A significant safety alert has been issued for numerous BMW vehicles, impacting over 145,000 models across the United States. This urgent recall, publicized by the National Highway Traffic Safety Administration (NHTSA) and officially announced by BMW on Thursday, Sept. 25, addresses a critical starter motor defect that carries the potential for engine compartment fires. For any vehicle owner, the prospect of an engine fire is profoundly concerning, necessitating a thorough understanding of the issue and immediate action if their vehicle falls within the affected population.
In line with the objective and factual principles of Consumer Reports, our in-depth analysis aims to provide comprehensive, research-backed information to empower you, the consumer. We will meticulously delve into the precise nature of this defect, outlining how a seemingly minor electrical issue can escalate into a serious hazard. Understanding the mechanics behind the problem—where “the vehicle’s engine starter may not start the vehicle properly, causing the engine to overheat,” as per BMW, and how an “overheated starter motor can ignite nearby combustible material in the engine compartment”—is key to appreciating the gravity of this recall.
This article will detail the specific BMW models implicated in this safety campaign, offering clarity on which vehicles are at risk and the reasons behind their inclusion. We emphasize that while BMW has stated it “has not received any reports of accidents or injuries related to the issue,” the inherent risk underscores the importance of prompt attention to this recall. Knowledge is your best defense against potential product issues, and we are here to provide the detailed insights and practical guidance you need to navigate this situation effectively, ensuring your vehicle’s safety.
1. **2019-2020 BMW X5: Unpacking the Risk for a Leading SUV**At the forefront of BMW’s latest recall initiative are the 2019 and 2020 BMW X5 models, accounting for a substantial 82,153 vehicles. This large luxury SUV, a popular choice among consumers for its blend of performance and sophisticated engineering, is unfortunately subject to a defect in its starter motor that could lead to serious safety implications. The sheer volume of X5s impacted highlights the widespread nature of this particular issue across BMW’s product line that utilizes the brand’s inline-six engines, which are central to the fault.
The core of the safety concern in these X5 vehicles stems from a malfunction in the starter motor’s intended operation. According to BMW’s official statements to the NHTSA, the problem is initiated when “the engine starter may not start the vehicle properly.” This failure to crank the engine as expected leads drivers to make “repeated attempts” to restart the vehicle, which, in turn, “may overheat from an electrical overload” within the starter motor itself, causing it to generate excessive heat.
This generated heat is not merely an operational anomaly; it poses a direct and tangible fire risk. The recall announcement clearly states that “if the starter overheats, part of the engine’s protection material could catch on fire.” These protective materials, vital for various functions within the engine compartment, become highly combustible under such extreme thermal conditions, significantly increasing the likelihood of a fire developing within the vehicle’s engine bay.
Owners of affected 2019-2020 BMW X5 models are strongly advised to be particularly vigilant for any signs that might indicate this developing problem. BMW has explicitly warned that “occupants may see or smell smoke while driving or when leaving their vehicle.” This symptom is a critical warning signal that the starter motor is experiencing an electrical overload and potentially reaching dangerous temperatures, necessitating immediate investigation and professional repair.
It is important for X5 owners to understand that while BMW confirmed “there have been no crashes, injuries, or fatalities linked to this defect” at the time of the notice, the potential for such incidents cannot be ignored. This situation underscores the Consumer Reports philosophy of proactive safety measures. Therefore, prompt attention to the recall notice and arranging for the required service at a BMW dealership is not just recommended, but essential for maintaining vehicle safety and preventing future hazardous situations.
Car Model Information: 2019 BMW X5 xDrive40i
Name: BMW X5
Manufacturer: BMW
Class: Mid-size,luxury vehicle,crossover SUV
BodyStyle: SUV
Production: 1999–present
Layout: Front-engine, four-wheel-drive layout,Front-engine, rear-wheel-drive layout
Categories: 2000s cars, 2010s cars, All-wheel-drive vehicles, All articles with unsourced statements, Articles with short description
Summary: The BMW X5 is a mid-size luxury crossover SUV produced by BMW. The X5 made its debut in 1999 as the E53 model. It was BMW’s first SUV. At launch, it featured all-wheel drive and was available with either a manual or automatic gearbox. The second generation was launched in 2006, and was known internally as the E70. The E70 featured the torque-split capable xDrive all-wheel drive system mated to an automatic gearbox. In 2009, the X5 M performance variant was released as a 2010 model.
