Starter Motor May Overheat and Cause a Fire

Affected vehicles (8)

Component / system

Defect

BMW of North America, LLC (BMW) is recalling certain 2021-2023 Toyota Supra, 2022-2023 2 Series Coupe, 2021-2024 5 Series (xDrive), 2021-2022 Z4, 2022-2024 4 Series (Gran Coupe), 2021-2024 4 Series (Convertible and xDrive Convertible), 2021-2023 4 Series (Coupe), 2021-2024 3 Series, 2021-2023 X4, 2021-2024 X3 vehicles. Please see the recall report for a complete list of all models. The engine starter may overheat and catch fire due to wear on an internal component.

Risk / consequence

Fire increases the risk of injury.

Remedy

Dealers will replace the engine starter, free of charge. A letter informing owners of the safety risk was mailed on March 27, 2026. Owners will receive another letter once the remedy is available. Owners may contact BMW customer service at 1-800-525-7417 or Toyota's customer service at 1-800-331-4331. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 24, 2026.

Chronology of events

1. September 2025

   In September 2025, an engineering investigation focused upon field incidents involving several vehicles that had experienced engine starter issues with indications of thermal damage, but in which a root cause had not yet been determined. These incidents included three (3) cases between October 2024 and

2. March 2025

   March 2025, involving a Model Year 2023 BMW 4 Series, and two Model Year 2022 BMW 3 Series.

3. In October, endurance (bench) tests were planned simulating large numbers of starting attempts, in order to examine possible effects upon internal components after being subject to such conditions. A tear down analysis, involving field return parts of starters, was conducted. Electronic information and data from vehicle assembly records, and also dealer service visits, was reviewed in an attempt to identify possible issues such as deviations in tightening torque, occurrences of housing cracks, and loose cable connections, that could affect starter functionality. Computer tomography of starters was also conducted in an attempt to help identify those possible issues.

4. On November 27th, the first field return part, with indications of a build-up of metallic material in the electrical relay chamber, was found.

5. On December 4th, the first bench test result with indications of a build-up of metallic material in the electrical relay chamber, as a result of increased abrasion, was available.

6. In December, further reviews were conducted of bench test results in which parameters such as temperature, humidity, and voltage levels had been varied. Statistical analyses were conducted involving field return parts with an attempt to determine if similar parameters could affect functionality.

7. Jan 7, 2026

   In January 7, 2026, a field incident involving a Model Year 2021 BMW 3 Series was reviewed (incident date: November 20, 2025) with indications of thermal damage to the engine starter.

8. In January, interim results of the investigation of the field return parts were available which indicated that some of the starters had a buildup of metallic material due to abrasion in the electrical relay chamber. Further discussions with the supplier occurred including a review of the findings from BMW. Further reviews of all test results were conducted. Vehicle assembly and service information and supplier production records were reviewed to determine the number and production dates of potentially affected vehicles,

Notification schedule

Dealer notification

Jan 30, 2026 - Jan 30, 2026 No Dealers

Owner notification

Mar 24, 2026 - Mar 24, 2026 Phased Recall