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61 05 25_DELIVERY STOP: 48V BATTERY THREADED CONNECTIONS

2025-05-28
This Service Information Bulletin (Revision 1) replaces SI B61 05 25 dated March 24, 2025.
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THIS REPAIR IS MOBILE FRIENDLY
THIS REPAIR IS REMOTE SOFTWARE UPGRADE (RSU) FRIENDLY

What’s New:

CAUSE added
CORRECTION added
PROCEDURE added
PARTS INFORMATION added
CLAIM INFORMATION added
Attachment added for FRU worksheet

MODEL
E-Series
G45

Model Description
X3 Sports Activity Vehicle

Production Date
August 1, 2024 – February 12, 2025

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 March 22, 2025, you can see
a list of affected vehicles in Inventory Campaign Details (ICD) under ROSS.

SITUATION
BMW AG has issued a Delivery Stop (effective March 21, 2025) on certain Model Year 2025 BMW vehicles
that were produced between August 1, 2024, and February 12, 2025.
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
The terminals of the 48V battery may have not been torqued properly. In the event of a loose connection,
the vehicle’s electrical system might suffer numerous malfunctions. This is generally indicated by the
corresponding Check Control messages (CCMs) that will display.

CORRECTION
Inspect the threaded connections of the battery cables of the 48V battery, and rework if necessary.

PROCEDURE

1. Visual inspect the (5) threaded connection points below marked by yellow arrows. If a loose threaded

connections is detected, unfasten the nut and check the connection point (cable shoe, nut, bolt) for
damage.

Threaded connection points to be tested
(Power distribution, base Z83*1B, Z83*2B and 48-volt battery G14*2B and G14*3B)

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61 05 25_DELIVERY STOP: 48V BATTERY THREADED CONNECTIONS

2. When consequential damage is visible: renew the associated cable, nut, 48V battery, distributor, or Power
Control Unit (PCU) if necessary. Select and follow the appropriate repair instructions in AIR based on the
extent of damage that has occurred.
3. If no consequential damage is visible or found, reassemble the threaded connection points in accordance
with specifications.
4. Retorque the threaded connections to 19 Nm and reassemble the vehicle.

Guidelines:
In most cases, incorrect threaded connections lead to component damage. Please, observe the steps
below:

When renewing or disconnecting any battery, the procedure in the repair instructions must be
followed
Do not use force when disconnecting terminal covers from the battery
Do not pull on the ground cables
Do not place any tools under the terminal clip to lever off the terminal cover
Use a torque wrench and set the tightening torque in accordance with repair instructions
Use the battery size (capacity) installed standard upon battery replacement
Delete fault code entries associated with battery replacement
Clean the contact surfaces and have them checked by a second person
Screws or nuts of the threaded connections must always be tightened to the specified torque. If
possible, have a second person check the torque.
Always update software on newly installed 48V vehicle batteries
Perform battery registrations when installing a new battery; make sure to perform prediagnosis to determine the cause of the battery failure

Note: 48 V screw connections form REH-HIN-P-0001-48VOLT - V.2 can be found in AIR/ISTA.
Important: Follow repair instructions and ensure all battery cables are fastened with the correct nut
to the specified torque.

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61 05 25_DELIVERY STOP: 48V BATTERY THREADED CONNECTIONS

Note: Damage to the 48V Battery electronics can occur if it is disconnected from the on-board electrical
system while active!
Only activate the 48V electrical system when the 48V battery is fully installed (connected).

PARTS INFORMATION
When applicable for WP #3, consequential replacement of cables, nuts, 48V battery, distributor, and/or the
PCU as required.
To determine the part numbers that apply to a specific vehicle being repaired, enter the VIN/chassis number
into either ETK or AIR, this will consider the specific equipment and/or options that are fitted to the vehicle.
Sublet - Bulk Supply Material
Part Number
83 19 5A32851
Or:
83 19 2468442

Description
HT-12 Antifreeze RTU (Bulk Drum DN = 1/10 Liter) (Pre-mix)

Quantity
As needed

BMW Antifreeze/Coolant (DN = 1 Gallon Concentrate) - HT-12

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’s resources according to the respective vehicle type. Invoiced these items separately under the
Repair Code listed in this bulletin.

