2004 BMW 3 Series Complaint Log

TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT STATED THAT THE GROUND WIRES WERE OVERHEATING, MELTING THE PLUG AND CAUSING THE TAIL LIGHTS TO MALFUNCTION. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 117,000 AND THE CURRENT MILEAGE WAS 120,000. *TR

TL* THE CONTACT OWNS A 2004 BMW 330I. WHILE DRIVING AT AN UNKNOWN SPEED, BOTH PROJECTOR HEADLIGHTS FAILED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE PROJECTOR HEADLIGHT LENSES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 190,000.

THE VERY FIRST TIME I TRIED TO DRIVE THE CAR AT NIGHTTIME TO GO BACK HOME, MY WIFE AND KIDS WERE ON BOARD, AND WE WERE MORE THAN 200 MILES FROM HOME. AFTER I TURNED ON THE LOW-BEAM HEAD LAMPS AND STARTED ROLLING, I COULD BARELY SEE THE ROAD BECAUSE THE HEADLAMPS WERE NOT PROPERLY ILLUMINATING. I FLIPPED THE SWITCH SEVERAL TIMES TO NO AVAIL.' PUTTING LIVES AND PROPERTIES AT RISK, I CONTINUED DRIVING UNTIL WE GOT HOME, ALL THE WHILE DRIVING WITH THE HIGH-BEAM LAMPS ON AND APPARENTLY GETTING THE OTHERS DRIVERS ON THE ROAD FUMING. I TOOK THE CAR TO BOTH A LAMP-ADJUSTING STATION AND A BMW DEALER WHERE I WAS TOLD THE LAMPS COULD NEITHER BE ADJUSTED NOR THEIR BULBS MERELY REPLACED BECAUSE THE PROBLEM WAS THE REFLECTOR BOWLS WERE DEFECTIVE AND HAD LOST THEIR ABILITY TO PROJECT LIGHT PROPERLY. I WAS ALSO TOLD THAT BOTH THAT THE REFLECTOR BOWLS COULD NOT BE REPLACED INDIVIDUALLY, AND THAT BOTH (LEFT AND RIGHT SIDES) ASSEMBLIES MUST BE REPLACED AT A TOTAL COST OF MORE THAN $2000.00. MANY POSTERS IN THE BMW FORUMS HAVE VOICED OUT EXACTLY THE SAME PROBLEMS, AND I WISH THAT ALL WOULD FILE A COMPLAINT TO NHTSA. I NEVER DROVE THIS CAR AGAIN AT NIGHT UNTIL I HAD ? IN AUGUST 2014 ? PURCHASED AND FINALLY RECEIVED AND INSTALLED THE HEAD LAMPS ASSEMBLIES IN OCTOBER 2014. I HAVE IN MY POSSESSION THE HEADLAMP ADJUSTING STATION'S INVOICE AND RECOMMENDATION PLUS THE RECEIPT AND INVOICE FOR THE NEW HEADLAMP ASSEMBLIES THAT HAD TO BE SPECIALLY ORDERED FROM GERMANY. ON NOVEMBER 17, 2014, BY CERTIFIED MAIL, I SENT BMW OF NORTH AMERICA MY REQUEST FOR REIMBURSEMENT, BUT I HAVE YET TO RECEIVE A RESPONSE. DUE TO THIS DEFECT WHICH AFFECTS SAFETY, I STRONGLY AND RESPECTFULLY SUGGEST THAT A RECALL BE ISSUED ON THIS BMW MODEL, OR SOME SORT OF DIRECTIVE BE ISSUED FOR BMW TO REIMBURSE THOSE OWNERS 'SUCH AS I' WHO HAD ALREADY REPLACED THEIR LAMP ASSEMBLIES AT THEIR OWN EXPENSE. *TR

