BMW Group has recalled 105,588 vehicles to address a problem where a faulty starter motor can overheat during repeated attempts to start the engine, according to the National Highway Traffic Safety Administration.
The recall covers certain X5, X6 and X7 SUVs, 3 Series sedans, 7 Series sedans and 8 Series coupe and convertible models that were produced between September 2018 and May 2020. The majority of the recalled vehicles (68,105) are 2019-2020 X5 models.
According to NHTSA documents, the areas around the starter motor are covered with an acoustic protection material designed to reduce noise in the cabin. However, this material can absorb oil if engine oil leaks are present, which in rare cases can increase the risk of fire if the starter motor becomes overheated. BMW estimates that the defect is present in 1% of the recalled vehicles.
The automaker was first made aware of the problem in March 2023 after receiving several field reports of engine no-start conditions due to defective starters, as well as visible signs of thermal damage within the engine compartment of some vehicles. The automaker then launched an engineering investigation to look into the issue.
The initial findings by BMW found only a few incidents of thermal damage when compared to the number of engine no-start conditions that were reported. At that time, BMW said it was still unclear if there was a direct relationship between the engine starter problem and the signs of thermal damage in the engine compartment, according to NHTSA documents.
However, additional analysis by BMW in November 2023 included a review of starter failures due to mechanical issues, which in turn led to a higher number of repeated engine start attempts by drivers. The automaker concluded that this was the cause of starter overheating.
BMW was also notified of several additional field incidents in June, prompting the company to voluntarily issue the recall on July 25. It reviewed supplier records to determine the production dates and exact number of potentially affected vehicles.
BMW is not aware of any accidents or injuries from an overheated starter motor, but has received approximately 12 customer complaints and associated field incidents related to the issue.
Dealers will update the software on the recalled models free of charge to help prevent electrical overload of the starter. Owner notification letters are expected to be mailed Sept. 23.
