9/27/24, 9:15 AM

61 19 24_DELIVERY STOP: REPLACE CELL MODULES – I20

SIB 61 19 24
DELIVERY STOP: REPLACE CELL MODULES – I20

2024-09-24

This Service Information Bulletin (Revision 1) replaces SI B61 19 24 dated August, 2024.
What’s New:
Situation updated
Cause added
Correction added
Procedure added
Parts Information added
Claim Information added
Attachment added
Please perform the procedure outlined in this Service Information on all affected vehicles before customer
delivery. In the event the customer has already taken delivery of the vehicle, please perform the procedure
the next time the vehicle is in the shop.

MODEL
E-Series
i20

Model Description
iX Sports Activity Vehicle Battery Electric
Vehicle (BEV)

Production Date
February 28, 2024 – June 2, 2024

AFFECTED VEHICLES
Vehicles which require this campaign to be completed will show it as “Open” when checked either in AIR,
AWP, Campaign Summary or Warranty Vehicle Inquiry.
Please make sure you check your dealer inventory as soon as possible. As of August 10, 2024, you can
see a list of affected vehicles in Inventory Campaign Details (ICD) under ROSS.

SITUATION
BMW AG has issued a Delivery Stop (effective August 9, 2024) on a small number of Model Year 2025
BMW vehicles that were produced between February 28, 2024, and June 2, 2024.
A manufacturing defect in high-voltage cells of the high-voltage battery can result in electrolyte leakage
which might result in a conductive connection with surrounding components. Depending on the contact
resistance, a yellow or red Check Control message will then be displayed; it is permitted for you to continue
driving, but this will result in a charging interruption during charging.
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.

CAUSE
A manufacturing defect in high-voltage cells of the high-voltage battery can result in electrolyte leakage.

CORRECTION
Replacing the identified cell modules of the high-voltage battery.

PROCEDURE
Important Warning for Working on the High-Voltage (HV) systems on BMW Group vehicles:

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61 19 24_DELIVERY STOP: REPLACE CELL MODULES – I20

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”.
Prior to disconnecting, or the removal of any HV component, the HV system needs to be disabled
and secured (by means of the HV Service Disconnect Switch and lock out) by a properly trained HV
technician, who has a minimum HV Qualification level after completing the Technical Training
Course “ST2324 High Voltage Drivetrain Systems” which as of 1/2023* includes ST1824 Alternative
Drive Part 1.
* Note: As of January 2023, the HV component portion of the “ST2205 Generation 5 High-voltage
class” (except for the High Voltage Battery) has been merged into “ST2324 High Voltage Drivetrain
Systems”.
Up to Generation 4 Vehicles: Once the vehicle’s HV system is disabled (the “Blitz” - lightning bolt
icon is 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.
For Generation 5 Vehicles however, the specific vehicle training is required to diagnose, remove and
service any HV component and it is NOT allowed for non HV certified technicians to work on the
high voltage system.

High Voltage Battery removal and rework can ONLY be performed by a High-voltage Certified
Technician with a HV Battery Certification level corresponding to a specific Electric or Hybrid
vehicle, for example:
To repair GEN4 HV battery of G05 PHEV a certification from Technical Training Course “ST2006 –
SP44 HV Battery” or equivalent ST1825 – Alternative Drive Part 2 is required (or as of 1/2023 the
equivalent “ST 2325 for High Voltage Battery Systems”).
And
To repair A GEN5 HV battery the Technical Training Course “ST2205 Generation 5 High-voltage
class” is required or as of 1/2023* the equivalent “ST 2325 for High Voltage Battery Systems”.
*Note: As of January 2023, the “ST2205 Generation 5 High-voltage stand-alone class” has been
merged into “ST2324 for High Voltage Drivetrain Systems” and “ST2325 for High Voltage Battery
Systems”
Caution:
Please create a TSARA case for ALL vehicles prior to any disassembly.
The steps below must be followed precisely:
1. Please perform the cell module serial number 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 >
Cell modules, traceability: Reading out serial numbers stored in the SME > High-voltage battery unit:
Read out stored serial number.
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61 19 24_DELIVERY STOP: REPLACE CELL MODULES – I20

2. Once the Cell module read out test plan has been performed, please submit a TSARA case titled
“Delivery Stop: Replace Cell Modules – I20” for assistance in identifying the affected faulted module(s)
(attach the module serial number read out to the case). TSARA will provide the location of the cell module(s)
that needs to be replaced.
3. Replace the defective high-voltage cell modules using repair instructions 61 27 711 to 61 27
723 depending on the affected cell module location.
Other HV Battery Repairs Beyond the Scope of this Action
If other eligible and covered HV battery-related repair work is performed because of performing the ISTA
diagnostics, the related test plans, and/or other approved diagnosis, claim this work with the applicable
Repair Code and the labor operation codes (including the diagnosis) that applies, less any overlapping
labor.

