Recall 25V644 covers 145,102 2019-2025 BMW 340I, 740LI, 840I, X5, X6, and X7 vehicles for starter-motor overheating. Repair is free at any franchised BMW dealer.
BMW is recalling 145,102 2019-2025 vehicles, including the 840I, X5, 740LI, 340I, X7, and X6, because repeated starter attempts can overload and overheat the starter motor. That heat can ignite nearby combustible material in the engine compartment and increase fire risk, and BMW dealers will complete the recall repair free of charge.
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What's wrong?
The engine starter on these 2019-2025 BMW 840I, X5, 740LI, 340I, X7, and X6 vehicles is the electric motor that turns the engine so it can start. When the start button is pressed, the starter draws electrical power for a short burst, spins the engine, then shuts off once the engine is running.
On affected vehicles, the starter has a certain production configuration that fails to start the engine properly after repeated attempts. That repeated load can create an electrical overload and local overheating at the starter. If nearby engine acoustic protection material is contaminated, the overheated starter can ignite it and start a thermal event while driving or shortly after parking.
If the problem happens, occupants can see or smell smoke while driving or when leaving the vehicle. A no-start condition after repeated start attempts also fits the failure pattern, because the overload begins when the starter keeps trying to turn the engine.
Who's affected?
Covers six BMW model lines across the 2019-2025 model years, all tied to the engine starter.
| 2023 BMW 840I | electrical system |
|---|---|
| 2024 BMW 840I | electrical system |
| 2025 BMW 840I | electrical system |
| 2019 BMW X5 | electrical system |
| 2021 BMW 740LI | electrical system |
| 2020 BMW 840I | electrical system |
| 2020 BMW 340I | electrical system |
| 2020 BMW X5 | electrical system |
| 2020 BMW 740LI | electrical system |
| 2021 BMW 840I | electrical system |
| 2022 BMW 840I | electrical system |
| 2019 BMW X7 | electrical system |
| 2020 BMW X7 | electrical system |
| 2022 BMW 740LI | electrical system |
| 2020 BMW X6 | electrical system |
| Units affected | 145,102 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific vehicle.
What's the safety risk?
An overheated starter motor can ignite combustible material in the engine compartment, increasing fire risk. If you see or smell smoke while driving or after parking, stop in a safe place, shut the vehicle off, and call a BMW dealer before driving again. Repair is free at any franchised BMW dealer.
What should I do?
- Check your VIN to confirm your 2019-2025 BMW 840I, X5, 740LI, 340I, X7, or X6 is included in this recall.
- Contact a franchised BMW dealer to schedule the free starter replacement that addresses starter overheating and fire risk.
- Tell the dealer if your vehicle was repaired under recall 24V576; this recall requires another repair.
- Bring the recall notice if BMW mailed one, or reference recall number 25V644 when you call.
- Avoid repeated start attempts until the repair is complete because the starter can overheat and ignite nearby material.
What happens at the repair
At the dealer, a BMW technician replaces the engine starter. Parts and labor are covered under the recall. Vehicles already repaired under recall 24V576 still need this repair again, so tell the service desk if your BMW had the earlier recall work completed. If you've already paid out of pocket for an engine starter repair before the recall notice, BMW's standard reimbursement plan covers eligible documented expenses. Bring your repair paperwork and receipts when you schedule or arrive for service.
| Reimbursement | Reimbursement available |
|---|
Timeline
| September 25, 2025 | NHTSA published the recall |
|---|---|
| September 25, 2025 | Dealer notification began |
| September 25, 2025 | Dealer notification ended |
| November 17, 2025 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| February 9, 2026 | Owner notification mailed |
Frequently asked questions
What is recall 25V644?
Recall 25V644 covers 145,102 2019-2025 BMW 840I, X5, 740LI, 340I, X7, and X6 vehicles with a starter motor that can overheat after repeated start attempts. An overheated starter can ignite material in the engine compartment, increasing fire risk. BMW dealers will replace the engine starter for free.
What should I do if my 2019-2025 BMW 840I, X5, 740LI, 340I, X7, or X6 is on this recall?
Check your VIN to confirm your specific vehicle is included in recall 25V644. If it is, contact a franchised BMW dealer to schedule the starter replacement. Reference recall number 25V644 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to repair safety defects at no cost, and BMW dealers will replace the engine starter free of charge. This also applies to vehicles repaired under recall 24V576, since BMW says those vehicles need the new recall repair again.
What is the safety risk?
The risk is an engine-compartment fire. After repeated attempts to start the vehicle, the starter motor can overheat from an electrical overload. If nearby combustible material ignites, fire risk increases. The fix is a free starter replacement at a franchised BMW dealer.
When did BMW notify owners about recall 25V644?
BMW mailed owner notification letters on February 9, 2026. VINs became searchable for this recall on November 17, 2025. If you never received a letter, check your VIN and call BMW customer service at 1-800-525-7417 or a franchised BMW dealer.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V644000 |
|---|---|
| BMW customer service | 1-800-525-7417 |
| NHTSA recall # | 25V644 |
| NHTSA recall # (full) | 25V644000 |
Source documents
-
Download Owner Notice (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Document (PDF) (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 19, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →