Headlight assembly wiring insulation disintegrated.

- Pompano Beach, FL, USA

I have owned this vehicle for a while. I was stationary while I discovered the following. Door locks did not work consistently with the key fob, convertible top also, windows sometimes worked, wipers also. I read forums to realize the general module failed relays is a known problem. This known problem endangers the operator, passengers, and the public, and a recall and redesign should be ordered for the safety of the public. I tried to add pictures, but the form crashes.

- Germantown, MD, USA

The oem factory zkw headlight reflector bowl is cheaply made and is known to burn out. The cheap plastic used cannot handle the heat of the bulb and the metallic reflector film eventually starts to go bad causing very poor headlight visibility. This is a safety hazard and concern. BMW needs to be accountable and should find a replacement option without using the poorly made oem zkw reflector bowl.

- Pasadena, CA, USA

Over the last several years, the light intensity has steadily declined in both headlights of my car, to the point where they no longer function. My mechanic has looked inside the headlights and found that the projector bowl reflector has prematurely worn out -- it has lost its reflective ability. According to the mechanic and based on multiple reports in online group discussions, this is a known issue with these zkw xenon headlights. This defect in the headlights compromises safe operability and increases the risk of a night-time accident. This is a part of the headlight that should not wear out or need replacement under normal operating conditions, as has been the case with my vehicle. I have resorted to using my fog lights or high beams for driving at night. BMW and zkw are deflecting the issue. I would like to request an investigation regarding a potential widespread defect in these xenon zkw headlights. We should not have to wait for an accident to correct the problem.

- Austin, TX, USA

Passenger headlight low beam reflector is burnt out due to faulty material being used. Reflector is made out of plastic and normal heat from bulb melts the plastic. This makes it very unsafe and difficult to see at night. This seems to be extremely common on the internet. The solution is very expensive and due to this cost, most people will not fix and drive under this unsafe situation. Please look into this and hold BMW responsible.

- Arroyo Grande, CA, USA

I presented this problem to the dealer a few years ago the instrument panel light kept telling me a bulb was out and when you look at it all the bulbs were working. I have replace the rear taillight assembly due to the prong where starting to melt. So I call bmwna and they too ignored my first request for the recall on the 2005 BMW rear tail light hazard, I have since tried to called several times again and was told that my car was not within the recall time frame but it seems obvious that my car is having the same problem all the others ones have had and wish to get this potential hazard fixed because if the light on the dash will read one thing but the tail light is showing something different to those traveling behind me. I have enclosed the two photos of the burnt casing and harness. I feel this hazard is putting me and my family in great danger because there are no definite sign when or where these lights malfunction the blinker, brake, etc.

- Fayetteville, NC, USA

Insulation cracking on wires to xenon head lights leading to head light failure due to shorting or wire breakage; notation on when it happened is estimate because I had replaced one headlight for this issue several years ago (not knowing it was the cause at the time). I believe this is a manufacturer's defect after noting similar complaints from others. Vehicle has been garage kept. Photos are from wires to both lights. On light that was replaced new wires were spliced to old wires by dealership and photo is of original wire.

- Ocala, FL, USA

Side mirrors fading into a brown color. Making the visibility through them impossible. Many times I have almost side swiped cars that are on the side of me due to my not being able to see our of my side mirrors. Also front light keeps going out. I have changed it 3 times in two months and it keeps either going out or falling out of the hole making the indicator light come on.

- Leavenworth, KS, USA

I brought my car to BMW freeport was a tail light recall & they refused to fix my vehicle. Said the harness & wires were melted too much & it would cost $1400 to fix. Now I have a safety hazard as I'm driving with no tail light or my wires could catch on fire. This should be covered for free under a recall from 2011.

- Copiague, NY, USA

The projector bowls on my 2005 E46 330I show signs of burning. This problem seems to affect all E46 models with zkw xenon headlights. The burn bowls effect the light output often resulting in a poorly lit view of the road ahead.

- Lincoln, NE, USA

The contact owns a 2005 BMW 330ci. The contact stated that while driving at 40 mph, the passenger front headlight failed to illuminate intermittently. The contact also mentioned that the failure was sudden. The vehicle was taken to a dealer and the mechanic stated that igniter, controller, and bulb had to be replaced. The vehicle was not repaired. The manufacturer was notified. The failure mileage was 63,000.

