BMW of North America (BMW) is recalling 145,102 model-year 2020 340I, X6, 2020-2025 840I, 2020-2022 740LI, 2019-2020 X7, and X5 vehicles. After repeated attempts, the DENSO Europe supplied starter motor may overheat from an electrical overload. (This is a recall of a previous recall – AutoCrat. Read BMW Recalls More than 100,000 SUVs, Cars for Software Glitch)
“This safety recall involves the engine starter. In certain cases, the engine starter may not start the vehicle properly. These improper starting attempts could result in local overheating of the engine starter,” BMW said in the mandatory safety defect filing made public by the National Highway Traffic Safety Administration this morning.
“If the starter overheats, locally, during these starting situations, the engine acoustic protection material can be ignited if contaminated. In rare cases, this could lead to a thermal event [recall obfuscation\-speak for fire – AutoCrat] while driving or shortly after parking, if the vehicle had a starting event shortly before being parked. If this occurs, occupants may see or smell smoke while driving or when leaving their vehicle,” BMW said.
Chronology
- In March 2025, three field incidents involving BMW X5 models that had experienced thermal damage became known. Parts were requested for evaluation and each vehicle history was reviewed. Analysis indicated that the incident for each vehicle had occurred after having had the 24V-576 remedy performed.
- In April, a problem-solving team was established to further analyze the cases. A test program was established, and a comprehensive review of prior field incidents was initiated. One additional field incident occurred.
- In May, bench testing of engines and fault tree analyses were initiated. The 24V-576 remedy was reviewed, and tests were conducted on engines with and without the remedy. Analysis of various engine and engine-adjacent parts were conducted. CAD analyses were performed involving various vehicle geometries to further understand any relationship between the starter and other parts in the starter surrounding area, such as the oil level sensor and under shield insulation. During this time, three additional field incidents became known.
- In June, root cause analysis continued.
- In August, analysis continued into thermal events after completion of recall 24V-576. The software remedy effectiveness continued to be analyzed, along with additional root cause analysis with supplier support. Vehicle assembly information and supplier production records were reviewed to determine the number and production dates of potentially affected vehicles.
- On 16 September 2025, BMW decided to conduct a voluntary safety recall. BMW has not received any reports, nor is BMW otherwise aware, of any accidents or injuries related to this issue. The engine starter will be replaced with one involving a different design.
Dealers will replace the engine starter, free of charge as required by law. This recall includes vehicles previously repaired under NHTSA recall 24V576 and those owners will need to have their vehicle repaired again. The engine starter will be replaced with one involving a different design. Owner notification letters are not expected to be mailed until 17 November 2025. Owners may contact BMW customer service at 1-800-525-7417. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning 17 November 2025, if – big if – the Republican government shutdown is resolved.
About Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn.
He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe.
Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap.
AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks.
Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.
Fires – BMW Recall for Starter Motor Overheating
BMW of North America (BMW) is recalling 145,102 model-year 2020 340I, X6, 2020-2025 840I, 2020-2022 740LI, 2019-2020 X7, and X5 vehicles. After repeated attempts, the DENSO Europe supplied starter motor may overheat from an electrical overload. (This is a recall of a previous recall – AutoCrat. Read BMW Recalls More than 100,000 SUVs, Cars for Software Glitch)
“This safety recall involves the engine starter. In certain cases, the engine starter may not start the vehicle properly. These improper starting attempts could result in local overheating of the engine starter,” BMW said in the mandatory safety defect filing made public by the National Highway Traffic Safety Administration this morning.
“If the starter overheats, locally, during these starting situations, the engine acoustic protection material can be ignited if contaminated. In rare cases, this could lead to a thermal event [recall obfuscation\-speak for fire – AutoCrat] while driving or shortly after parking, if the vehicle had a starting event shortly before being parked. If this occurs, occupants may see or smell smoke while driving or when leaving their vehicle,” BMW said.
Chronology
Dealers will replace the engine starter, free of charge as required by law. This recall includes vehicles previously repaired under NHTSA recall 24V576 and those owners will need to have their vehicle repaired again. The engine starter will be replaced with one involving a different design. Owner notification letters are not expected to be mailed until 17 November 2025. Owners may contact BMW customer service at 1-800-525-7417. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning 17 November 2025, if – big if – the Republican government shutdown is resolved.
About Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn. He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe. Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap. AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks. Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.