CLAIM INFORMATION
Reimbursement for this Action will be via normal claim entry utilizing the applicable work package
information below, and for WP # 3, including the BMW part numbers that were needed for the consequential
repair work as noted above.

Plusposition (+)

Main work

Completion before the first vehicle delivery to a customer (New in-stock/No
in-service date), or the vehicle is already in the workshop for another reason
and/or repair, identified by the “(Plusposition)” reference in the descriptions
below.
The vehicle arrives for this Recall, no other Main work will be
performed/claimed during this workshop visit, identified by the “(Main work)”
reference in the descriptions below

Only one of the flat rate labor operation codes below can be used for claim submission and reimbursement. Also, only one
Main work flat rate labor operation code can be claimed per workshop visit.

Repair Code:

0061180900

G45 Check and if necessary, rework threaded
connection, battery cable 48V battery

Below are the special flat rate labor operation code choices for this action.
Retorqueing the Threaded Connections Only (No additional related consequential repair work WAS
Not required)
Work Package
#1
Or:
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Labor Operation

Description

Labor
Allowance

00 78 648

Access, check and retorque the 48V
battery cable threaded connections (No
additional consequential repairs are
needed) (Plusposition)

5 FRU

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61 05 25_DELIVERY STOP: 48V BATTERY THREADED CONNECTIONS

Access, check and retorque the 48V
battery cable threaded connections (No
additional consequential repairs are
needed) (Main work)

00 78 121

7 FRU

Or when the:
Affected Vehicle arrives with 48V Battery Cable Threaded Connection related CCMs displayed
(Additional diagnosis and related consequential repair work WAS required)
Work Package

#3

Labor Operation

Description

Labor Allowance

00 78 122*

Access, check 48V battery cable
threaded connections and repair,
including the related consequential
work/part replacements (Procedure steps
# 1 to #5 including the Guidelines that
apply) (Plusposition or Main work as
applicable)

Up to 125 FRU WT
with the necessary
time support (Refer
to the FRU
worksheet below)

Please do not use Plus Code operation 00 78 649 for your WP # 3 claim submission.
Claim labor operation code 00 78 122 one time only for the supported total sum FRU allowance that
applies to the additional related repairs performed.
Labor Operation Code Reference Guide/FRU Allowance Worksheet for WP # 3
For help in determining the FRU allowance amount that applies to this Action when consequential repairrelated work is required to be performed, please refer and use the attached FRU allowance worksheet:
B610525_AT_1 FRU Worksheet 05_2025

The AIR labor operation codes listed in the attachment are for reference use only, please do not use
them to submit your claim
If you are using a Main labor code for another repair, use the Plus code labor operation 00 00 556 as your
reference instead of 00 00 006, or exclude them (including 61 21 528) when the Vehicle Test is included in
another repair (For example, an open programming/encoding technical campaign will be performed after this
repair is completed).
Work time labor operation codes 61 00 006, 61 00 009, and 61 99 000 are not considered Main labor operations.

Overlapping Labor Removal (AIR client’s FRU Plausibility Check Tool)
Depending on the scope of repairs, the reference AIR labor operations correspond to the work performed
may contain overlapping inclusive labor tasks, please work together with your center’s Warranty Manager,
Warranty Administrator, and/or Booker to identify the overlapping labor contained in the flat rate labor
operation codes listed above. As determined by the AIR Client’s FRU Plausibility Check Tool; calculate,
claim, and submit for the reduced FRU allowance that applies.
(*) Based on which one applies to your center, please refer to SI B01 01 20 or B01 07 20 for the applicable procedure for
documenting, and explaining, on the RO and in the claim comments, your diagnosis work time (WT), job/repair work time
(WT), and the vehicle repairs your center performed, unless otherwise required by State law.
Note: Diagnosis Worktime Flat Rate 00 58 500 is not claimable with this Action.