- Conklin, NJ, USA

Purchased the car in April 2012. Noticed that the xenon headlights were not outputting as much light as I thought they should. Inspected the area behind the headlights (the reflective bowls) and discovered that they were burned. Upon researching online, I have found that this is a common problem for the zkw xenon equipped BMW 3 series (E46) vehicles, and the NHTSA has many complaints about this problem already. This is a safety defect in my mind. Headlight reflectors should not burn from their designed usage. This will cost thousands of dollars to replace the headlight assemblies. BMW should issue a recall for this serious problem.

- San Francisco, CA, USA

I received a recall letter from BMW for the problem with rear lamps. At that time, all real lamps were working on my car. However for safety concern, I brought my car to be checked; few months later, one of the tail light not working. I took my car back to the dealer, they said they were done for the recall. I need to pay if I want to fix the problem. But I found there was no positive voltage on the light bulb circuit. I traced the wire and discovered the wire was broken. Then I also found all other wires for the tail lights were aging, the plastic of the wires were deteriorated and the copper wire explored to visible. That mean the dealer didn't do the right work last time. Because it's no reason the wire will deteriorate that fast if they did it right for the recall. I complaint to BMW and the representative said they already done with my car. If I need any work to be done I need to pay by myself. The copper wires explored to visible, it would cause electric fire. This is a safety issue. I have the picture showing the aging wire condition on my car. I can email to you if you need it.

- San Jose, CA, USA

The contact owns a 2005 BMW 330I. The contact stated that while driving 30 mph, the headlights were activated but appeared very dim. The vehicle was taken to the dealer for inspection where the technician stated that the headlight assembly needed to be replaced. The vehicle was not repaired. The manufacturer was not notified. The failure mileage was 130,000.

- Wakefield, MN, USA

Zkw brand xenon headlights - the back of the projector bowl is made of plastic (vs. Metal in the al/Bosch brand, also used by BMW), which over time burns from the heat put out by the headlights. The burn turns the plastic from white to brown/orange, which severely reduces light output, making night driving dangerous. The headlight from my car is so poor that at night I can see the shadow of my car produced from cars behind me. Severe tire damage has been caused due to poor light.

- Trujillo Alto, PR, USA

In August 2011 I got a warning indicator that there may be a problem with my right taillight. In November 2011 (in for routine service and other work) BMW mechanics at my area dealership informed me that my taillight suffered from the same problems identified in the current recall for 2003-2005 3 series taillights that may cause a fire. BMW told me my VIN "did not appear" to be listed on their recall list and that despite the assessment of their certified mechanics, I would have to file a complaint with NHTSA in order to get you to tell BMW to add my car to the list so that my dealership will fix it. Please do so.

- Leavenworth, KS, USA

Dash mounted warning light indicated tail light issues. Checked the light and all the bulbs were fine but the entire tail light was not working. I then noticed the the brown wire in the connector had melted through the case and was touching other wires in the connector which caused it to short out the entire light. The brown wire has visible signs of melting. I have since found out that this is a common problem with my type BMW and a recall has been issued. Right now my VIN number does not fall under the notice but I have no tail lights.

- Peoria, AZ, USA

Rear taillights intermittently work. Noticed that the rear connectors, specifically the grounding wire was melted. The turn signals will intermittently not turn on.

- East Brunswick, NJ, USA

The contact owns a 2005 BMW 330I. While driving approximately 30 mph, the rear tail light assembly warning light illuminated on the instrument panel. The contact inspected the vehicle and noticed that the rear tail light connecting wires were melted. The vehicle was not taken to the dealer for diagnostics. The contact referenced NHTSA campaign id number: 11V438000 (exterior lighting:tail lights) but was advised by the manufacturer that the VIN was not included in the recall. The vehicle was not repaired. The approximate failure mileage was 85,000.

- Kingwood, TX, USA

Zkw brand xenon headlights - the back of the projector bowl is made of plastic (vs. Metal in the al/Bosch brand, also used by BMW), which over time burns from the heat put out by the headlights. The burn turns the plastic from white to brown/orange, which severely reduces light output, making night driving dangerous. I don't feel comfortable driving at night unless my hi-beams are on, which is hard to pull off unless I'm the only car on the road. This issue is most prevalent in 2002-2005 3 series sedans, and the issue is well documented in the BMW community.

- Kenmore, WA, USA