NHTSA Complaint #10871663 — 2006 BMW X5 SAV

FIRE HAZARD, POTENTIAL ENGINE SHUTTING OF UNEXPECTEDLY: BATTERY CABLE AT CHARGE POINT UNDER HOOD MELTED AND CHARRED . DISCOVERY PRECEDED BY NOTICEABLE BURNING SMELL IDLING IN TRAFFIC. PLASTIC TERMINAL MOUNTING BASE MELTED AND CHARRED, TERMINAL DISCONNECTED FROM BASE, PLASTIC INSULATION AROUND CABLE TERMINAL CRIMP CHARRED AND MISSING. PARTS AFFECTED: 12 42 7 531 720 MAIN POWER CABLE CHARGE POINT TO ALTERNATOR; 12 52 1 439 674 BASE B+; 61 13 8 371 016 COVER BASE B+. EXAMINATION OF THE CRIMPED TERMINAL CONNECTING THE CABLE TO THE CHARGE POINT BOLT SHOWS THE CABLE NOT FULLY INSERTED IN THE TERMINAL BEFORE CRIMPING AND THE TERMINAL NOT COMPLETELY SOLDERED TO THE CABLE RESULTING IN A HIGH ELECTRICAL RESISTANCE AT THE TERMINAL AND EXCESSIVE HEATING WHEN THE ELECTRICAL SYSTEM UNDER LOAD WHEN THE ENGINE IS RUNNING. POSSIBLE CONSEQUENCES OF OVERHEATING OF THE CABLE INCLUDE THE POSSIBILITY OF FIRE IN THE ENGINE COMPARTMENT, FAILURE OF THE ELECTRICAL SYSTEM AND UNEXPECTED SHUT DOWN OF THE ENGINE AND ALL POWER ASSISTED SYSTEMS WHILE DRIVING.