BMW marketed the X5 officially as a “Sports Activity Vehicle” (SAV), rather than an SUV, to indicate its on-road handling capability despite its large dimensions. The X5 signaled a shift away from the utilisation of body-on-frame construction, in favour of more modern monocoque chassis construction. Although the Mercedes-Benz M-Class was introduced more than a year prior to the X5, the X5 was the first to utilise a monocoque chassis. The M-Class used body-on-frame construction until its second generation.
The X5 is primarily manufactured in North America, at BMW Group Plant Spartanburg. Assembly operations also took place in Russia by Avtotor until February 2022, along with operations in India, Indonesia, Malaysia, and Thailand. The X5 is also modified for armoured security versions, at the BMW de México Toluca plant.
The automaker’s SAV series, which was started by the X5, has expanded with derivations of other number-series BMWs. This began in 2003 with the X3, and continued in 2008 with the X6 (which shares its platform with the X5).
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Brand: BMW Model: X5
Price: $26,888 Mileage: 93,394 mi.
2. **2019-2020 BMW X7: The Flagship SUV’s Critical Safety Review**Following closely behind the X5 in terms of units affected, the 2019 and 2020 BMW X7 models are also part of this critical recall, encompassing 24,979 vehicles. As BMW’s flagship luxury SUV, the X7 shares many mechanical components with the X5, including the inline-six engines that are at the core of this starter motor defect. This commonality explains its significant inclusion in the recall, underscoring that the issue transcends specific model lines and affects a broader range of the manufacturer’s premium offerings.
The nature of the defect for the X7 remains consistent with that described for the X5: a starter motor prone to overheating due to electrical overload if the engine fails to crank properly after multiple start attempts. The NHTSA notice explicitly warns that “an overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire.” This direct statement from the auto safety regulator highlights the serious consequences of ignoring the issue.
For X7 owners, the recall serves as a vital reminder to prioritize vehicle safety, even in a luxury vehicle designed for comfort and performance. Given the significant investment in an SUV of this caliber, ensuring its operational integrity and safety features are paramount. Adhering to the recall instructions and promptly scheduling the necessary repair is not merely a matter of compliance; it is a proactive step to safeguard their vehicle and, more importantly, themselves and their passengers from potential fire hazards.
BMW has proactively informed owners that the remedy for this issue involves the replacement of the existing engine starter for free with a starter that has a different design. This permanent fix, unlike a previous software update for a related recall, is a hardware replacement intended to eliminate the risk of overheating and subsequent fire. The company is “currently accelerating shipment of replacement parts” to its authorized service centers, with “deliveries beginning at the end of this month,” according to a BMW spokesperson, indicating the urgency of the corrective action.
The inclusion of the X7 in this recall highlights BMW’s diligent approach to addressing potential safety flaws across its lineup, ensuring that even its highest-end models meet stringent safety standards. Despite the absence of reported accidents or injuries linked to this particular recall at the time of the announcement, the manufacturer’s swift action to notify owners and implement a comprehensive corrective measure demonstrates a commitment to consumer safety and product reliability. Owners are strongly encouraged to utilize the resources provided by BMW customer service at 1-800-525-7417 or the NHTSA Vehicle Safety Hotline at 1-888-327-4236 to verify their vehicle’s status and schedule the essential repair.
Car Model Information: 2024 BMW X7 xDrive40i
Name: BMW X7
Manufacturer: BMW
ModelCode: G07
Production: December 2018 – present
ModelYears: 2019–present
Assembly: ubl
Class: Full-size,luxury car,crossover SUV
BodyStyle: SUV
Layout: Front-engine, four-wheel-drive layout
Platform: BMW CLAR platform
Related: unbulleted list
Engine: unbulleted list
Transmission: ZF 8HP transmission,automatic transmission#Hydraulic automatic transmissions
Wheelbase: 3105 mm
Abbr: on
Length: convert
Width: 2000 mm
Height: convert
Weight: convert
Designer: Julien Sarreméjean,Anders Thøgersen (facelift)
Drivetrain: MHEV
Categories: 2020s cars, All-wheel-drive vehicles, All articles with dead external links, Articles with dead external links from July 2025, Articles with permanently dead external links
Summary: The BMW X7 is a full-size luxury crossover sport utility vehicle manufactured by BMW. It is BMW’s largest and second most expensive SUV in its line-up, and is considered a flagship SUV for the brand.
