BMW Recalls Over 145,000 Vehicles Due to Engine Starter Fire Risk

According to a Part 573 Safety Recall Report submitted to the National Highway Traffic Safety Administration (NHTSA), BMW of North America, LLC is initiating a voluntary safety recall affecting over 145,000 vehicles due to a potential defect in the engine starter that could lead to overheating and fire. The recall encompasses several BMW models manufactured between 2018 and 2025, including the 340i, 840i, 740Li, X7, X6, and X5.

The defect specifically involves an engine starter with a particular production configuration. In certain instances, these starters may not initiate the vehicle’s engine properly. These repeated unsuccessful starting attempts can cause localized overheating of the starter component. If this overheating occurs and the engine acoustic protection material becomes contaminated, it could ignite, potentially resulting in a thermal event. This risk could manifest while the vehicle is being driven or shortly after it has been parked, particularly if a starting issue occurred just before parking. Owners may notice smoke while driving or upon exiting their vehicle if this condition arises.

The affected vehicles include 10,867 units of the 2020 BMW 340i produced between February 21, 2019, and July 28, 2020. Additionally, 12,456 units of the 2020-2025 BMW 840i, manufactured from February 18, 2019, to February 11, 2025, are part of the recall. The recall also covers 11,893 units of the 2020-2022 BMW 740Li, produced from February 12, 2019, to June 13, 2022. Multipurpose passenger vehicles affected are 24,979 units of the 2019-2020 BMW X7, manufactured from October 30, 2018, to July 29, 2020, and 2,754 units of the 2020 BMW X6, produced between July 15, 2019, and July 29, 2020. The largest group of affected vehicles is the 2019-2020 BMW X5, with 82,153 units manufactured from March 20, 2018, to July 29, 2020.

The investigation into this issue began in March 2025, when three field incidents involving BMW X5 models with thermal damage were reported. Analysis revealed these incidents occurred after the vehicles had received a remedy for a previous recall, NHTSA Safety Recall ID 24V-576. A dedicated problem-solving team was formed in April to further examine these cases, which included establishing a testing program and reviewing prior field incidents. During this period, one additional field incident was reported.

In May, bench testing of engines and fault tree analyses were initiated. The remedy for the earlier recall was reviewed, and comparative tests were conducted on engines with and without that remedy. Investigations also extended to various engine and adjacent engine parts, as well as CAD analyses of vehicle geometries to understand potential interactions between the starter and surrounding components like the oil level sensor and under shield insulation. Three more field incidents were identified during May. Root cause analysis continued through June and August, with ongoing evaluation of the software remedy’s effectiveness for the previous recall and further collaboration with the supplier on root cause analysis. Vehicle assembly information and supplier production records were instrumental in determining the specific vehicles and production dates involved in this current recall. BMW has stated that it has not received any reports of accidents or injuries related to this specific issue.

BMW has decided to replace the engine starter with a unit featuring a different design. Owners of affected vehicles will be notified by mail and instructed to bring their cars to an authorized BMW dealer for a free remedy. The date for dealer notification is September 25, 2025, with owner notifications scheduled to begin and conclude on November 17, 2025. Owners will be able to check if their vehicle identification number (VIN) is subject to this recall starting November 17, 2025. BMW also has a reimbursement plan in place for owners who may have already paid for this specific repair prior to the official recall notification, in accordance with federal regulations.

Article by Mel Anara, based upon information from BMW of North America, LLC and NHTSA.

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