BURNT BOWL IN THE HEADLIGHTS CAUSING THE XENON LIGHT TO HAVE DIMINISHED LIGHT OUTPUT. NIGHT DRIVING IS VERY DIFFICULT DUE TO THE HEADLIGHT NOT BEING BRIGHT ENOUGH ANYMORE. REPLACEMENT OF THE ASSEMBLIES WILL ONLY FIX THIS TEMPORARILY UNTIL THE BOWLS BUT AGAIN AND THE PROBLEM RETURNED. *TR

THE DRIVER SIDE MIRROR WILL NOT MAINTAIN IT'S SET POSITION. ON MY CAR THE MIRROR WOULD CHANGE POSITION EVERY MINUTE. THIS CONTINUED ALL DAY AND NIGHT FOR THREE DAYS. THIS MADE LANE CHANGES, ENTERING A LANE, OR TURNING. VERY DANGEROUS AND DIFFICULT. I IMMEDIATELY ACCOUNTED FOR MY MIRROR NOT BEING USABLE AND PLOTTED MY LANES CHANGES AND DRIVING LANES AHEAD OF TIME. THIS IS A PROBLEM THAT CAN HAPPEN IMMEDIATELY WITHOUT WARNING. I COULD ENDANGER A DRIVER NEEDING TO CHANGE LANES, WHEN THEY LOOK OVER AND HAVE NO MIRROR, OR IS FACED WITH A MIRROR THAT WILL NOT HOLD POSITION. THIS IS A SERIOUS SAFETY ISSUE. ===================EXAMPLES BMW BULLETIN ==LINK PROVIDED UPON REQUEST===== SI B51 36 08 BODY EQUIPMENT APRIL 2009 TECHNICAL SERVICE THIS SERVICE INFORMATION BULLETIN SUPERSEDES SI B51 36 08 DATED FEBRUARY 2009. DESIGNATES CHANGES TO THIS REVISION SUBJECT OUTSIDE MIRROR MOVES WHEN UNLOCKING THE VEHICLE MODEL E90, E91 (3 SERIES SEDAN AND SPORTS WAGON) PRODUCED UP TO 9/2008 AND EQUIPPED WITH POWER FRONT SEATS, OPTION CODE SA459 S TO A RANDOM POSITION. PRESSING THE SEAT MEMORY BUTTON TYPICALLY WILL RETURN THE MIRROR TO THE STORED POSITION. CAUSE WHEN THE UNLOCK SIGNAL IS SENT TO THE CAR, A MIRROR POSITION SELF-CHECK IS PERFORMED. ONE OF THE FACTORS IN DETERMINING THE MIRROR'S PRESENT POSITION IS AN EXPECTED RESISTANCE VALUE IN THE CIRCUIT. DUE TO A HIGHER THAN EXPECTED RESISTANCE, THE FOOTWELL MODULE (FRM) CALCULATES THE MIRROR POSITION INCORRECTLY. THE MIRROR IS THEN MOVED TO WHAT IS BELIEVED TO BE THE CORRECT POSITION. THE UNEXPECTED RESISTANCE VALUE IS CAUSED BY ONE OF THE FOLLOWING: * CORROSION ON THE LIN-BUS CONNECTION AT THE MIRROR, SWITCH BLOCK, OR FRM * POOR CONNECTION AT THE MIRROR, SWITCH BLOCK, OR FRM * DAMAGED MIRROR ELECTRONICS. *TR

TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT STATED THAT THE REARVIEW MIRRORS WERE DISTORTED. WHILE DRIVING DURING NIGHT, THE MIRROR WOULD DISPLAY DOUBLE OBJECTS. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE MIRRORS NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

BMW E46 EQUIPPED WITH ZKW BRAND HEADLIGHTS SUFFER FROM A BURNT, MELTED, AND CRACKED REFLECTOR BOWL DRAMATICALLY REDUCING THE BI-XENON LIGHT OUTPUT, MAKING IT DIFFICULT AND UNSAFE TO DRIVE AT NIGHT. THIS IS A VERY COMMON ISSUE AND NEEDS TO BE RESOLVED FOR DRIVERS AND OTHERS SAFETY DURING NIGHT. *TR

