BMW Overheating Plug / High Contact Resistance

BMW EV charger cable or plug becomes very hot during charging, sometimes with a plastic smell

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Worn or oxidized contacts in Type 2 plug, Loose crimp connections inside BMW Wallbox cable, Undersized or damaged supply wiring causing heat at terminals, Continuous operation at maximum current in high ambient temperature

How to Fix / Troubleshooting

Safety first: Stop charging immediately if you smell burning plastic. Turn off the Wallbox breaker and allow everything to cool.

  • Inspect plug and inlet: After cooling, check for discoloration, warping, or melted plastic on the Type 2 plug and vehicle inlet. Do not continue using damaged components.
  • Check cable routing: Ensure the cable is not coiled tightly or covered, which can trap heat.
  • Reduce current: In the BMW Wallbox settings, lower the maximum charging current and monitor temperature during the next session.
  • Have terminals checked: Ask a qualified electrician to open the Wallbox (per manual) and verify that all terminal screws are tight and there are no signs of overheating.

If overheating recurs or any melting is visible, the cable assembly or affected terminals must be replaced. This should be done by a BMW-authorized service partner.

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Repair Difficulty

Hard 4/5

Required Part

BMW Wallbox Type 2 Charging Cable and Terminal Block
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