PARTS INFORMATION
Only use and invoice the part numbers below.
Part Number
07 14 9 487 466
61 27 9 487 465
61 27 9 487 464
33 32 6 775 040
31 11 6 899 302
61 27 8 846 469
61 13 6 925 452
61 27 8 846 470
61 27 9 454 854
61 27 9 468 423
07 14 8 860 492
07 14 8 838 288

Part Description
Screw
Screw
Screw
Hexagon screw with washer
Multi-purpose bolt
Dual-cell module for high-voltage battery
Abrasion-resistant fabric adhesive tape
Dual-cell module for high-voltage battery
Screw
Housing gasket
Screw
Sealing bolt

Quantity
18
6
8
2
14
As required
1
As required
20
1
94
24

Bulk Supply Material - Sublet
Part Number
83 19 5A32851
Or:
83 19 2468442

Description
HT-12 Antifreeze RTU (Bulk DN = 1/10 Liter) (Pre-mix)
BMW Antifreeze/Coolant (DN = 1 Gallon Concentrate) - HT-12

Quantity
As needed
As needed

Additionally, other materials and small parts that are not specified above, such as fluids, lubricants, one-time
use screws, nuts, and seals, which must be replaced or installed (according to the ISTA repair
instructions/ETK/AIR), are to be selected from the Electronic Parts Catalog, and/or other approved BMW
Group resources according to the respective vehicle type. Invoiced these items separately under the Repair
Code listed in this bulletin.
Part Retention
Parts that are removed from BMW vehicles cannot be used for resale! The parts are the property of
BMW NA.
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.

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61 19 24_DELIVERY STOP: REPLACE CELL MODULES – I20

Please DO NOT return these replaced High Voltage (HV) battery modules directly to the WPRC. You
must use the return process in the aftersales bulletin below:
Bulletin #: C-2-0824-0612 LITHIUM-ION BATTERY RECYCLING PROGRAM
For more information refer to CenterNet: “Menu>BMW>Latest Bulletins”.
HV Battery Return Packaging - Bulk Payment
For this Service Action, to help offset the time to properly package the lithium-ion batteries for return, a bulk
payment of $20.00 per battery module will be made through monthly miscellaneous billing credit.
Payments will be identified as “Parts-$20 credit/HV battery returns”.
Payment will not be issued for any lithium-ion batteries that were improperly packaged or shipped.
Hazardous materials or dangerous goods are defined as substances and articles that when offered for
transportation in commerce pose an unreasonable risk to health, safety, property, and the environment.
Therefore, BMW of North America would like to remind you all applicable regulatory requirements must be
followed when transporting hazardous materials. Your center is responsible for ensuring that your
procedures are in compliance with all current D.O.T. regulations.

CLAIM INFORMATION
Reimbursement for this Action will be via normal claim entry utilizing the relevant work package (WP 1 or
WP 2), the expanded work package items performed, and the part numbers listed above that apply.
Plusposition (+)
Main work
Repair Code:

Completion before the first vehicle delivery to a customer or the vehicle is
already in the workshop.
The vehicle arrives for this Action shows open, no other Main work will be
performed/ claimed during this workshop visit
0061770800

I20 cell modules, replace high-voltage battery

Below are the special flat rate work time (WT) labor operation code choices for this action.
Work Package

Labor Operation

#1

00 77 518

Description
Removing and installing high-voltage
battery, including removing and
installing lid (Plusposition) (Includes
61 27 900 performing EoS test for
high-voltage battery unit)

Labor Allowance
As applicable

Or:
#2

00 77 013

Removing and installing high-voltage
battery, including removing and
installing lid (Main work) (Includes 61
27 900 performing EoS test for highvoltage battery unit)

As applicable

00 77 519

Replace identified affected module
based on the workload

WT FRU - Below

And:
See below

Only one Main work flat rate labor operation code can be claimed per workshop visit.
Note: Claim labor work time operation code 00 77 519 one-time only for the applicable “total
FRU allowance” that applies. Itemize the total work time (WT) FRU allowance claimed on the

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61 19 24_DELIVERY STOP: REPLACE CELL MODULES – I20

technician’s RO notes and in the claim comments.
Work time labor operation code 00 77 519 is not considered a Main labor operation.
Expanded WP

A

Labor
Operation

00 77 519

Description

Labor Allowance

Perform the cell module read out test
plan in ISTA to determine the serial
numbers and locations of the highvoltage cell module(s) affected by this
Action (Includes 00 00 556/61 21 528),
submitting a TSARA case
titled “Delivery Stop: Replace Cell
Modules – I20.” TSARA will provide the
location of the faulty cell module that
needs to be replaced.”.

5 FRU

And, as instructed by TSARA:
Replacing a Top Cell Module Position 1
Expanded WP

Labor
Operation

Description (CM 1)

Labor Allowance

B

00 77 519

Replacing top cell module position 1
(Includes 61 27 700 and EoS test)

11 FRU

Or:
Replacing a Bottom Cell Module (2, 11, 3, 10)
Expanded WP

Labor
Operation

Description

Labor Allowance

C

00 77 519

Removing and installing top cell
module position 1

10 FRU

00 77 519

Preliminary work of removing and
installing the retaining frame for cell
module position 1 and SME

9 FRU

Labor
Operation

Description (CM Position- FRU)

2

00 77 519

Replacing one bottom cell module
position 2, 11, 3, or 10, labor allowance
is for each as noted (Includes 61 27
700)

And:
D
And:
Expanded WP
E

11

3

10

7

7

11 11

Description (CM Position - FRU)

4

9 5 8 6 7

Replacing one bottom dual-cell module
position 4, 9, 5, 8, 6 or 7, labor allowance

14 14 15 14 14 14

Or:
Replacing a Bottom Cell Module (4, 9, 5, 8, 6, 7)
Expanded
WP
F

Labor
Operation
00 77 519

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61 19 24_DELIVERY STOP: REPLACE CELL MODULES – I20

is for each as noted (Includes 61 27 700
and EoS test)
And, with the above work that was performed:
Expanded WP
G

Labor
Operation

Description

Labor Allowance

00 77 519

Additional work with pressure test
cooling system high-voltage battery unit
Associated work (coolant drained) (to
high-voltage battery unit

4 FRU (One-time)

00 77 519

Evaluation of a cell module/dual-cell
module for transport

1 FRU (Each)

And:
H

Claim Repair Comments
Reference this SIB number, the work package (WP) number, expanded work packages performed, and the
cell module position number replaced in the technician’s RO notes and in the claim comments (For
example: B61 19 24 WP 1, A, B, G, H, cell module 1), unless otherwise required by State law.
Sublet – Bulk Materials (RO and Claim Comments Required)
Sublet Code 4

Reimbursement for the supported repair-related bulk supply
materials (Do not use the BMW part numbers for claim
submission)

Up to $100.00

Sublet reimbursement calculation for claiming the applicable repair-related bulk supply material (BMW part
number) is at the dealer net (DN) price for the full or proportional quantity used plus your center’s handling.
BMW Antifreeze/Coolant: Claim the corresponding sublet dollar amount for the quantity needed to replace
what was drained. The one gallon concentrate part number quantity for a 50/50 coolant/water solution.
Enter this material cost in sublet and itemize the amount on the repair order and in claim comment section.
BMW Group’s AIR Application Resource for Flat Rate Labor Operation Codes
To obtain the corresponding flat rate unit (FRU) allowance information from the BMW Group AIR application
resource, start by entering the Chassis Number (last seven (7) characters of the VIN), and click on the
“Search” icon. If the “Vehicle Selection” window displays two or more model possible vehicle choices, select
the applicable Model, or enter the full VIN (17 characters) instead to proceed. Click on the “Flat Rate Units”
button and enter a flat rate labor operation code number “without spaces” in the field to the right, click on the
“Search” icon to display the corresponding listing of “Flat rate unit group details” that are available and their
corresponding FRU allowances.
Alternative Mobility Solution (AMS) for Vehicle Owners (RO and Claim Comments Required)
This Service 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

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Technical Feedback
Warranty Feedback
Parts Feedback

61 19 24_DELIVERY STOP: REPLACE CELL MODULES – I20

To submit feedback for the technical topic 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 B611924 Attachment
C_2_0824_0612_Lithium_Ion_Battery_Recycling_Program_REV1.pdf

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Attachment to B611924

September 2024

Bulletin #: C-2-0824-0612
☐ Retail Operator
☐ General Manager

☒ Take Note
☐ Sales Pre-Owned
☐ Sales New Car

☒ Take Action

☐ Business Manager
☒ Service

☒ Parts & Accessories
☐ Administration

Name: Cesar Ortiz

Phone Number: 201-571-5143

Title: Chemical & Battery Program Manager

Aftersales Business Development

Date: 08-28-2024

Supersedes: C-2-0407-0602 / C-2-0407-0603 / C-20323-0606

LITHIUM-ION BATTERY RECYCLING PROGRAM
TAKE NOTE