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61 16 22_DELIVERY STOP: HIGH-VOLTAGE BATTERY

SIB 61 16 22
DELIVERY STOP: HIGH-VOLTAGE BATTERY

2022-11-17

This Service Information Bulletin (Revision 1) replaces SI B61 16 22 dated August 17, 2022.
What’s New:

Cause, Correction, Procedure, Parts, Claim sections added

MODEL
E-Series
I20

Model Description
iX Sports Activity Vehicle
(SAV)

Production Date
April 29, 2022 – September 22, 2022

AFFECTED VEHICLES
Vehicles which require this Campaign to be completed will show it as “Open” when checked either in AIR,
the "Service Menu" of DCSnet (Dealer Communication System), ISPA Next or Warranty Vehicle Inquiry.
BMW AG has issued a Delivery Stop (effective August 17, 2022) on a small number of Model Year 2022
BMW iX SAV vehicles that were produced between April 29, 2022 to September 22, 2022.
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.

SITUATION
The low voltage wiring harness plug connected to cell module to was manufactured without its insulation
compound. This insulation layer is designed to protect the contact from environmental influences such as
moisture or dirt contamination.

CAUSE
A short circuit may form between the individual electrical contacts of the low voltage connector due to the
presence of moisture or dirt contamination.
This may result in Check Control Message being displayed to the customer accompanied by a loss of
power.
In rare cases, the fault can also lead to a shutdown of high-voltage system.

CORRECTION
Removal and replacement of affected high-voltage cell modules.

PROCEDURE
Important Warning for Working on the High-Voltage (HV) systems on BMW Group vehicles:
Only properly trained personnel, who passed all applicable HV Technical Training Courses, should
perform repairs which require disconnecting, or removal of High Voltage battery components on any
Hybrid or Electric Vehicle. Work performed on High Voltage systems by unqualified persons may
result in severe injury or damage to the vehicle. Additional safety information is found in Repair
Instruction 61 00… “Observe safety instructions when handling electric vehicles”.
Additional Information:
Scheduled Maintenance, or Quality Certification 1 (Pre-Delivery Inspection) on Electric or Hybrid
vehicles does not require HV technical training.

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61 16 22_DELIVERY STOP: HIGH-VOLTAGE BATTERY

Prior to disconnecting, or the removal of any HV component, the HV system needs to be disabled
and secured (by means of the HV Disconnect Switch) by a properly trained technician, who has a
minimum HV Qualification level after completing the Technical Training Course ST1824 (Alternative
Drive Part 1). Once the vehicle’s HV system is disabled (the “Blitz” - lightning bolt icon displayed in
instrument cluster, see below), a technician without HV Certification may remove a HV component
(e.g., EH Heater, EKK Compressor, EME Control Unit, et.), except for the High Voltage Battery.

High Voltage Battery removal and rework can be performed ONLY by a HV Specialist Technician
(certified by the Technical Training Course ST1825 – Alternative Drive Part 2), AND with a HV Battery
Certification level corresponding to a specific Electric or Hybrid vehicle (e.g., to repair GEN4 battery
of G05 PHEV, certification from Technical Training Course “ST2006 – SP44 HV Battery” is required).
Therefore, to perform this SIB 61 16 22 a GEN5 battery Certification is required from Technical
Training Course “ST2205 Generation 5 High-voltage” class).
The steps below must be followed precisely:
1. 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.
Diagnostic path:
Vehicle management > Service function > Electric drive > High-voltage battery unit >
High-voltage battery unit: Read out stored serial numbers ABL.
Submit a TSARA case titled “Gen 5 Cell module low voltage connector” for assistance in
identifying the affected modules.
Please attach the cell module serial number read out to the TSARA case.
2. Replace the defective high-voltage cell modules using repair instructions 61 27 703 to 61 27
723 depending on the affected cell module location.
i20 xDrive50/xDrive60 - SE10 HV Battery module locations shown below-

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61 16 22_DELIVERY STOP: HIGH-VOLTAGE BATTERY

PARTS INFORMATION
Only use and invoice the applicable part listed number below.
Note:
Please order “as required” hardware depending on the cell module you are replacing.
Part Number
07 14 9487466
61 27 9487465
31 11 6899302
61 27 9487464
51 16 1881149
61 27 9468425
07 14 8838288

