 213).

CAUSE

Faults from Safety box (S-Box) in the high-voltage battery.
CORRECTION

Replace Safety box (S-Box).
PROCEDURE

Only properly trained personnel, who have passed all applicable technical training courses,
should perform any maintenance or repairs on any Hybrid or Electric Vehicle. Work
performed by unqualified persons may result in severe injury or damage to the vehicle.
Additional information may be found in REP 61 00… Observe safety instructions when
handling electric vehicles.
Note: Prior to replacing any parts, refer to SI B00 03 06 to determine if a TC PuMA case is
required.
1. Perform a vehicle test with ISTA/D and check to see if the battery management electronics
(SME) contains one or more of the following fault codes:
21F10A - High-voltage safety switch (Service Disconnect): Evaluation implausible
21F159 - High-voltage battery: Current implausible
21F15B - High-voltage electrical system: Voltage implausible, no substitute value
21F15D - High-voltage electrical system: Voltage implausible, substitute value

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21F144 - High-voltage battery unit: Internal CAN bus between SME and voltage and current
sensor, communication fault
Were one or more of the fault codes stored in the SME?
YES – go to step 2.
NO- follow the instruction from ISTA/D diagnosis.
2. Allow the vehicle to enter sleep mode and delete the fault memory with ISTA/D.
3. Replace the S-Box per repair instructions:
F15 PHEV - 61 27 551 - Replace safety box
F30 PHEV - 61 27 551 – Replacing the safety box
4. Perform another vehicle test with ISTA/D.
Were one or more of the fault codes again stored in the SME?
YES – follow the instruction from ISTA/D diagnosis.
NO- Reinstall all removed parts. Repair is complete.
PARTS INFORMATION

F15 PHEV (X5 xDrive40e)
Part number

Description

Quantity

61 27 8 651 068

Safety box

1

07 12 9 908 570

ISA screw

13

07 11 9 905 949

Self-locking hex nut

4

61 27 8 614 090

Seal for HV battery

1

61 27 7 643 663

Hexagon bolt with inside Torx

28

61 27 8 614 091

Seal, service cover, HV battery

1

Part number

Description

Quantity

61 27 8 651 068

Safety box

1

07 11 9 905 949

Self-locking hex nut

6

07 12 9 908 570

ISA screw

4

F30 PHEV (330e)

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61 27 8 626 650

Sealing screw

6

61 27 8 626 643

Seal, high-voltage battery unit

1

61 27 8 625 078

Hexagon screw with torx socket

36

R134a (Gas 1 oz units)

As needed

Bulk Materials
83 19 2 221 349
WARRANTY INFORMATION

Covered under the terms of the BMW New Vehicle Limited Warranty for Passenger Cars and Light
Trucks.
For the models listed in this bulletin, the High-Voltage Lithium-Ion Battery (Component-specific)
Limited Warranty is 8 years/80,000 miles, whichever occurs first.
Defect Code:

61 27 04 12 00

Labor Operation:

Labor Allowance:

Description:

00 00 006

Refer to KSD2

Performing “vehicle test” (with vehicle
diagnosis system – checking faults)

Refer to KSD2

Connect an approved battery
charger/power supply(indicated in
KSD2 as “Charging battery”)

Refer to KSD2

Removing and installing high voltage
battery unit (includes discharging,
evacuating and refilling air conditioner)

Refer to KSD2

Remove and install the contactor box
(after vehicle diagnosis)

And:
61 21 528
And:
61 25 510
And:
61 27 551

If you are using a Main labor code for another repair, use the Plus code labor operation 00 00 556
instead.
Refer to KSD2 for the corresponding flat rate unit (FRU) allowances.
And, as necessary:

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Sublet – Bulk Materials

Sublet Code 4

Reimbursement for the repair-related
See sublet reimbursement bulk materials (excluding R134a)
calculation below
Please, do not use these 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 handling.
Enter this material cost in sublet and itemize the amount in the claim comment section.
Other Repairs
If other eligible and covered work is performed as a result of performing the ISTA diagnostics and
related test plans, claim this work with the applicable defect code and labor operations listed in
KSD2.
[ Copyright ©2016 BMW of North America, Inc. ]

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