BMW has announced a recall of 29,119 plug-in hybrid vehicles across the United States because of a potential fire hazard. Interestingly, the issue does not originate from the high-voltage battery. As per the recall notice issued by the National Highway Traffic Safety Administration (NHTSA), the problem has been traced to a faulty engine starter relay.

According to NHTSA documentation, moisture can infiltrate the engine starter relay, which may lead to corrosion and cause a short circuit, resulting in the starter overheating. In severe situations, this overheating could trigger a fire, even when the vehicle is stationary with the engine turned off. Consequently, BMW has advised owners of the affected models to park their vehicles outdoors until the necessary repairs are completed.

The recall applies to specific models including the 2016–2018 BMW 330e iPerformance, the 2018–2020 BMW 530e iPerformance and 530e xDrive, as well as the 2017–2019 BMW 740Le xDrive plug-in hybrid sedans. The company has stated that, to date, there have been no reported accidents or injuries linked to this defect.

This situation may sound familiar to some, as BMW previously recalled nearly 200,000 vehicles in September of last year for the same issue. At that time, engineers had reviewed plug-in hybrid variants, but those models were not included in the earlier recall campaign. However, the PHEVs continued to be monitored and tested, and following further assessment — including a field incident in February 2026 involving a 2017 3-Series — BMW opted to issue a new recall specifically for its plug-in hybrid range.

To address the defect, BMW dealerships will replace the engine starter assembly at no cost to the owners. Affected customers will be notified by mail once replacement parts are available and can then contact their local BMW service centre to schedule repairs. The company expects to begin notifying owners from August 28, 2026.