2004 BMW 3 Series ELECTRICAL SYSTEM,EXTERIOR LIGHTING

THE INTERIOR WIRES OF THE BMW E46 HEADLIGHT ASSEMBLIES HAVE INSULATION MATERIAL THAT READILY BREAKS OFF OF THE WIRE, CAUSING THE BEAR WIRE CONDUCTOR TO BE VISIBLE. THIS RESULTS IN A FAILURE OF THE HEADLIGHTS AS THE WIRES CONDUCTORS ARE ALLOWED TO TOUCH. THIS IS ALSO A POSSIBLE SOURCE OF A VEHICLE FIRE.

PASSENGER SIDE HEADLIGHT ASSEMBLY WIRES BREAK AND CAUSE THE HEADLIGHT TO STOP EMITTING LIGHT OR OTHERWISE WORKING. REPEATED ATTEMPTS TO REPAIR THE WIRING HARNESS EVENTUALLY FAIL. THIS OCCURS WITH MERE NORMAL USE OF THE CAR AND PASSAGE OF TIME. THE HEADLIGHT ASSEMBLY AND BULB ARE STILL INTACT, BUT SIMPLY RECEIVE NO POWER DUE TO THE BROKEN WIRES. THE ASSEMBLY CAN FAIL AT ANY TIME, WHETHER STATIONARY, IN MOTION, OR ON BACK ROADS OR HIGHWAYS. WHEN THIS ISSUE IS GOOGLED ON THIS PARTICULAR CAR, A 2004'2006 BMW 3 SERIES E46 COUPE WITH BI-XENON ADAPTIVE HEADLIGHTS, MANY MANY USERS REPORT THE SAME ISSUE. NO MATTER THE CONDITION, LOCATION, AND SERVICE HISTORY OF THE CAR, THE HEADLIGHT ASSEMBLY ON THE PASSENGER SIDE WILL ALWAYS STOP WORKING SIMPLY BECAUSE OF THE WIRING. SEE: HTTPS://FORUM.E46FANATICS.COM/SHOWTHREAD.PHP?T=1073501 IF REPAIRED ENOUGH TIMES, THE ASSEMBLY BECOMES UNREPAIRABLE, AT WHICH POINT THE USER IS STUCK DRIVING WITHOUT A HEADLIGHT, A DANGEROUS SITUATION TO BE IN. ORDERING AN INCREDIBLY COSTLY $1500 PART TO REPLACE IT IS NOT ONLY COSTLY, BUT WILL EVENTUALLY RESULT IN THE SAME CRITICAL ISSUE RE-APPEARING BECAUSE THE DESIGN IS INHERENTLY DEFECTIVE. THIS IS A SERIOUS SAFETY ISSUE. OTHER COSTS INCLUDE MECHANICS WHO INSIST TO CUSTOMERS THAT THE ISSUE IS BOTH WIRING AND THE BULB TOO, CAUSING UNSUSPECTING USERS TO BE CHARGED EXTRA FOR REPLACEMENT BULBS AND THE ASSOCIATED LABOR AS WELL. FIRST OCCURRENCE ON MY CAR WAS APRIL 2019, SECOND WAS OCTOBER 2019, AND THIRD WAS FEBRUARY 2020 AT WHICH POINT THE PART WAS DEEMED UNREPAIRABLE. 2004'2006 BMW 325CI AND BMW 330CI WITH ADAPTIVE BI-XENON HID HEADLIGHTS

MY LEFT REVERSE/TAIL LIGHT DOES NOT WORK. I HAVE REPLACED THE BULB AND ASSEMBLY AND ALSO HAVE FOUND ONLINE THAT THERE WERE RECALLS FOR THIS SPECIFIC ISSUE.

CAR SITTING IN DRIVEWAY OF PRIMARY RESIDENCE FOR SEVERAL DAYS AFTER REPEATED HEAVY RAINS AND HURRICANES AND SPONTANEOUSLY CAUGHT FIRE. FIRE WAS SELF EXTINGUISHED BUT STARTED IN DASH ON LEFT SIDE OF STEERING WHEEL CENTERED ON THE HEAD-LIGHT CONTROL MODULE.