The X7 was first announced by BMW in March 2014. It was officially unveiled on October 17, 2018, with pre-orders being taken online. The X7 has been available at dealers since March 2019.
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Brand: BMW Model: X7
Price: $63,792 Mileage: 20,728 mi.
3. **2020-2025 BMW 840I: Scrutiny for the Performance Gran Tourer**The recall extends its critical reach beyond the popular SUV segment to include certain 2020 through 2025 BMW 840I models, impacting a total of 12,456 vehicles. This notable range of model years indicates that the specific starter motor design implicated in this recall may have been utilized in these high-performance grand tourers for an extended production period. The 840I, renowned for its sophisticated engineering, luxurious comfort, and dynamic performance, makes its inclusion in a widespread safety recall particularly significant for its discerning owners.
The underlying mechanical fault in the 840I vehicles precisely mirrors the issue identified in the X5 and X7 models. The problem arises when “the starter motor may not start the vehicle properly” during ignition. Should the starter motor fail to successfully crank the engine on the first attempt, “after repeated attempts, the starter motor may overheat from an electrical overload,” as detailed in the NHTSA recall notice. This electrical stress directly leads to the starter motor reaching dangerously high temperatures.
This overheating mechanism is a critical safety concern, as it directly creates a hazardous condition: “An overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire.” For owners of the 2020-2025 BMW 840I, vigilance and prompt response to the official recall notification are therefore not just recommended, but absolutely essential. While the 840I is designed for a premium driving experience, the fundamental safety of the vehicle must always take precedence over convenience.
Any indication of the described symptoms, such as the presence of smoke, a burning smell, or an unusual odor originating from the engine compartment, should prompt immediate caution and a professional inspection. BMW’s guidelines emphasize that “if this occurs, occupants may see or smell smoke while driving or when leaving their vehicle.” This is a clear signal that the vehicle’s integrity is compromised and that urgent attention is required by a certified BMW service center.
BMW’s remedy for the 840I, consistent with the other affected models, involves a complimentary replacement of the faulty starter motor with a newly designed unit. This redesigned starter is specifically engineered to mitigate the risk of electrical overload and subsequent overheating, thereby eliminating the fire hazard permanently. This proactive and comprehensive measure ensures that affected 840I owners can continue to enjoy their sophisticated vehicles with renewed confidence in their safety and long-term reliability. Owners are strongly advised to check their vehicle identification numbers (VINs) on NHTSA.gov starting November 17 to confirm their vehicle’s inclusion and to schedule the necessary repair without delay.
As we continue our in-depth examination of BMW’s critical starter motor recall, it’s essential to expand our understanding to the full scope of affected vehicles. Beyond the X5, X7, and 840I, several other models are implicated in this safety campaign, each presenting the same inherent risk of engine compartment fire due to an overheated starter motor. Our objective, as always, is to provide clear, actionable information to help consumers navigate this significant safety concern with confidence.
4. **2020-2022 BMW 740Li: Executive Sedan Under Scrutiny**The recall extends its reach into BMW’s executive sedan lineup, encompassing 11,893 units of the 2020 to 2022 BMW 740Li. This model, a pinnacle of luxury and advanced engineering, is unfortunately not immune to the starter motor defect that has prompted this widespread safety notice. The inclusion of the 740Li underscores that this issue is not confined to a single class of BMW vehicles but affects various segments employing the specific inline-six engine and starter assembly at fault.
The root cause for the 740Li models mirrors that of the previously discussed vehicles: a starter motor that may fail to properly initiate engine start-up. In scenarios where drivers make “repeated attempts” to crank the engine, the starter motor is subjected to an “electrical overload” that leads to dangerous overheating. This accumulation of excessive heat within the component is the critical precursor to the potential ignition of nearby materials.
The hazard associated with this overheating is explicitly detailed by both BMW and the NHTSA. An “overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire.” For owners of the 740Li, a vehicle often used for long-distance travel and daily commuting, awareness of this risk and the symptoms associated with it is paramount. Any detection of smoke or unusual odors originating from the engine bay should be treated with immediate concern.
