BMW of North America has announced a recall of 196,355 vehicles across the US, prompted by a defect in the engine starter.
The recall affects a range of models, including the 2019-2022 BMW Z4, 2019-2021 BMW 330i, 2022 BMW 230i, 2020-2022 BMW 530i, X4, X3, Toyota Supra, and 2021-2022 BMW 430i and 430i Convertible.
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According to the US National Highway Traffic Safety Administration (NHTSA) recall report, the defect is estimated to be present in 0.1% of the vehicles.
The safety concern stems from the potential for water to come into contact with the starter’s electrical relay, which, over time, could lead to corrosion that might affect the electrical connection within the relay, compromising the engine’s ability to start.
In more severe scenarios, the corrosion could cause a short-circuit, leading to overheating of the starter and possibly a fire while the vehicle is in operation or when parked with the ignition off, the NHTSA said.
The auto agency said that an engineering investigation was launched in July 2024, following continuous monitoring and field cases that reported thermal events.
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By GlobalDataIt included incidents involving a 2021 BMW 5 Series and a 2020 BMW 3 Series.
The investigation revealed that the positive battery cable connection to the engine starter was either damaged or improperly connected in these vehicles.
Subsequent analyses between September and November suggested that the damage to the vehicles likely occurred before the thermal events, potentially due to an improper repair or an accident.
The hypothesis of water ingress to the starter was considered, and tests were conducted, but these did not immediately lead to overheating.
A “problem-solving team” was established on 16 January 2025 to intensify the focus on this issue.
Further reviews and on-site investigations were carried out, including a comprehensive review of older field incidents and a parts collection campaign to analyse starters with no reported complaints.
Finally, on 16 September 2025, BMW opted to initiate a voluntary safety recall.
There have been no reports of accidents or injuries connected to this defect, according to BMW.
As a remedy, the engine starter will be replaced with a redesigned version. The agency noted that the vehicle owners will be informed by mail and directed to bring their vehicles to a company dealer for the free repair.
The NHTSA has advised owners “to park their vehicles outside and away from structures until the recall remedy is complete.”
Owner notifications are scheduled to begin on 14 November 2025.
The recall follows one last year by BMW, which involved 291,112 vehicles due to interior cargo rails that could detach during a rear crash, posing an increased risk of injury.