HEADLIGHT WIRING INSULATION ON STANDARD BMW HEADLIGHTS IS BRITTLE AND FALLING OFF EXPOSING BARE COPPER WIRES WITHIN THE HEADLIGHT ASSEMBLY. IN ORDER TO PROTECT THE HEADLIGHTS I HAVE HAD TO WRAP THE WIRES IN ELECTRICAL TAPE AND SHRINK WRAPPING. THIS ISSUE HAS EXISTED FOR SEVERAL YEARS.

TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT STATED THAT THE TURN SIGNALS AND THE HEADLIGHTS FAILED TO ACTIVATE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE LIGHT MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 202,000. UPDATED 4/7/15*CN

WIRE LOOSING COATING ON INSIDE OF ADAPTIVE HEADLIGHTS, CAUSING SHORTS OR BROKEN WIRES WHERE THE HEADLIGHTS AND OR TURN SIGNALS WILL FAIL TO WORK. WIRE IS VERY BRITTLE AS THIS IS ALSO ROUGHLY 20 GAUGE WIRE. THIS CAN BE AN EXTREME HAZARD ESPECIALLY AT NIGHT. THIS SEEMS TO BE AFFECTING BMW'S 3/5/6/ SERIES FROM AT LEAST 2004 TO 2008 FROM MY INDEPENDENT RESEARCH. MANY PICTURES AND COMPLAINTS ON VARIOUS BMW FORUMS TO DOCUMENT THIS PROBLEM. MY PROBLEM OCCURRED WHEN I LOST ONE HEADLIGHT ON MY WAY HOME IN THE DARK AND AN INDICATOR CAME ON TO IDENTIFY A FAULT IN THE HEADLIGHT. ORIGINALLY I THOUGH IT WAS A BULB, CHANGED BULB AND IT STILL DID NOT WORK. FURTHER INVESTIGATION LED TO A BROKEN WIRE INSIDE OF THE HEADLIGHT ASSEMBLY. I FIXED THE BROKEN WIRE AND THEN NOTICED TWO MORE WIRES WHERE THE COATING ON THE WIRE SEEM TO HAVE FLAKED OFF CAUSING BARE WIRE. I ALSO FIXED THOSE WIRES AND ALL WAS WELL. A DAY OR TWO LATER, THE INDICATOR CAME ON AGAIN POINTING TO THE SAME HEADLIGHT. THIS TIME THE TURN SIGNAL WAS OUT. I OPENED THE ACCESS PANEL TO CHECK THE WIRING AND NOW A FORTH WIRE HAS BEEN SEVERED, HOWEVER I CAN NOT FIX IT AS IT IS DOWN PRETTY FAR INSIDE THE HEADLIGHT AND TO REPAIR WOULD REQUIRE REMOVING THE HEADLIGHT AND TAKING IT APART. APPARENTLY BMW USED BIODEGRADABLE WIRE FOR THE HEADLIGHTS?? SOURCE OF THE HEADLIGHT IS BELIEVED TO BE HELLA. SUPPOSEDLY BMW KNOWS ABOUT THE ISSUE BUT UNWILLING TO FIX UNLESS YOU PURCHASE A $800-1500 NEW HEADLIGHT. THIS IS CRAZY FOR A CAR THAT IS 10 YEARS OLD AND WELL MAINTAINED. THIS IS A SAFETY HAZARD AS YOU WILL CAN LOOSE A HEADLIGHT IN THE DARK AND MAYBE BOTH HEADLIGHTS GOING OUT, PLUS THE FACT OF BARE WIRES THAT CAN SHORT AND CAUSE A FIRE. *TR