BMW has committed to addressing this defect with a permanent solution. The remedy for affected 740Li owners involves a complimentary replacement of the existing faulty starter motor with a redesigned unit. This new starter is engineered to eliminate the electrical overload and overheating risk, thereby restoring the vehicle’s safety integrity. Owners are urged to ensure this crucial repair is carried out promptly once notified.
5. **2020 BMW 340I: Performance Sedan Faces Safety Check**Among the vehicles recalled is the 2020 BMW 340I, with 10,867 units identified as having the critical starter motor defect. This model, known for its dynamic performance and sporty driving characteristics, highlights that even vehicles designed for exhilarating experiences must also meet stringent safety standards. The presence of this flaw in a popular performance sedan demonstrates the broad impact of the underlying component issue.
The problem in the 2020 BMW 340I is precisely the same as that affecting the other recalled models: the engine starter may not function correctly during ignition. If a driver makes “repeated attempts” to start the vehicle following an initial failure, the starter motor can become “overheated from an electrical overload,” as stated in the recall documents. This scenario creates an environment where temperatures inside the engine compartment can escalate rapidly.
The direct consequence of this electrical overheating is a heightened fire risk. The NHTSA notice clearly articulates that “an overheated starter motor can ignite nearby combustible material in the engine compartment, increasing the risk of a fire.” This is a serious concern that demands immediate attention from owners. Symptoms such as seeing or smelling smoke while driving or after parking are direct indicators of this potential hazard and should prompt immediate inspection by a certified service technician.
BMW’s comprehensive resolution plan extends to the 340I, ensuring that all affected vehicles receive the necessary corrective action. Owners will have their existing starter motor replaced free of charge with a newly designed component that mitigates the risk of electrical overload and subsequent overheating. This proactive measure aims to definitively resolve the safety concern and allow 340I owners to enjoy their vehicles with renewed peace of mind regarding their operational safety.
Car Model Information: 2018 BMW 340 Gran Turismo xDrive
Name: BMW B58
Caption: B58B30O1 in a G22 M440i
Manufacturer: BMW
Production: 2015–present
Predecessor: BMW N55
Configuration: Straight-six engine
Displacement: cvt
Bore: cvt
Stroke: cvt
Block: Closed-deck aluminium
Head: Aluminium
Valvetrain: DOHC,Multi-valve#Four valves
Timing: Chain
Compression: 11.0:1
Turbocharger: turbocharger#Twin-scroll
Fuelsystem: Gasoline direct injection
Management: Robert Bosch GmbH
Fueltype: Petrol engine
Oilsystem: Wet sump
Coolingsystem: Radiator (engine cooling)
Power: cvt
Torque: cvt
Redline: 7,000 rpm
Weight: cvt
Categories: Articles with short description, BMW engines, Gasoline engines by model, Products introduced in 2015, Short description is different from Wikidata
Summary: The BMW B58 is a turbocharged straight-six engine, which began production in 2015. The B58 replaced the N55 and was launched in the F30 340i.
The B58 is part of BMW’s modular engine family, each engine using a displacement of 500 cc (30.5 cu in) per cylinder, following the B38 and B48 engine.
The B58 engine was named to Ward’s World’s 10 Best Engines four times, in 2016 (installed in the 340i), 2017 (M240i), 2019 (X5) and 2020 (M340i).
The S58 engine, which was released in early 2019, is the high-performance version of the B58. It was named to Ward’s World’s 10 Best Engines in 2023 (installed in the M2).
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Brand: BMW Model: 340I
Price: $19,993 Mileage: 88,304 mi.
6. **2020 BMW X6: Sport Activity Coupe Under Recall**Completing the list of models impacted by this significant recall is the 2020 BMW X6, with 2,754 units requiring attention. Although this represents the smallest number of vehicles in this particular recall campaign, the safety implications are no less critical for owners of this distinctive Sport Activity Coupe. The inclusion of the X6 reinforces the idea that the starter motor defect affects a cross-section of BMW’s inline-six engine-equipped lineup.
The fundamental issue for the 2020 BMW X6 remains consistent: a starter motor prone to overheating if it fails to properly engage the engine and drivers make subsequent restart attempts. This scenario, driven by an “electrical overload” within the starter, generates excessive heat that can reach critical levels. The potential for this heat to ignite surrounding engine compartment materials poses a serious and undeniable fire risk.
