BMW Recalls Nearly 60,000 Plug-In Hybrid and Electric Vehicles Over Fire Risk

BMW of North America, LLC has announced a voluntary safety recall affecting a significant number of its plug-in hybrid and electric vehicles due to a potential fire hazard. The recall, initiated as a precautionary measure, involves vehicles where the electrical wiring harness for the air conditioning system may be vulnerable to damage during routine cabin air filter replacement. This damage could lead to a short circuit and, in extreme cases, a thermal event or fire.

The recall encompasses a total of 58,713 vehicles across several models, including the 2025 BMW M5 Sportswagon, 2025-2026 BMW M5, 2024-2025 BMW 750e xDrive, 2025-2026 BMW 550e xDrive, 2023-2025 BMW i7 models (eDrive50, xDrive60, M 60 xDrive), 2023-2025 BMW 7 Series models (740i, 740i xDrive, 760i xDrive), 2024-2026 BMW i5 models (eDrive40, xDrive40, M 60 xDrive), and 2024-2026 BMW 5 Series models (530i, 530i xDrive, 540i xDrive). The production dates for the affected vehicles range from as early as June 18, 2024, for some M5 models to July 4, 2022, for some i7 and 7 Series models, extending up to April 9, 2025, for various models.

The issue stems from the routing of the air conditioning system’s electrical wiring harness, which is situated in proximity to a section of the cabin air filter housing cover. During the replacement of the cabin air filter, a screw used to secure the housing cover could inadvertently damage this wiring harness. While the estimated percentage of vehicles with this specific defect is reported as 0.1%, BMW is taking a comprehensive approach to address the potential risk across the identified vehicle population.

BMW of North America initiated an engineering investigation in March 2025 following reports of thermal events involving several 2023 and 2024 model year 7 Series vehicles. Initial assessments considered the possibility of wiring harness damage during cabin air filter maintenance. Subsequent reviews of vehicle diagnostics and physical inspections of vehicles that had their cabin air filters replaced did not yield conclusive results. However, continued monitoring of field incidents, including two instances where vehicles that had undergone the service action (involving the installation of a retaining strap and bracket) still experienced thermal activity after filter replacement at independent repair facilities, prompted further investigation. This led to the decision to conduct a voluntary safety recall.

As a precautionary measure, BMW advises owners of the affected vehicles to park them outside and away from structures until the necessary repairs can be performed. This advisory is a critical step to mitigate any potential fire risk. BMW has stated that it has not received any reports of accidents or injuries related to this issue.

The remedy for the recall will involve an inspection of the air conditioning system’s electrical wiring harness. If damage is found, the wiring harness will be replaced. Additionally, a retaining strap and bracket will be installed to secure the wiring harness and move it away from the cabin air filter housing cover screw connection. This repair will be performed free of charge by authorized BMW dealerships. Owners will be notified by first-class mail and instructed on how to schedule their vehicle for the remedy. The date when vehicle identification numbers (VINs) can be checked for eligibility is planned for April 13, 2026.

Owners who have previously paid for repairs related to this issue prior to the official recall notification may be eligible for reimbursement in accordance with BMW Group’s reimbursement plan. The dealer notification for this recall is scheduled for February 19, 2026, with owner notifications to begin on April 13, 2026.

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

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