MY BI-XENON HEADLIGHTS HAVE BEEN SLOWLY FADING RESULTING IN EXTREMELY POOR VISIBILITY DURING NORMAL NIGHTIME DRIVING. THIS DEGRADATION HAS BEEN OCCURRING WITHOUT MY KNOWLEDGE UNTIL IT BECAME OBVIOUS AFTER DRIVING ANOTHER VEHICLE. AS IT TURNS OUT, MY MECHANIC HAS ADVISED THERE IS A COMMON ISSUE WITH CERTAIN BMW ASSEMBLIES THAT THE PROJECTOR LENSES LITERALLY BURN DUE TO HEAT RESULTING IN THE NEED TO REPLACE THE ENTIRE ASSEMBLY. THIS LOSS OF HEADLIGHT INTENSITY RESULTING IN POOR VISIBILITY IS A SIGNIFICANT SAFETY SITUATION AND REQUEST SOMEONE LOOK INTO WHY NO RECALL HAS OCCURRED AS THIS IS OBVIOUSLY A SAFETY CONCERN. I HAVE ENTERED TODAY'S DATE AS INCIDENT DATE AS I AM NOT SURE WHEN DEGRADATION OF THE PROJECTORS BEGAN. *TR

DRIVER SIDE BRAKE LAMP HAS GONE OUT. IN RESEARCHING, FOUND THAT THIS IS A COMMON PROBLEM WITH THIS MODEL IN THE LED TAIL LIGHT AND CAN CAUSE A CRASH DUE TO OTHER DRIVERS NOT BEING ABLE TO TELL THAT YOU ARE STOPPING. FOUND RECALL INFORMATION ON NHTSA SITE AND CONTACTED BMW. I WAS INFORMED THAT MY SPECIFIC VIN WAS NOT INCLUDED IN THIS CAMPAIGN, YET THE PROBLEM IS THE SAME PROBLEM THAT AFFECTS 241,000 OTHER CARS. I WOULD LIKE TO ASK THAT MY SITUATION (AND VIN) BE EVALUATED AND INCLUDED IN THE RECALL SINCE THIS IS A KNOWN ISSUE WITH THIS MODEL. THANK YOU FOR YOUR ASSISTANCE! *TR

I PURCHASED MY 2004 BMW 330I IN SEPT 2010, AT LEAST IN PART BECAUSE IT WAS ADVERTISED AS HAVING FACTORY INSTALLED XENON LIGHTS AND I HAVE ALWAYS WANTED BRIGHTER HEADLIGHTS THAN OTHER CARS I HAVE OWNED. WITHIN 3 MONTHS I WAS SO DISGUSTED WITH THE DIMNESS OF THOSE XENON'S THAT I PURCHASED 2 NEW D2S BULBS AND HAD THEM INSTALLED AT THE COST OF ABOUT $400. (I WAS TOLD THAT EVEN XENON'S "WEAR OUT" OVER TIME SO I FIGURED I WOULD BITE THE BULLET THIS ONE TIME) I FOUND RIGHT AWAY THAT THESE NEW BULBS WERE NO BETTER THAN I HAD BEFORE. AS A MATTER OF FACT, THE RIGHT SIDE LIGHTS SHINED AGAINST A WALL WERE ACTUALLY DIMMER THAN A D CELL FLASHLIGHT. I SUFFERED THOUGH TRYING TO DRIVE WITH MY PASSING LIGHTS ON AT NIGHT (YOU ACTUALLY HAVE TO HOLD THE HIGH BEAM STICK IN TO GET THESE LIGHTS TO STAY ON ) FOR A YEAR BEFORE I DECIDED TO REPLACE THE WHOLE HEADLIGHT ASSEMBLY BUT NO-ONE SELLS A REPLACEMENT FOR THE XENON EQUIPPED CARS. I THEN REMOVED THE ASSEMBLIES MYSELF AND WAS SHOCKED TO SEE CLEAR SIGNS OF BURNING OR CORROSION ON THE INSIDE OF THE REFLECTOR BOWLS. NO WONDER THE LIGHTS WOULD NOT SHINE ON THE HIGHWAY. IT IS SO BAD THAT EVERY TIME I AM PASSED ON THE HIGHWAY AT NIGHT I ACTUALLY SEE MY CAR'S SHADOW DIRECTLY IN FRONT OF ME FROM THE HEADLIGHTS OF THE CAR 50-100 FEET BEHIND ME. I NOW UNDERSTAND FROM FURTHER INVESTIGATION THIS IS AN ONGOING PROBLEM WITH ZKW HEADLIGHTS ON E46 BMW'S. I DO NOT HAVE THE TECHNICAL EXPERTISE OR EXTRA CASH TO FIX THESE DEFECTS. CAN YOU HELP?? NO ACCIDENTS OR INJURIES HAVE OCCURRED YET BUT I HAVE SEEN MANY PEDESTRIANS OR BIKERS AS I PASS THEM AT NIGHT ON THE SIDE OF THE ROAD THAT I NEVER SAW UNTIL I WAS NEXT TO THEM. *TR

