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64 05 25_HVAC FLAP LINKAGE NOT FULLY CONNECTED

SIB 64 05 25
HVAC FLAP LINKAGE NOT FULLY CONNECTED

2025-09-08

This Service Information Bulletin (Revision 7) replaces SI B64 05 25 dated August 2025.
What’s New:

Procedure: The linkage may bottom out on the HVAC case before fully seating into the flap.
Apply outward pressure on the flap while applying inward pressure on the linkage.
Overview video link added

☐
☐

THIS REPAIR IS MOBILE FRIENDLY
THIS REPAIR IS REMOTE SOFTWARE UPGRADE (RSU) FRIENDLY

MODEL
E-Series
G45

Model Description
X3 Sports Activity Vehicle

SITUATION
1. The customer states that the output air from one of the vehicle vent assemblies doesn’t match the desired
temperature, will change temperature opposite of climate settings.

2. The customer states that the output air from one of the vehicle vent assemblies doesn’t match the desired
temperature, nor change from Hot/Cold.

CAUSE
1. Center vent temperature sensor wiring harness pinned incorrectly.
2. The air flap linkage may not be fully locked into the air mixing flap.

CORRECTION
1- Check the wiring between the BCP and the center driver and passenger vent temperature sensors.
2- Check that the linkage has not come loose from the flap in the heating, ventilation, and air conditioning
(HVAC) system.
The linkage connection to the right front mixed air flap (5B) is the one we have found loose on most
vehicles. For specific instructions on how to fix this flap, refer to Attachment B64 05 25 RF Mix Flap.
This can occur to ANY of the flaps in the HVAC system.
See attached video for one example
BV64 02 25 G45 Flap Linkage

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There is a push-in end on the linkage that can
be reinserted into the flap and fully seated.

Check that the linkage has not come loose from
the HVAC flap for the zone that is
malfunctioning.
There is a white plastic mechanism that
connects the black linkage arm and the HVAC
flap assembly.

To test if the mechanism is fully seated into the
HVAC flap assembly, perform a wiggle test of
the white plastic (in/out). Here you can see the
white plastic mechanism has backed out of the
HVAC case and is not locked into the flap.
This can occur to ANY of the flaps in the HVAC
system.
See video attached to the bulletin for one
example.
If using a borescope to inspect if the flap is fully locked into the linkage, you can see the White
plastic mechanism push pin mushroom
must
into the flap
Copyrightshaped
©2025end
BMW
of engage
North America,
Inc.by being pushed in
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until it fully goes past the plastic flap ramp. The pictures below show fully locked in vs not fully
locked.

PROCEDURE
1- Check the wiring between the BCP and the center driver and passenger vent temperature sensors.

Module A528 BCP A528*7B pin 12 to B151 Vent Temp Sensor Left Front pin 3 B151*1B
Module A528 BCP A528*7B pin 10 to B151 Vent Temp Sensor Left Front pin 1 B151*1B
Module A528 BCP A528*7B pin 10 to B152 Vent Temp Sensor Right Front pin 1 B151*1B
Module A528 BCP A528*7B pin 13 to B152 Vent Temp Sensor Right Front pin 3 B151*1B
The wiring could be swapped at connector x1559*1B which is in line between BCP and the vent
temperature sensors.
See Wiring diagram SSP-SP0000074179

2-See attachments for the Procedure.
The linkage connection to the right front mixed air flap (5B) is the one we have found loose on most
vehicles. For specific instructions on how to fix this flap see Attachment B64 05 25 RF Mix Flap
For an overview of the 5B flap repair, refer to video BV641225 Flap 5B Repair overview.mp4
Check that the linkage has not come loose from the HVAC flap. This can occur to ANY of the flaps in the
HVAC system.
There is a white plastic mechanism that connects the black linkage arms and the HVAC flap assembly.
To test if the mechanism is fully seated into the HVAC flap assembly, perform a wiggle test of the white
plastic (in/out).
There is a push-in end on the linkage that can be reinserted into the HVAC flap and fully seated.
The white plastic mechanism push pin can be reinserted into the HVAC flap and fully seated.

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Make sure to push in until you can feel the
white plastic mechanism push pin
mushroom-shaped end engage into the flap
ramp.
NOTE: The linkage may bottom against the
HVAC case before it fully seats into the flap.
This is because the flap may have some
side-to-side free play. In this case apply
OUTWARD pressure* on the flap while
pressing INWARD on the linkage until it fully
engages. This may require more
disassembly of the ducts to access the flap.
The fresh air blend uses two linked flaps,
and you may have to go around the top flap
to put pressure on the lower flap.
*The location of where to position the
screwdriver tip (arrow) is shown in the 5B
flap repair, refer to video BV641225 Flap 5B
Repair overview.mp4
The flap and linkage may be out of alignment and only snap in one way.
Move flap or use BCP_SP21 test plan to move linkage to align.
The test plans can be found in Procedure Heating and air conditioning functions:

Move flap motors to installation position (ABL-DITAS6450_SP21_KLAP_MOTOR_MONTAGEPO) This is the middle of travel flap setting.
Flap motors, calibration run (ABL-DIT-AS6450_SP21_KLAP_MOTOR_EICHLAUF)

CLAIM INFORMATION
This Service Information Bulletin provides technical, diagnostic and/or repair-related information.
Damage and/or issues caused by outside influences are not covered under the BMW Limited Warranties.
Eligible and Covered Work/Repairs
Repairs that address a verified defect in materials and/or workmanship are covered under the terms of the
BMW New Vehicle Limited Warranty for Passenger Cars and Light Trucks.
To submit a claim, please following the established and applicable warranty policy and procedures
(Labor/Part/Sublet – Bulk supply materials) that apply to the repair being performed.
Refer to AIR for the claim-related line item’s Repair Code. For the corresponding repair that was performed, obtain the
corresponding labor operation codes and their flat rate unit (FRU) allowance(s), including the diagnosis* that applies.