TL* THE CONTACT OWNS A 2004 BMW 325CI. THE CONTACT STATED THAT SHE NOTICED THERE WAS A LEAK FROM UNDER THE FRONT OF THE VEHICLE. THE CONTACT THEN ATTEMPTED TO START THE VEHICLE BUT TO NO AVAIL. THE VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION WHERE THEY ADVISED HER THAT THE BATTERY FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED BUT PROVIDED NO ASSISTANCE. THE FAILURE MILEAGE WAS 63,000.

NO IN PASSENGER SEAT WHEN STARTING THE CAR AND THE PASSENGER AIR BAG LAMP WAS ILLUMINATED ON DASHBOARD. TURNED CAR OFF AND THEN BACK ON AND THE LIGHT WAS OFF. WENT ABOUT 15 FEET AND THE LIGHT CAME BACK ON. TURNS ON AND OFF WITH OR WITHOUT ANYONE IN THE SEAT. BMW REPRESENTATIVE STATED RECALL ID# 81074 DID NOT RELATE TO MY VIN. *TR

THE DRIVER'S SIDE SEAT BELT REPEATEDLY STOPS WHEN EXTENDING. IT CAN TAKE 10 TO 15 ATTEMPTS TO GET IT TO EXTEND LONG ENOUGH. THESE FAILURES CAUSE DRIVERS TO "GIVE UP" AND NOT BOTHER TO USE THE SEAT BELT. I HAVE SPOKEN WITH BMW AND THEY WANT $500 TO REPLACE THE SEAT BELT. I BELIEVE THIS IS DANGEROUS AND A FLAW IN THE DESIGN. *TR

WHILE DRIVING AT HIGHWAY SPEEDS, THE CAR BEGAN TO PULL/SWERVE. A METAL ON METAL GRINDING NOISE ALSO BEGAN. I WAS ABLE TO GET OFF THE HIGHWAY AND HAVE THE CAR TOWED. A MECHANIC FOUND THAT THE REAR PASSENGER SIDE PARKING BRAKE HAD ENGAGED AND DISINTEGRATED INTO SEVERAL PIECES OF METAL. ALL OTHER WHEELS WERE UNAFFECTED. THE PARKING BRAKE LEVER WAS DOWN, AND HAD NOT BEEN USED IN SEVERAL MONTHS. *TR

THE GENERAL MODULE 5 IN E46 3 SERIES MODEL YEARS 2004-2006 FAIL CAUSING FAILURE OF TURN SIGNALS, CENTRAL LOCKING, WIND SHIELD WIPERS, AND HAZARD LIGHTS. THIS DEFECT IS KNOWN BY BMWNA BUT HAS NOT BEEN ADDRESSED. *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

TL* THE CONTACT OWNS A 2004 325 BMW. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, THE VEHICLE BEGAN TO DECELERATE INDEPENDENTLY TO 35 MPH. THE CONTACT ATTEMPTED TO ACCELERATE BUT THE VEHICLE STALLED. THE CONTACT PULLED OVER AND ATTEMPTED TO RESTART THE VEHICLE BUT IT FAILED. THE VEHICLE WAS TOWED TO A MECHANIC FOR INSPECTION WHERE THEY STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND STATED THAT THERE WERE NO RECALLS FOR THE VEHICLE. THE FAILURE MILEAGE WAS 160,000.

