B610225 Service Campaign

NHTSA ID Number: 11017283

Manufacturer Communication Number: B610225

TSB/Document Date: 2025-04-28

Summary

Due to unfavorable tolerances, the Power Control Unit (PCU) may switch off under heavy loads and nolonger charge the Lithium-Ion (Li-Ion) Auxiliary (AUX) battery. This leads to the failure of the roll stabilization,and loss of communication to the EARS modules (S 0421 & S 0422).

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TSB/Document ID: B610225
- Identifier the manufacturer uses to identify the communication and the way it can be located by those searching for it.

Replacement Service Bulletin Number:
- Replacement service bulletin number.

MFR Communication Date: 2025-04-18
- Date the communication was disseminated by the manufacturer.

MFR Internal Campaign ID/Software Version: 0061140900
- Manufacturer's unique identifier for the service campaign if this communication is a related one.

Communication Type: Service Campaign

- Service Bulletin / Repair Instructions
- Service Campaign
- Warranty Program / Extension
- Over The Air
- Emissions
- Other

NHTSA Components: ELECTRICAL SYSTEM
- NHTSA Component(s) of the products involved in communications.

MFR Component System:
- Manufacturer's top-level component of the products involved in communications.

MFR Component Subsystem:
- Manufacturer's component subsystem of the top-level component identified above.

4/28/25, 2:14 PM

61 02 25_DELIVERY STOP: REPLACE 12V POWER CONTROL UNIT (PCU)

SIB 61 02 25
DELIVERY STOP: REPLACE 12V POWER CONTROL UNIT (PCU)
☒
☐

2025-04-18

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

This Service Information Bulletin (Revision 2) replaces SI B61 02 25 dated March 2025.
What’s New:

Claim Information for labor operation 00 78 603 updated.
Claim comment recommendation updated

MODEL
E-Series
F95
F96
G06
G07

Model Description
X5 M Sports Activity Vehicle
X6 M Sports Activity Coupe
X6 Sports Activity Coupe
X7 Sports Activity Vehicle

Production Date
August 13, 2024 – September 3, 2024
May 6, 2024 – August 10, 2024
August 19, 2024
April 16, 2024 – August 30, 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 February 15, 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 February 14) on certain Model Year 2025 BMW vehicles that
were produced between April 16, 2024, and September 3, 2024.
Due to unfavorable tolerances, the Power Control Unit (PCU) may switch off under heavy loads and no
longer charge the Lithium-Ion (Li-Ion) Auxiliary (AUX) battery. This leads to the failure of the roll stabilization,
and loss of communication to the EARS modules (S 0421 & S 0422).
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
Unfavorable tolerance in the 12V PCU module.

CORRECTION
Replace the 12V PCU and inspect the AUX battery.

PROCEDURE
1. Replace the PCU in accordance with repair instructions “Removing and installing the voltage
transformer/Power Control Unit (PCU) 61 42 050 | REP-REP-P-6142050-G07”.

2. After PCU replacement, the vehicle must be programmed. Determine the vehicle’s current I-level by either using
AIR or the Key Reader/AWP (Aftersales Workplace) applications. If needed, use the latest ISTA to work through test
modules.

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4/28/25, 2:14 PM

61 02 25_DELIVERY STOP: REPLACE 12V POWER CONTROL UNIT (PCU)

Programming via ISTA with the latest software.
Connect the battery charger to the vehicle
Connect the vehicle to ISTA
Determine the measures plan
Accept or work through the entire measures plan with the control units to be programmed/encoded
and, if necessary, activated
Follow the rework list
Depending on the rework list, carry out a vehicle test and delete the fault memory, if required
Always connect a BMW-approved battery charger/power supply (SI B04 23 10).
Note: ISTA will automatically reprogram and code all programmable control modules that do not have the
latest software. For information on programming and coding with ISTA, refer to TIS / Technical
Documentation / Diagnostics and Programming / Programming Documentation
3. Next, evaluate the additional Li-Ion AUX battery with ISTA test module “ABL-DIT-AT6121_DSSLTO_EARS”, via
the path below.
Vehicle management
Troubleshooting
Function Structure
Body
Voltage Supply
Vehicle electrical system support
Auxiliary battery
Lithium-ion auxiliary battery

4. When the Li-Ion AUX battery cannot be recovered or is determined to be defective, replace it following repair
instruction “Replacing 12-V lithium-ion auxiliary battery - registering with battery replacement - 61 21 086 |
REP-REP-P-6121086-G07_EMARS - V.4”.

5. Delete fault codes and perform a sleep cycle to ensure the registered battery characteristics are saved in the
vehicle’s memory.