MY BMW 325I XENON HEADLIGHT BOWLS HAD MELTED AND DIMMED TOA DANGEROUS POINT, THEY ARE ALL ORIGINAL AND UNALTERED. *TR

RIGHT SIDE SIGNAL LIGHT INTERMITTENT FAILURE. WHEN IT FINALLY FAILED THERE WAS A SCORCHED WIRE. UPON INVESTIGATION FOUND THERE IS A TSB FROM THE MANUFACTURER BUT ONLY IN WARRANTY. NO RECALL. *KB

REAR TURN-SIGNAL INDICATORS BEGAN FAILING TO OPERATE, ESPECIALLY IN HOT, HUMID CONDITIONS. INSPECTION OF WIRING HARNESS REVEALED EVIDENCE OF WIRING-CONNECTION DEGRADATION BY HEAT OR CORROSION. THE CAR HAS NOT BEEN DAMAGED OR FLOODED IN ANY WAY. IT IS KEPT IN A GARAGE. SINCE BOTH REAR BLINKER ASSEMBLIES HAVE BEEN AFFECTED, I BELIEVE THAT THE DESIGN OR ENGINEERING WAS DEFECTIVE. THE INTERMITTENT FAILURE OF TURN SIGNALS IS A SERIOUS SAFETY HAZARD. *TR

TAIL LIGHT WORKING INTERMITTENTLY IN BMW 2004 325 4 DOOR SEDAN. *TR

2004 BMW 325I - SAFETY DEFECT. REAR TAIL LIGHT WIRING, MISSING ADDITIONAL GROUND WIRE TO AVOID BURNING BULB CARRIER. BMW SERVICE INFORMATION BULLETIN ISSUED 2/2007 REVEALS BMW WAS AWARE OF THIS ISSUE AND FAILED TO NOTIFY CONSUMERS. PURCHASED CAR CPO IN MARCH 2007 AND WAS NOT TOLD. REPLACED SEVERAL TAILLIGHT BULBS DUE TO INTERMITTENT FALSE INDICATOR LIGHTS. FINALLY IN 2011, 1 YEAR AFTER CAR CAME OUT OF WARRANTY...REMOVED THE WIRING HARNESS CONNECTOR TO THE BULB CARRIER AND FOUND IT TO BE MELTING. CONTACTED DEALER AND WAS TOLD IT COULD DEFINITELY START A FIRE IF LEFT TOO LONG. BMW DEALER ALSO STATED THIS IS A DEFECT ON CARS PRODUCED FROM 2001 TO 2005. AFTER DOING RESEARCH FOUND THAT BMW HAS USED FAULTY WIRING AND THERE IS A ADDITIONAL GROUND WIRE NEEDED TO FIX. NEEDLESS TO SAY , HAD TO PAY 300.00 TO HAVE PEACE OF MIND AND REPAIR. *KB

2004 BMW 330I - TAIL LIGHT WIRING FAILURE. TAIL LIGHT BULB SOCKET (PART NUMBER W0133-1663035 FAILED DUE TO OVER HEATING AND MELTING OF CONNECTOR. RESULTS IN LOSS OF BRAKE LIGHT FUNCTION. PROBLEM COMMON TO BOTH DRIVER AND PASSENGER SIDE. PURCHASING NEW PART TO TRY TO CORRECT PROBLEM HOWEVER PROBLEM MAY ALSO INCLUDE FAILURE OF THE CONNECTOR (FEMALE) ON THE WIRING HARNESS WHICH IS NOT READILY AVAILABLE. OVER HEATING APPEARS TO BE DUE TO UNDERSIZING OF CONNECTOR/WIRE. THIS APPEARS TO BE A COMMON PROBLEM WITH E46 BMW'S (3 SERIES). PROBLEM WAS BROUGHT TO DEALER'S ATTENTION WHILE UNDER WARRANTY,...THEY DID NOT FIX IT. CONTACTED CORPORATE HEAD QUARTERS,...THEY DID NOT ACKNOWLEDGE THIS WAS A COMMON PROBLEM. (REF. EA09-019). *TR