E46 BMW'S WITH ZKW XENON HEAD LAMPS SUFFER FROM POOR BULB PROJECTORS WHICH BURN TO THE POINT THAT LIGHT OUTPUT IS NEARLY NONE. THIS IS DEFECT IS KNOWN BY BMWNA BUT NOTHING HAS BEEN DONE TO CORRECT IT. *TR

MODULE THAT CONTROLS CENTRAL LOCKING, WIPERS, AND SEVERAL OTHER PARTS (THE GM5) STARTED TO DEVELOP A FAULT. WE HAD PROBLEMS UNLOCKING DOORS, LOCKING DOORS, USING WINDOWS, AND WORST OF ALL - THE WIPERS WERE HIT OR MISS. BMW WANTED $750 FOR THE PART REPLACEMENT. *TR

AS REPORTED BY OTHER OWNERS, THE BI-XENON HEADLIGHTS NO LONGER LIGHT UP THE ROAD. IT IS A SAFETY HAZARD AND IS A KNOWN ISSUE WITH HEADLIGHTS MANUFACTURED BY ZKW ON 2003-2005 BMW 330 MODELS. THE REFLECTOR BOWLS ON THESE UNITS BURN OUT OVER TIME AND REDUCE THE HEADLIGHTS ABILITY TO REFLECT LIGHT. DRIVING AT NIGHT IS LITERALLY NO BETTER WITH THE HEADLIGHTS ON OR OFF. I HAVE TO RELY ON MY FOG LIGHTS JUST TO SEE ANYTHING. PLEASE LOOK INTO THIS SAFETY ISSUE AS IT IS WIDE-SPREAD. REPLACEMENT OF HEADLIGHTS IS EXPENSIVE AT $1300 EA, THIS HAS TO BE RESOLVED BY BMW IMMEDIATELY. *TR

I HAVE OWNED THIS CAR FOR APPROXIMATELY 4 YEARS NOW AND HAVE NOTICED A GRADUAL DECREASE OF THE BRIGHTNESS OF MY HEADLIGHTS DURING THAT TIME PERIOD. I TOOK THE CAR TO BMW AND THEY SAID I HAVE A MODEL OF CAR THAT THE REFLECTORS BREAK DOWN DUE TO THE HEAT OF THE XENON BULBS. IT APPARENTLY OCCURS IN MY MODEL CAR WITH ZKW REFLECTORS FROM YEARS 2003 - 2004. I ASKED THE MECHANIC IF THIS WAS SOMETHING THAT WAS GOING TO BE RECALLED AND HE LITERALLY LAUGHED. THIS DEFECT COSTS WELL OVER $2000 IN PARTS ALONE AND IS A DEFINITE SAFETY HAZARD. WHEN I AM ON ROADS THAT ARE NOT WELL LIT, IT SEEMS AS THOUGH MY FOG LIGHTS ACTUALLY PROVIDE BETTER ILLUMINATION OF THE ROAD THAT MY HEADLIGHTS DO. IN MY OPINION THIS IS A SERIOUS SAFETY HAZARD AND WARRANTS A RECALL. PLEASE INVESTIGATE THIS MATTER FURTHER. *TR

DEAR NHTSA, THE HEADLIGHT DESIGN OF BMW'S E46 BODIES ARE JUST HORRIBLE. LIGHT OUTPUT IS CLOSE TO NONE CREATING A SIGNIFICANT PROBLEM REGARDING VISIBILITY. THE REASON IS DUE TO BMW'S REFLECTOR BOWL THAT DETERIORATES THROUGH OUT TIME DUE TO ITS PLASTIC MATERIAL AND FINALLY ENDS UP BURNING. IT IS SO BAD THAT THE FOG LIGHTS PRODUCE MUCH MORE LIGHT THEN ITS LOW BEAMS. WE DEFINITELY NEED YOUR HELP NHTSA BECAUSE BMW SURE DOES NOT WANT TO HELP, THEIR SOLUTION IS THAT YOU HAVE TO REPLACE THE WHOLE HEADLIGHT WHICH IS 1200 A PIECE. MILLIONS OF E46 OWNERS HAVE TO DEAL WITH THIS PROBLEM AND IS A MAJOR SAFETY CONCERN. NHTSA INVESTIGATORS MUST GO AND INVESTIGATE THE PROBLEM SO THEY KNOW HOW BAD IT REALLY IS. YES THAT MEANS BMW WILL LOOSE MILLIONS OF DOLLARS BUT IT IS SAFETY THAT MATTERS, WE DON'T WANT ANY PERSON OR CHILD TO BE KILLED JUST BECAUSE OF A POOR HEADLIGHT DESIGN. ONLY SOLUTION TO THIS PROBLEM IS UP TO YOUR GUYS, NHTSA. THANK YOU FOR TAKING TIME TO READ MY MESSAGE, I REALLY APPRECIATE IT. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

