BMW Pulls 29,000 Plug-In Hybrids From US Roads Over Engine Fire Risk

BMW is recalling more than 29,000 plug-in hybrid sedans across the United States after discovering a manufacturing defect that could cause engine fires. The recall targets specific 2020 through 2024 model year vehicles, including the 330e, 530e, 740e, and X5 xDrive45e. The problem traces back to the engine’s electrical starter generator, which can overheat and ignite under certain conditions.

The German automaker says the issue stems from debris left inside the starter generator during production. When the debris comes loose and contacts internal components, it can cause a short circuit. BMW has confirmed at least one fire incident linked to the defect, though no injuries have been reported.

Owners will be notified starting in November and are advised to park their vehicles away from structures until repairs are completed.

Dealers will replace the starter generator free of charge. BMW is also urging drivers to avoid charging the hybrid battery or using the engine-start feature until the fix is applied. For now, customers can check their vehicle identification numbers on BMW’s recall website or contact their local dealership for more information.

The recall underscores the growing pains automakers face as they push deeper into electrified powertrains.