Only one Main labor operation code can be claimed per repair visit.
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.Copyright ©2025 BMW of North America, Inc.
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(*) 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, claiming, 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.

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 Attachment B64 05 25 RF Mix Flap.pdf
picture_as_pdf Attachment B64 05 25 G45 HVAC Master INFO AUG 22 2025.pdf
Videos
64 03 25
64 04 25
64 05 25
64 06 25
64 07 25
64 08 25
64 09 25
64 10 25
64 11 25
64 12 25

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Copyright ©2025 BMW of North America, Inc.
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Attachment to SI B64 05 25

August 2025

G45 HVAC: Air Vent Flaps/Kinematic & Stepper Motor Master Info.
G45 HVAC: Complete Assembly Overview
➢ OVERVIEW CHART
➢ Air Vent Flaps/Kinematic (+ push pin) Detailed Information
➢ Stepper Motor Control Detailed Information

CONFIDENTIAL

1

G45 HVAC: Air Vent Flaps/Kinematic & Stepper Motor Master Info.
OVERVIEW: Air Vent Flaps/Kinematic & Stepper Motor Control Chart
AIR VENT FLAPS
Vent Flap # Vent Flap Description

STEPPER MOTOR CONTROL INFORMATION

Vent Flap Visibility (for push pin)

Motor
Position #

Electrical ID

Motor Control Desc

1

Fresh Air Flap

Easily Visible: Just inside of HVAC

13

M 16 (Shared)

Fresh Air / Recirculated Air Distribution

2

Recirculated Air Flaps x2 (connected)

Easily Visible: Just inside of HVAC

13

M 16 (Shared)

Fresh Air / Recirculated Air Distribution

3

Defrost Air Flap

Easily Visible: Just inside of HVAC

10

M 61

4A

Front Cold Temp. Mixing Flap LEFT

Difficult: Bororscope through open Flap #3

2

M 23 (Shared)

Front Temperature Mixing LEFT

4B

Front Cold Temp. Mixing Flap RIGHT

Difficult: Bororscope through open Flap #3

9

M 83 (Shared)

Front Temperature Mixing RIGHT

5A

Front Warm Temp. Mixing Flap LEFT

Difficult: Bororscope through open Flaps #7

2

M 23 (Shared)

Front Temperature Mixing LEFT

5B

Front Warm Temp. Mixing Flap RIGHT

Difficult: Bororscope through open Flaps #7

9

M 83 (Shared)

Front Temperature Mixing RIGHT

6A

Front Footwell Air Flap LEFT

Easily Visible: Just inside of HVAC

5

M 21

Front Footwell Air Distribution LEFT

6B

Front Footwell Air Flap RIGHT

Easily Visible: Just inside of HVAC

4

M7

Front Footwell Air Distribution RIGHT

7A

Front Center Vent Air Flap LEFT

Easily Visible: Just inside of HVAC

7

M 20

Front Center Vent Air Distribution LEFT

7B

Front Center Vent Air Flap RIGHT

Easily Visible: Just inside of HVAC

12

M 22

Front Center Vent Air Distribution RIGHT

8A

Front Side Vent Air Flap LEFT

Easily Visible: Just inside of HVAC

3

M 020

Front Side Vent Air Distribution LEFT

8B

Front Side Vent Air Flap RIGHT

Easily Visible: Just inside of HVAC

11

M 022

Front Side Vent Air Distribution RIGHT

9

Rear Upper Vent Flap (Center Console)

Easily Visible: Just inside of HVAC

1

M 084 (Shared)

REAR Air Distribution

10

Rear Cold Temp. Mixing Flap

Difficult: Bororscope through open Flap #9

8

M 024 (Shared)

REAR Temperature Mixing

11

Rear Warm Temp. Mixing Flap

Other: No direct push pin (tied to Flap #10)

8

M 024 (Shared)

REAR Temperature Mixing

12

Rear Footwell Air Flaps L/R x2 (connected)

Easily Visible: Just inside of HVAC (D.S)

1

M 084 (Shared)

REAR Air Distribution

13

Indirect Air Flap

N/A: Different connection type (no push pin)

6

M 197

Indirect Air Distribution

Defrost Air Distribution

Please reference the FLAP diagram & STEPPER MOTOR control locations diagrams on the following pages.
CONFIDENTIAL

2

G45 HVAC: Air Vent Flaps/Kinematic & Stepper Motor Master Info.
FLAPS / Kinematic Diagram Details (Overview)
7A

7B

3
13

1

6A
2

6B

4B

4A

5A

5B
8B
11

8A

10

12L

9

12R

CONFIDENTIAL

3

G45 HVAC: Air Vent Flaps/Kinematic & Stepper Motor Master Info.
Stepper Motor Control Locations Diagram (OVERVIEW)
#7- M20
KLAPPE_BELUEFTUNG_FA

#6- M197