BMW 325xi Recalls

The BMW 325xi has 9 recalls spanning the 2000–2012 model years, with the most serious being a driver's side airbag inflator defect on 2006–2012 models where a replacement sport or M-sport steering wheel can contain an inflator that explodes during deployment, sending metal fragments into the cabin and potentially killing or seriously injuring occupants.

The airbag inflator issue runs across nearly the entire production span of this model and takes several forms. On 2006–2012 vehicles, a separate Takata inflator recall also covers the driver's side, with the same consequence of explosive rupture and metal fragmentation. The passenger side airbag on 2000–2005 models carries the same Takata inflator risk, where the propellant can degrade and cause the inflator to burst rather than deploy normally. On 2002–2005 models, the driver's frontal airbag inflator can rupture in a crash and send fragments toward the driver or other occupants. The 2002–2003 model years have an additional passenger-side inflator defect where excessive internal pressure during deployment can cause the same kind of rupture. These inflator issues collectively represent the most widespread safety concern across the production run.

On the electrical side, 2006–2011 vehicles have wiring and connectors for the heating and air conditioning system that can overheat, melt, and start a fire even when the vehicle is parked. The 2006 model year alone has a crankcase ventilation valve heater that can short circuit, melt internal components, and also create a fire risk while the vehicle sits unattended.

The 2006 model year has one additional issue: vehicles equipped with the Sport Seat option have a passenger seat occupant classification sensor that can fail and deactivate the front passenger airbag, leaving that occupant without airbag protection in a crash.

Going back to the 2002 model year, rear brake rotors can develop a crack where the disc meets the parking brake drum. Under braking, that crack can propagate until the drum separates entirely from the disc, eliminating braking ability at that wheel.