Claim Repair Comments

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Reference the SIB number, the issue (briefly), and the work package (WP) number performed in the technician’s RO notes,
and in the claim comments (For example: B61 05 25 Rework 48V Battery Cable Threaded Connection WP 1), unless
otherwise required by State law.
For WP 3, please explain the additional work that was needed to be performed.

Sublet – Bulk Supply Materials (RO and Claim Comments Required)
Sublet Code 4

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

See the sublet
reimbursement
calculations below

Sublet reimbursement calculation for claiming the applicable repair-related bulk supply materials (BMW part
numbers) is at the Dealer Net (DN) price for the full or proportional quantities 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’s part number quantity as needed to obtain 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.
Vehicle Programming and Encoding – Additional Work (RO and Claim Comments Required)
This procedure automatically reprograms and encodes any vehicle control modules that do not have the latest software Ilevel.

If one or more control modules fail during the reprogramming procedure, claim the required consequential
repair work procedures to address this issue (including performing the IRAP Control Unit Recovery first as
required; refer to the SIB in AIR) under the Repair Code in this bulletin together with the corresponding labor
operation codes and their flat rate unit (FRU) allowance(s), including the diagnosis* that applies.
Please explain the additional work procedures that were performed (The why and the what) on the repair order and in the
claim comments.

For covered repairs that address control module failures that occurred prior to performing this
reprogramming procedure, claim this work with the appliable Repair Code listed in AIR together with the
corresponding labor operation codes and their flat rate unit (FRU) allowance(s), including the diagnosis* that
applies.
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 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 Action’s repair qualifies for Alternative Mobility Solution (AMS) expense reimbursement, claim this item
under the Repair 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.

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FEEDBACK REGARDING THIS BULLETIN
Technical Feedback
Warranty Feedback
Parts Feedback

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 B610525_AT_1 FRU Worksheet.pdf

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Attachment 1 to SI B61 05 25

Repair
Code:

May 2025

G45 Check and if necessary, rework threaded connection, battery cable
48V battery (Additional diagnosis and consequential repairs required)
FRU Allowances
Labor Operation Code Reference Guide/FRU Allowance Worksheet
as Applicable
Labor
Description
WP 3: 00 78 122
Operation
Carrying out vehicle test
00 00 556
(Plusposition work)
Or:
Carrying out vehicle test
00 00 006
(Main work)
61 21 528
Supporting voltage of the vehicle electrical system
0061180900

And, as needed
61 00 006*

Carrying out vehicle diagnosis, ABL (Test Plan) (Work time - WT FRU)

61 00 009*

Additional electrical/electronic troubleshooting performed to determine the
scope of the consequential repair work (Work time - WT FRU)

If you are using a Main labor code for another repair, select the Plus code labor operation 00 00 556
instead of 00 00 006, or exclude it (including 61 21 528) when the Vehicle Test is included in another
repair.
And the following as applicable / required (Includes accessing the 48V Battery area)
Removing and installing/replacing rear positive battery cable power
61 14 540
distribution
Replacing 48-V battery, registering with battery includes drain and top up
61 21 523**
the low-temperature coolant circuit
61 42 601**

Replace 48V Power Control Unit (PCU 48)

When applicable, for vehicles without an open programming/encoding Technical Campaign (**)
Program/encode control unit(s), includes deleting the fault memory (After
61 00 730
performing 61 21 523 / 61 42 601, or when otherwise required)
Performed other work/job task(s) WITH a specified flat rate operation code/FRU allowance in AIR

AIR client’s FRU Plausibility Check Tool – Use to review and identify overlapping labor for removal
from the above.
Performed other work/job task(s) WITHOUT a specified flat rate operation code/FRU allowance in AIR
(Explanation comments required for each)
61 99 000*
The AIR labor operation codes listed above are for reference use only, please do
not used them to submit your claim.
Claim labor operation code 00 78 122 one time only for the total FRU amount that
applies

WP 3: 00 78 122