Description
Screw (12x1.5x50 10.9)
Screw (12x1.5x100 10.9)
Multi-purpose bolt (10x45 ZNS3)
Screw
Expanding rivet
Screw
Sealing screw (M8x28)

61 27 9468423
61 27 9454855

Housing seal
Screw

33 32 6775040
61 27 9893951

Hex bolt with washer (M14x1.5x148)
Screw (M8GFX46-10.9)

61 27 9454854

Screw

61 27 9893948

ASA combination bolt (M8x84-10.9)

Depending on the
availability
61 27 8846469
61 27 8846470
Or:
61 27 8838260
61 27 8838259

Quantity
18
10
14
8
6
94
Order as
required
1
Order as
required
2
Order as
required
Order as
required
Order as
required

Double cell module for high-voltage battery
Double cell module for high-voltage battery

Up to 5
Up to 6

Double cell module for high-voltage battery
Double cell module for high-voltage battery

Up to 5
Up to 6

Part Retention
The parts replaced to perform and submit for this Recall repair procedure are the property of BMW NA.

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61 16 22_DELIVERY STOP: HIGH-VOLTAGE BATTERY

Your center is responsible for the proper identification, storage, and documentation of these parts. They
must be held in a secure retention area until notification of claim payment is made by BMW NA through
DCSnet.
If these replaced parts are requested to be returned, a corresponding DCSnet Part Return tag will be
generated.
Refer to Aftersales Business Development & Marketing Bulletin #: B-2-0719-0603 for the high-voltage
battery part return information that applies to this Service Action.
Please DO NOT return the HV battery modules directly to the WPRC. Your center is responsible to follow
any special rules and regulations that apply to returning these parts to BMW as instructed in the ABDM
bulletin.
For more information, refer to CenterNet: Menu>BMW>Aftersales>Business Development & Marketing
Portal>Batteries.
Any return requested parts that are not received by the within 60 days of the claim credit date may be
subject to debit.

CLAIM INFORMATION
Reimbursement for this Action will be via normal claim entry utilizing the relevant work package, the
additional work labor for the applicable FRU allowances, and the part numbers listed above that apply.
Plus work
(+)
Main work
Defect Code:

Completion before the first vehicle delivery to a customer or the vehicle is already
in the workshop
The vehicle arrives at your center and this Action shows open (No other Main work
will be performed or claimed during this workshop visit)
0061040700

I20 Plug connector seal (replace cell module)

Refer to the below for the corresponding flat rate unit (FRU) allowances.
Work Pkg

#1

Labor
Operation

Description

Labor
Allowance

00 73 541

Removing and installing high-voltage
battery unit, and removing/installing lid for
high-voltage battery unit (Includes 61 27
900 - High-voltage battery unit final test,
draining and topping up the coolant circuit)
(Plus work)

75 FRU

00 73 012

Removing and installing high-voltage
battery unit, and removing/installing lid for
high-voltage battery unit (Includes 61 27
900 - High-voltage battery unit final test,
draining and topping up the coolant circuit)
(Main work)

76 FRU

Or:

#2

Only one of the flat rate labor operation codes listed above can be used for claim submission and
reimbursement. Also, only one Main work flat rate labor operation code can be claimed per workshop visit.
Additional Work with Labor Operation 00 73 541 (WP 1) or 00 73 012 (WP 2)

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61 16 22_DELIVERY STOP: HIGH-VOLTAGE BATTERY

Note: For the following, claim labor operation 00 73 542 one-time only for the applicable total FRU
allowance that applies.
Itemize the total work time (WT) FRU allowanced claimed on the RO and in the claim comments.
Labor
Operation

00 73 542

Labor Description

Labor Allowance

Only when the test module “High-voltage battery unit:
Read out stored serial numbers” is not
available: Please submit a TSARA case titled “Gen 5 HV
Battery cell module ID process” for assistance. Perform
Vehicle Test (Includes 00 00 556/61 21 528) and run the
HV battery discharge procedure

7 FRU

Then, after the test module becomes available for the vehicle being repaired:
Labor
Operation
00 73 542

Labor Description

Labor Allowance

Perform the cell module read out test plan in ISTA to
determine the serial numbers and locations of the highvoltage cell modules affected by this Action (Includes 00
00 556/61 21 528) and run the HV battery discharge
procedure

7 FRU

And, as instructed above, and as applicable with the repair below that applies:
A. 00 73 542 – Cell Module 1 Only
Labor Description
Replacing cell module 1
And:
Additional work with pressure test cooling system high-voltage battery unit
Associated work (coolant drained) (to high-voltage battery unit) (One-time)
Total labor allowance (A)

