61 07 02 (875) Battery Master Document
61 07 02 (875) Battery Master Document
All model series
Situation:
The electrical system of BMW vehicles has been subject to an ongoing development process over the last few years. This has led to increased demands being placed on the battery. This document summarises all important information about how the battery should be handled in the dealership.
Procedure:
The complaint "flat battery" can have various causes, most of which do not concern the battery itself. For this reason, replacing the battery will not usually lead to a lasting solution to the problem. The cause must be properly analysed in order to perform a repair that actually rectifies the cause.
Below you will find list of the available aids. These must be worked through step-by-step to investigate the problem. The documents listed can be accessed via hotspots.
Engage Fault analysis (energy diagnosis)
1st
Fundamentally, the following causes are possible for a breakdown resulting from a flat battery or problems in the vehicle's electrical power supply:
Vehicle faults
- Battery defective / alternator fault
- Vehicle does not "go to sleep"
- Vehicle keeps being woken up
- Excessive closed-circuit current
Operating error
- Side lights/parking lights/hazard warning lights left on too long
- Terminal R/15 left on too long
- Unfavourable driving profile (e.g. extremely short distances)
- Unfavourable usage profile (e.g. parked period too long, use of auxiliary consumers)
For E65, E66, E67 from model year 03/2004 and for E60, E61, E63, E64, E81, E82, E87, E90, E91, E92, E93, E70, E71, E72, R55, R56, R57, R60, F01, F02, F03, F04, F07, F10, F11, RR4 it is necessary in the case of the "flat battery" complaint to work through the energy diagnosis testing procedure.
Text search in ISTA or path: Function structure > 03 Body > Power supply > Energy diagnosis
IMPORTANT: The prerequisite for invoicing a battery through the warranty channel is to work through the testing procedure
Energy diagnosis through to the diagnosis result:
- Show cause
- Show help instructions
- Show corresponding diagnosis code
Exceptions are:
- Obvious battery damage and leakage
In such cases, use the correct defect code (61 21 00 49 or 61 21 00 01).
- Use of mobile service and battery replacement on site to restore customer mobility as quickly as possible.
NOTE: The aim of energy diagnosis is to identify the most probable cause for a breakdown caused by a flat battery or for problems in the vehicle's electrical power supply. The causes listed above are stored in energy diagnosis.
- For vehicles with automatic engine start/stop system, if this function is not fully available: If the test module instruction MSA power management appears, the battery must be replaced. In this case use defect code 61 21 08 98.
NOTE: To enable the applicant to use the correct defect code, make sure that both the customer's statement and the diagnosis results are adequately documented. These must be made available to the applicant.
For all other model series
For model series that do not have energy diagnosis, the customer should be interviewed to make sure that the operating errors described above can be ruled out as the cause of the battery discharging.
2. Off-load current measurement
Service Information bulletins:
"Off-load current SI 61 03 99 (474)
measurement"
BMW diagnosis system (function
description):
For E38, E39, E46, E53,E83, E85
Path: Complete vehicle > Drive > Voltage and current control > Voltage and current supply > Off-load current measurement
For E65, E66, E67
Path: Complete vehicle > Body > Power supply > Voltage and current supply > Off-load current measurement > Off-load current diagnosis
For E60, E61, E63, E64, E81, E82, E84, E87, E89, E90, E91, E92, E93, E70, E71, E72, R55, R56, R57, R60, F01, F02, F03, F04, F07, F10, F11, RR4
Path: Service functions > Body > Power supply > Off-load current
3. Testing alternator
TIS Hotline Information bulletins:
"Battery discharged" HLI 12 51 83 (000)
NOTE: TIS Hotline Information bulletins (HLI) are only available on the TIS CD until 12/2003. After this, all HLI subjects were transferred to the "PuMA" system.
BMW diagnosis system (function description):
For all except E65, E66, E67
Path: Complete vehicle > Drive >
Voltage and current control > Voltage and current generation
For E65, E66, E67
Path: Complete vehicle > Body > Power supply > Alternator
4. For vehicles F10 as from 06/2010 there will be an OnBoard diagnosis for assessing the battery condition.
5. When the battery is replaced For E65, E66, E67 always, for E60, E61, E63, E64
and E81, E82, E84, E87, E89, E90, E91, E92, E93, E70, E71, E72, R55, R56, R57, R60, F01, F02, F03, F04, F07, F10, F11, RR4
- Providing an intelligent battery sensor (IBS) is fitted (depends on vehicle equipment)-
Register the new battery using the BMW diagnosis system.
IMPORTANT: If the new battery is not registered, incorrect readings may appear in the display of the onboard monitor due to old data in the power management system (check control message "Recharge battery" appears even though the battery is new).
Only E65, E66, E67, F01, F02, F03, F07 and vehicles with SA536 (independent heating), intelligent generator control or automatic engine start-stop function
NOTE: Only AGM batteries should be installed in these vehicles.
6. Recharging the battery
The battery may only be recharged with a battery charger that has been approved by BMW and that has a constant charge voltage of 14.8V.
If possible, the battery temperature should be between 15°C and 25°C during recharging. Under these conditions, the battery is adequately charged when the charge current drops below 2.5 amps.
If the battery is recharged at lower temperatures, the process should not be ended until the charge current drops below 1.5 amps.
On vehicles with IBS, recharging the battery is directly at the battery terminals could lead to a misinterpretation of the battery condition and even unwanted Check-Control messages or fault memory entries.
If the battery is recharged while it is installed, it must be recharged using the jump-starting points, whenever jump-starting points are provided in the engine compartment (all vehicles except R55, R56, R57, R60).
Only then can you be sure that recharging is correctly recognised by the vehicle electronics on vehicles with intelligent battery sensor (IBS).
For R55, R56, R57, R60: These vehicles do not have any jump - starting points in the engine compartment.
On these vehicles, the positive terminal of the battery charger must be directly connected to the battery. On vehicles with spark - ignition engine, the negative terminal can be connected to the lifting eye (attachment eye) on the transmission and on vehicles with diesel engines to a flange on the engine bearing block on the engine.
7. Additional publications of the subject of "Batteries"
BMW Service:
AGM battery-description SBT 61 01 02
of components (005)
Service instructions SBT 61 01 02
for AGM batteries (005)
Service Information bulletins:
"SIP Battery basics" SI 00 09 01
(683)
"Battery charging SI 61 03 98
calendar" (387)
"Notes on charging SI 61 08 01
batteries" (776)
"Electronic battery SI 61 02 04
master switch"
All model series (103)
"Battery positive SI 61 12 01
terminal with battery, (000)
in luggage compartment, E36"
"Equipment battery SI 61 40 01
discharges,E38/3" (000)
"Replacing system, SI 61 45 01
battery E38 M73" (000)
"Checking electrical SI 61 47 01
connection for secondary
air pump Z3" (000)
TIS Hotline Information bulletins:
"Discharging battery, HLI 61 13 85
E39" (000)
"Battery discharge with HLI 61 53 89
key in lock" (000)
"Battery discharge; HLI 61 36 79
battery master switch
not fitted" (000)
NOTE: TIS Hotline Information bulletins (HLI) are only available on the TIS-CD until 12/2003. After this, all HLI subjects were transferred to the "PuMA" system.