BMW Recalls 29,119 Plug-In Hybrids for Fire Risk

BMW is initiating a safety recall for 29,119 plug-in hybrid sedans in the United States due to a critical fire hazard stemming from a faulty engine starter relay. The National Highway Traffic Safety Administration (NHTSA) identified the defect, which affects specific luxury models produced between 2016 and 2020. The affected vehicles include the 2016 to 2018 330e iPerformance, the 2017 to 2019 740Le xDrive iPerformance, and the 2018 to 2020 530e iPerformance variants. Owners of these vehicles are strongly advised by BMW to park their cars outdoors and away from any structures until the necessary repairs can be completed by dealership technicians.

The underlying cause of the fire risk is a design flaw in the starter relay that allows water to intrude into the housing. This moisture ingress can lead to rapid corrosion of the component. The degradation of the starter relay can result in difficulties starting the engine and, in more severe cases, can trigger an electrical short circuit. BMW has stated that these compromised relays have the potential to overheat and ignite, posing a fire risk whether the vehicle is in operation or parked with the ignition off.

This recall for plug-in hybrid models follows a broader safety campaign initiated in 2025, which involved nearly 200,000 conventionally powered BMW models and the Toyota Supra. Following that earlier recall, investigators examined approximately 150 starter components from hybrid vehicles. Although no injuries or accidents have been reported in connection with these specific hybrid starter failures, the findings prompted BMW to proactively address the potential hazard. The automaker will be providing owners with a replacement starter relay featuring an upgraded design to mitigate the risk of water intrusion and subsequent fire.