Labor Allowance
11 FRU
4 FRU
15 FRU

Or:
B. 00 73 542 – Cell Modules 1, 2, 11, 3, 10
Labor Description
Replacing cell module 1
Or:
Removing and installing cell module 1

Labor Allowance
11 FRU
10 FRU

And:
Labor Description (Additional pre-work)
Preliminary work of removing and installing the retaining frame for cell module
1 and SME (Associated work) (Cell modules 2, 3 10 and 11) (One-time)

Labor Allowance
9 FRU

And:
Labor Description Replace
Cell module 2
And/or:

Labor Allowance
7 FRU

Labor Description
- Replace
Cell module 11

Labor
Allowance
7 FRU

Both
14 FRU

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Cell module 3

61 16 22_DELIVERY STOP: HIGH-VOLTAGE BATTERY

9 FRU

Cell module 10

9 FRU

18 FRU

And:
Labor Description (Additional after work)
Additional work with pressure test cooling system high-voltage battery unit
Associated work (coolant drained) (to high-voltage battery unit) (One-time)

Labor Allowance
4 FRU
30 FRU to 58
FRU

Total labor allowance range (B)
Or:
C. 00 73 542 – Cell Modules 4, 9, 5, 8, 6, 7
Labor Description Labor Allowance
Replace
Cell module 4
14 FRU
And/or:
Cell module 5
15 FRU
And/or:
Cell module 6
14 FRU

Labor Description
- Replace
Cell module 9

Labor
Allowance
14 FRU

Cell module 8

14 FRU

29 FRU

Cell module 7

14 FRU

28 FRU

Both
28 FRU

And:
Labor Description (Additional after work)
Additional work with pressure test cooling system high-voltage battery unit
Associated work (coolant drained) (to high-voltage battery unit) (One-time)
Total labor allowance range (C)

Labor Allowance
4 FRU
18 FRU to 89
FRU

Or:
D. 00 73 542 – B and C, up to 10 Cell Modules as applicable
Labor Description
Claim the sum of the FRU amounts that apply to the cell modules replaced
along with the required additional after work (4 FRU for the Pressure Test,
one-time).

Labor Allowance
As noted (D)

Or:
E. 00 73 542 – All Cell Modules (11)
Labor Description
Replacing all cell modules
And:
Additional work with pressure test cooling system high-voltage battery unit
Associated work (coolant drained) (to high-voltage battery unit)
Total labor allowance (E)

Labor Allowance
104 FRU
4 FRU
108 FRU

Claim Repair Comments
Only reference this SIB number, the work package (Pkg) number performed, and cell modules replaced by
their reference number in the RO technician notes and the claim comments (For example: B61 15 22 WP 1,
Cell modules 2, 4, 5), unless otherwise required by State law.
Sublet – Bulk Materials (RO and Claim Comments Required)

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Sublet
Code 4

61 16 22_DELIVERY STOP: HIGH-VOLTAGE BATTERY

Up to $100.00 Reimbursement for the repair-related bulk materials (Do not use the
BMW part numbers for claim submission)

Sublet reimbursement calculation for claiming the applicable repair-related bulk materials (BMW part
numbers) is at the dealer net price amount for the quantities used plus your center’s handling.
Enter this material cost in sublet and itemize the amount on the repair order and in claim comment section
Alternative Mobility Solution (AMS) for Vehicle Owners (RO and Claim Comments Required)
This Action repair qualifies for Alternative Mobility Solution (AMS) expense reimbursement, claim this item
under the Defect Code noted above as follows:
Sublet Code 2 - Itemize the AMS sublet amount on the repair order and in the claim comment section.
Please refer to SI B01 29 16 for additional information.

FEEDBACK REGARDING THIS BULLETIN
Technical Feedback
Warranty Feedback
Parts Feedback

To submit feedback for the technical topics of this bulletin: Submit your
feedback in the rating box at the top of this bulletin
To submit feedback for the CLAIMS section of this bulletin: Submit an IDS
ticket to the Warranty Department, or use the chat available in the Warranty
Documentation Portal
To submit feedback for the PARTS section of this bulletin: Submit an IDS
ticket to the Parts Department

Supporting Materials
picture_as_pdf B611622 C_2_0322_0301_HV_Battery_Recall_Training.pdf

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