BMW of North America is recalling nearly 30,000 plug-in hybrid sedans due to a defect in the engine starter that could pose a fire risk. The recall affects 29,119 vehicles across several models from 2016 to 2020, including the 2018‑2020 BMW 530e xDrive, 2018‑2020 BMW 530e iPerformance, 2017‑2019 BMW 740Le xDrive and 2016‑2018 BMW 330e iPerformance. The issue stems from water exposure to the engine starter’s electrical relay, which can lead to corrosion over time and potentially disrupt electrical connections needed to start the engine. In the worst case, a short circuit or overheating could occur in the starter, even when the ignition is off, according to the National Highway Traffic Safety Administration (NHTSA). The recall notes that a short circuit in the starter relay may increase the risk of a fire, per the NHTSA report. No injuries or accidents have been reported to date in connection with the recall.
The recall process follows two field incidents: one in November involving a 2019 BMW 5 Series and another in May involving a 2017 BMW 3 Series. BMW has advised owners to park their vehicles outside and away from structures until the repair is completed. BMW will notify affected owners by mail starting August 28 and will replace the starter at no cost at authorized dealers. Owners who previously paid for a starter replacement may be reimbursed.
The recall underscores ongoing attention to safety-related components in plug-in hybrids as manufacturers balance performance with reliability and risk controls. The company is also highlighting its commitment to U.S. manufacturing with a broader investment program as it implements the recall repairs. BMW North America CEO Sebastian Mackensen has emphasized the company’s long‑term plan to expand production capacity in the United States, including a significant investment tied to its South Carolina operations, which supports a broader push to localize high‑tech vehicle manufacturing as part of its growth strategy.
