MINI Countryman HV Battery Fault (2017-2023)
Under-voltage fault(s) logged during regenerative braking
Over-voltage fault(s) logged during regenerative braking
Cell supervision circuit fault
The following fault code(s) may be present
This case involved a MINI Countryman HV battery fault, with under-voltage and over-voltage faults logged during regenerative braking. No specific fault codes were documented in this particular case. The sending workshop completed an ISTA test plan, but the exact DTCs were not provided.
The workshop who required this repair were able to remove the battery from the vehicle and send it to us for repair, retaining the labour and keeping their customer.
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Parts Repaired/Replaced
- HV battery cell modules replaced and State of Charge (SOC) balanced
Affected Vehicles
MINI Countryman Cooper S E ALL4 (PHEV)
- MINI Countryman Cooper S E ALL4 (2017)
- MINI Countryman Cooper S E ALL4 (2018)
- MINI Countryman Cooper S E ALL4 (2019)
- MINI Countryman Cooper S E ALL4 (2020)
- MINI Countryman Cooper S E ALL4 (2021)
- MINI Countryman Cooper S E ALL4 (2022)
- MINI Countryman Cooper S E ALL4 (2023)
Common Failure Symptoms
- Under-voltage and over-voltage fault logging during regenerative braking
- Intermittent HV battery behaviour under high load/regen conditions
- Suspected issue localised to specific Cell Module and/or the cell supervision circuit
MINI Diagnostic Report
Initially, the customer reported under-voltage and over-voltage faults occurring specifically during regenerative braking on the motorway. The vehicle was inspected by the garage, who completed an ISTA diagnostic test plan and recommended battery removal for charging and/or module replacement. The battery was then assessed on the bench to verify module condition and check for evidence of supervision circuit issues.
MINI Repairs
The high-voltage battery was removed and opened to allow targeted testing. Wiring checks confirmed a faulty temperature sensor on module 3. Three temperature sensors were replaced and the battery was reassembled and resealed, and a pressure test was completed to confirm integrity. An EOS Test was carried out, the A/C system was recovered and recharged, then the vehicle was rescanned to verify all temperature readings were normal and all faults were cleared.
- HV battery bench read carried out
- HV battery fully stripped; testing completed on all modules
- Cell modules balanced as required
- Pack rebuilt and sealed
- EOS test completed
Resolution
Following testing and balancing, the HV battery pack was rebuilt and validated with an EOS test. The customer was updated and the battery was returned to the workshop ready for onward delivery.
Following the repair:
- Module condition verified and documented via bench testing
- Required balancing completed before reassembly
- Pack rebuilt and EOS-tested prior to return
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