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BMW of North America has announced a safety recall involving 4,397 vehicles across several 2025 models due to a defect in the starter-generator that may lead to engine stalling or, in extreme cases, fire. The affected vehicles, which include popular models such as the 330i, 530i, various 4 Series variants, and the X3 30 xDrive, were manufactured between October 2024 and March 2025.
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According to the company’s report to the National Highway Traffic Safety Administration (NHTSA), the defect involves a potential gap at the power connector of the starter-generator, caused by deviations in the supplier’s production process. This gap may lead to a loose connection between the connector and the vehicle’s positive battery cable, resulting in resistive heating. The issue poses a significant safety risk as it could lead to loss of the charging function, engine stalling without warning, or, over time, overheating that may result in smoldering or fire.
The starter-generators were produced by Shanghai Valeo Auto-Elec System Co. Ltd., a supplier based in China. Initial reports of the issue surfaced in December 2024 from a non-U.S. market, where a vehicle experienced a no-start condition and burning odor in the engine compartment. Following additional reports and an internal engineering investigation, BMW traced the defect to specific production batches from one supplier. By late March 2025, the company opted to initiate a voluntary safety recall.
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No accidents or injuries related to the defect have been reported to date. BMW will notify dealers and affected owners, beginning April 1 and May 23 respectively. Owners will be instructed to bring their vehicles to authorized dealers for inspection and, if necessary, replacement of the starter-generator and positive battery cable at no cost. Vehicles that already underwent this repair under the standard warranty program will not require reimbursement.
Article by multiple RFHC contributors, based upon information from the BMW of North America recall filing with the National Highway Traffic Safety Administration (NHTSA).
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