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 auxiliary materials. These must be worked through step-by-step to investigate the problem. The documents listed can be accessed via hotspots.
1. Fault analysis (energy diagnosis)
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 standby current
Operating errors
- Side lights/parking lights/hazard warning flashers left on too long
- Terminal R/15 left on too long
- Unfavourable driving profile (e.g. extremely short distances)
- Unfavourable usage profile (e.g. immobilisation period too long, use of auxiliary consumers)
In event of a "dead battery" complaint, the energy diagnosis procedure must be followed 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.
Text search in ISTA or path: Function Structure > 03 Body > Voltage 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
- Use the correct defect code in such situations (61 21 00 49 or 61 21 00 01).
- Use of BMW Group 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 procedure 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. Standby current measurement
Service Information bulletins:
"Standby current measurement" SI 61 03 99 (474)
BMW diagnosis system (functional
description):
For E38, E39, E46, E53, E83, E85
Path: Complete vehicle > Powertrain >
Voltage and current control > Voltage
and current supply > Standby current
measurement
For E65, E66, E67
Path: Complete vehicle > Body > Voltage
supply > Voltage and current supply >
Standby current measurement > Standby
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 > Voltage
supply > Standby current
3. Test 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 (functional description):
For all except E65, E66, E67
Path: Complete vehicle > Powertrain >
Voltage and current control > Voltage
and current generation
For E65, E66, E67
Path: Complete vehicle > Body > Voltage
supply > Alternator
4. For F10 vehicles: 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 on-board
computer 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 (auxiliary
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 charging
voltage of 14.8V.
If possible, the battery temperature
should be between 15 °C and 25 °C
during charging. 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 directly at the
battery terminals could lead to a
misinterpretation of the battery
condition and even unwanted Check
Control messages or fault entries.
If the battery is recharged while it is
installed, it must be recharged using the
jump start terminal points, whenever jump
start terminal 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 start terminal 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 a petrol engine, the negative terminal
can be connected to the lifting eye
(suspension lug) on the transmission and on
vehicles with diesel engines to a flange on
the engine bearing block on the engine.
7. Charging the high-voltage battery
Charge high-voltage battery
Notes on charging the high-voltage battery
on standing vehicles (new and used cars)
8. Additional publications of the subject of "Batteries"
BMW Service Technology:
AGM battery - brief BMW Service Technology 61 01 02 (005)
component description
Service instructions for BMW Service Technology 61 01 02 (005)
AGM batteries
Service Information bulletins:
"SIP Battery basics" SI 00 09 01 (683)
"Battery charging calendar" SI 61 03 98 (387)
"Notes on charging batteries" SI 61 08 01 (776)
"Electronic battery master switch" SI 61 02 04 (103)
All model series
"Battery positive terminal with SI 61 12 01 (000)
battery in luggage compartment,
E36"
"System battery discharges, E38/3" SI 61 40 01 (000)
"Replace system battery, E38 M73" SI 61 45 01 (000)
"Checking electrical connection SI 61 47 01 (000)
for secondary air pump, Z3"
TIS Hotline Information bulletins:
"Discharging battery, E39 HLI 61 13 85 (000)
"Battery discharge with key in HLI 61 53 89 (000)
lock
"Battery discharge; battery HLI 61 36 79 (000)
master switch not fitted"
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.