For owners of the 2020 BMW X6, the recall serves as a vital reminder to prioritize vehicle safety. Even with a lower number of units affected, the potential for “occupants may see or smell smoke while driving or when leaving their vehicle” is a clear warning sign. Responding promptly to the recall notification and scheduling the necessary service is an essential step to eliminate this hazard and ensure the continued safe operation of their vehicle.
**A Crucial Distinction: This Recall Versus Last Year’s**
It is vital for BMW owners to understand that this latest recall (NHTSA recall number 25V644) is distinct from a previous starter-related recall issued in August 2024 (NHTSA recall number 24V576), although some vehicles may be impacted by both. The current campaign specifically addresses a risk of “electrical overload” if the starter motor fails to properly crank the engine after multiple attempts, leading to overheating. In contrast, the August 2024 recall stemmed from starters that “were prone to water intrusion, potentially leading to short circuits and overheating.”
The implications for owners were also different. The prior recall, due to a “significantly higher fire risk,” even “included guidance for owners to park their vehicles outside as a precaution.” For this current recall, however, the starters “posing a significantly lower fire risk, with no recommendation for outdoor parking.” Initially, the 2024 campaign attempted a fix with a “software update,” but failures continued to emerge in March 2025, leading to the broader hardware replacement strategy seen in this new recall. This distinction is paramount, as some vehicles previously repaired under the 2024 campaign are once again affected and will require the new, definitive hardware solution.
**The Comprehensive Resolution Plan and Essential Actions for Owners**
BMW is taking definitive steps to resolve this safety concern across all affected models. The core of the resolution plan involves a permanent hardware fix: “dealers will replace the engine starter for free with a starter that has a different design.” This redesigned starter is specifically engineered to prevent the electrical overload and overheating issues that are at the heart of this recall.
For drivers who may have previously paid for out-of-pocket repairs related to this issue, BMW has indicated that reimbursement may be available. To facilitate the timely resolution of this widespread issue, BMW is “currently accelerating shipment of replacement parts” to its authorized service centers, with “deliveries beginning at the end of this month.” This proactive approach underscores the manufacturer’s commitment to swiftly addressing the safety of its vehicles.
Owner notification letters are scheduled to be mailed on November 17. Starting on the same date, vehicle owners will be able to verify if their specific vehicle is included in the recall by checking their Vehicle Identification Numbers (VINs) on the NHTSA.gov website. It is strongly advised that owners take immediate action upon receiving their notification or confirming their vehicle’s status online. Scheduling the free starter replacement at a BMW dealership should be a top priority. For any questions or assistance, owners can contact BMW customer service at 1-800-525-7417 or the NHTSA Vehicle Safety Hotline at 1-888-327-4236. Your proactive engagement is key to ensuring your safety and the continued reliability of your BMW.
Car Model Information: 2023 BMW X6 xDrive40i
Name: BMW X6
Caption: BMW X6 (G06)
Manufacturer: BMW
Production: December 2007 – present
ModelYears: 2008–present
Class: Executive car,crossover SUV
BodyStyle: coupé SUV
Layout: Front-engine, four-wheel-drive
Related: BMW X5
Categories: 2000s cars, 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in British English
Summary: The BMW X6 is a mid-size luxury crossover SUV by German automaker BMW. The BMW X6 is the originator of the sports activity coupé (SAC), referencing its sloping rear roof design. It combines the attributes of an SUV (high ground clearance, all-wheel drive and all-weather ability, large wheels and tires) with the stance of a coupé (styling featuring a sloping roof). It is built in BMW’s North American plant in Greer, South Carolina alongside the BMW X5, whose platform it shares. Prior to the release of the X7, the X6 was considered a flagship SUV for BMW.
The first generation (E71) was released for sale in April 2008 for the 2008 model year, while the second-generation X6 (F16) was launched at the Paris Motor Show in 2014. The third-generation X6 was revealed in July 2019.
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Brand: BMW Model: X6
Price: $63,487 Mileage: 13,679 mi.
This comprehensive safety campaign, affecting over 145,000 vehicles, demonstrates BMW’s commitment to addressing critical product issues. While the prospect of a recall can be concerning, the detailed information and clear path to resolution provided by both BMW and the NHTSA are designed to empower you, the consumer, to take the necessary steps to secure your vehicle’s safety. By understanding the problem, recognizing the symptoms, and promptly acting on the recommended repairs, you can ensure your BMW continues to deliver the driving experience you expect, free from undue safety risks.