6. The exchanged PCU should not be discarded and is required for analysis purposes. The following steps must
be taken after removal of the damaged parts:
a. Store at your facility as a special damage part.
b. Wait for the special claim return request to be sent to the parts department.
c. Return the exchanged PCU promptly for analysis

PARTS INFORMATION
Use and invoice the appliable part numbers below.
Please only order additional parts apart from the PCU 500 in accordance with ETK if a damage was
identified during the inspection, as the expected exchange rate is very low (< 1.0%).
Part Number
about:blank

Description

Quantity
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4/28/25, 2:14 PM

61 42 5 B62 A38
And if required:
61 21 5 B3F 328

61 02 25_DELIVERY STOP: REPLACE 12V POWER CONTROL UNIT (PCU)

Power Control Unit PCU control unit

12V lithium-ion auxiliary battery

The parts to be replaced as part of a technical action are generally not subject to the parts clearing process.
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
During this workshop visit, the affected vehicle may also show one or more programming and encoding
Technical Campaign repairs open, the programming and encoding procedure may only be invoiced one
time.
After replacing the Power Control Unit (PCU) control unit, and the 12V lithium-ion auxiliary battery if required, it is
recommended to select this open Technical Campaign to claim for updating the vehicle to the required I-level, or
higher when applicable (Includes labor operation codes 00 00 006/556, 61 21 528 and 61 00 730).
Please be sure to also perform any additional before and/or after work (including attaching labels) as required by
the other open campaigns on the vehicle. Close any remaining open programming and encoding Campaign repairs
as outlined in the corresponding Service Information Bulletin.

As determined by the above, reimbursement for this Action will be via normal claim entry utilizing the work
package information below and part numbers above that apply.
Repair Code:

0061140900

G06 G07 F95 F96 Replace Power Control Unit

Below are the special flat rate labor operation code choices for this action, only one Main work flat rate labor operation code
can be claimed per workshop visit.

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.
Work Pkg (WP)
#1

Labor Operation Description (Plusposition +)

Labor Allowance

00 78 546

Replace the Power Control Unit (PCU
500), programming and encoding the
13 FRU (G07/F95)
vehicle control units, includes Carrying 20 FRUs (G06/F96)
out vehicle test (00 00 556/61 21 528)

00 78 575

Replace the Power Control Unit (PCU
500), programming and encoding the
vehicle control units was performed in
conjunction with another
campaign/repair during the same
workshop visit

Or:

5 FRU (F95/G07)
12 FRU (G06/F96)

Or:
The vehicle arrives at your center and this Action shows open (No other Main work will be performed
or claimed during this workshop visit).
Work Pkg (WP)

Labor Operation Description (Main Work)

Labor Allowance

3/6

4/28/25, 2:14 PM

61 02 25_DELIVERY STOP: REPLACE 12V POWER CONTROL UNIT (PCU)

00 78 040

Replace the Power Control Unit (PCU
14 FRUs (G07)
500), programming and encoding the
15 FRUs (F95)
vehicle control units, includes Carrying
22 FRU (G06/F96)
out vehicle test (00 00 006/61 21 528)

00 78 063

Replace the Power Control Unit (PCU
500), programming and encoding the
vehicle control units was performed in
conjunction with another
campaign/repair during the same
workshop visit

Or:

6 FRU (G07)
7 FRU (F95)
14 FRU (F96/G06)

And when required with the work package information above that applies to the vehicle being repaired:
Replacing the 12V Lithium-Ion Auxiliary Battery
Expanded WP
A

Labor Operation Description (Associated work)
00 78 547

Additional work: Replacing the 12V
lithium-ion auxiliary battery / without the
programming/encoding portion

Labor Allowance
14 FRU

G07 (X7) with Third-Row Rear Bench Seat Option
Expanded WP
B

Labor Operation Description (Associated work)
00 78 603

Labor Allowance

G07 (X7) Only - Additional work for
access: Removing and installing the air
13 FRU
duct for those vehicles equipped with the
third-row rear bench seat

Claim Repair Comments
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 02 25 PCU Rplmt WP 1), unless otherwise required by State law.

And when applicable, also explain the additional work that applies and was performed.
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.
(*) 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
Copyright
©2025
BMWunless
of North
America,
Inc.
work time (WT), and the vehicle repairs
your center
performed,
otherwise
required
by State law.
about:blank

4/6

4/28/25, 2:14 PM

61 02 25_DELIVERY STOP: REPLACE 12V POWER CONTROL UNIT (PCU)

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.

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

5/6

4/28/25, 2:14 PM

61 02 25_DELIVERY STOP: REPLACE 12V POWER CONTROL UNIT (PCU)

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