TL* THE CONTACT OWNS A 2004 BMW 325XI. THE WIRE THAT PLUGS INTO THE DRIVER SIDE REAR TAIL LIGHT HARNESS BURNED WHICH MAKES IT IMPOSSIBLE FOR THE DRIVER TO ALERT OTHERS OF HIS INTENTIONS REGARDING DIRECTION OF TRAVEL AND SPEED. TECHNICAL SERVICE BULLETIN # 10020856(EXTERIOR LIGHTING:TAIL LIGHTS) SUMMARIZES THE FAILURE. THE FAILURE HAS NOT BEEN REMEDIED. THE CURRENT AND FAILURE MILEAGES WERE 59,770. UPDATED 12/09/09 *BF THE CONSUMER STATED THE SAME FAILURE HAPPENED ON THE PASSENGER SIDE. THERE WAS INSUFFICIENT GROUNDING WHICH CAUSED THE BURNOUT OF THE TAIL LIGHT WIRING.

AT FIRST I THOUGHT IT WAS DEFECTIVE LIGHT BULBS (ONE FROM TWO DIFFERENT SETS FAILED WHEN ONE SET WAS INSTALLED FOR MY TURN SIGNAL AND THE OTHER FROM MY BRAKE LIGHTS), BUT AS I BEGAN TO DO MORE RESEARCH ONLINE, I FOUND THAT OTHER PEOPLE WERE HAVING AN ISSUE SIMILAR TO MINE. THEY REPORTED THAT THERE SEEMED TO BE AN ELECTRICAL PROBLEM THAT WOULD CAUSE CORROSION AND A LOOSE CONNECTION. SO I DECIDED TO CHECK MY CAR OUT AS WELL AND DISCOVERED THAT THE PROBLEM HAD AFFLICTED MY VEHICLE AS WELL. I THEN FOLLOWED THE LINK TO THE TECHNICAL SERVICE BULLETIN RELEASED BY BMW, AND THE PROBLEM THAT I AM HAVING IS JUST AS THEY HAVE DESCRIBED. ONE OF THE 8-PIN REAR LAMP CONNECTORS HAS MELTED CAUSING A LOOSE CONNECTION AND MY CAR CONTINUING TO TELL ME THAT I HAVE A DEAD BULB, WHEN IN FACT IT IS THE CONNECTION. *TR

THIS IS A FORMAL PETITION FOR A SAFETY DEFECT INVESTIGATION. MY 2004 BMW 325XI HAS A LEFT TAIL LIGHT THAT DOES NOT WORK BECAUSE OF A POOR CONNECTION AT THE REAR LAMP CONNECTOR (THE GROUND WIRE RECEPTACLE AND HOUSING HAVE BURNT OUT BECAUSE THE GROUND IS NOT STRONG ENOUGH FOR THE CURRENT). MY RIGHT TAIL LIGHT STILL FUNCTIONS BUT I AM CONCERNED ABOUT THIS SIDE BURNING OUT AS WELL AND POSING A POSSIBLE FIRE HAZARD. BMW HAS ISSUED A SERVICE BULLETIN (SI B 63 03 06) WHICH ADDRESSES THIS ISSUE AND SAYS THAT THE CAUSE IS "MINOR CORROSION AT THE 8-PIN REAR LAMP CONNECTOR CREATES HIGH RESISTANCE CAUSING DAMAGE TO THE CONNECTOR HOUSING." BMW HAS NOT ISSUED A RECALL AND I AM WORRIED ABOUT GETTING INTO AN ACCIDENT WITHOUT A PROPERLY FUNCTIONING TAIL LIGHT. *TR