TL* THE CONTACT OWNS A 2004 BMW 325CI. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 20 MPH, THE AIR BAG WARNING INDICATOR ILLUMINATED AFTER THE SEAT WAS ADJUSTED. THE FAILURE RECURRED ON MULTIPLE OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER. THE TECHNICIAN DIAGNOSED THAT THE MAT WAS FAULTY. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

BOTH BIXENON HEADLAMPS ASSEMBLIES HAVE FAILED ON THE VEHICLE THEY EMIT LITTLE TO NO LIGHT DUE TO THE KNOWN BOWL BURN ISSUES WITH THE PLASTIC REFLECTORS (SHOULD HAVE BEEN FABRICATED FROM METAL), INSIDE THESE HEADLAMP ASSEMBLIES. IN LOOKING AT THE LIGHT ASSEMBLIES, THEY SEEMED TO HAVE FAILED A LONG TIME AGO. THIS IS A VERY UNSAFE AND HAZARDOUS SITUATION THAT RENDERS THE VEHICLE BASICALLY INOPERATIVE AT NIGHT TO THE OWNER, BECAUSE FELLOW DRIVERS, PEDESTRIANS, AND/OR BICYCLIST MAY BE NOT ABLE TO SEE YOUR HEADLIGHTS. THIS COULD CAUSE OR MAY HAVE ALREADY LEAD TO FATAL VEHICULAR ACCIDENT(S) OR THE DEATH OF A PEDESTRIAN(S) AND/OR BICYCLIST(S) BECAUSE OF THE LOW TO NO LIGHT EMITTED BY THESE FAULTY HEADLAMPS. WHILE PERFORMING IN DEPTH RESEARCH ON THE INTERNET DISCOVERED THAT THIS IS A VERY COMMON AND KNOWN PROBLEM ON THIS MAKE AND MODEL AT ALL MILEAGES. THE BMW FORUMS ARE FULL OF COMPLAINTS ABOUT THIS PROBLEM AND AN OPEN COMPLAINT SEEMS TO BE OPEN AND IN PROCESS WITH NHTSA SINCE 2009 SOME THREE YEARS AGO. NEITHER BMW OR ITS SUPPLIER OF THIS FAULTY PART MAKE A REASONABLY PRICED SERVICE PART THAT CAN BE PURCHASED TO CORRECT THIS KNOWN PRODUCT AND SAFETY PROBLEM. NOT EVEN THE AFTERMARKET INDUSTRY MAKES A SERVICE PART TO CORRECT THIS PRODUCT PROBLEM. TO CORRECT THIS ISSUE, YOU MUST PURCHASE TWO NEW COMPLETE HEAD LAMP ASSEMBLIES AT A COST OF APPROXIMATELY $ 1,200.00 EACH FROM BMW WHICH IS OUTRAGEOUS ESPECIALLY FOR SUCH A KNOW PRODUCT AND SAFETY PROBLEM. I CAN'T UNDERSTAND WHY A RECALL HAS NOT BEEN INITIATED FOR SUCH A KNOWN PROBLEM ON SO MANY VEHICLES THAT HAS BEEN ON GOING FOR SO LONG.. I CONTACTED BMW NORTH AMERICA FOR RELIEF WITH THIS KNOW SAFETY AND PRODUCT PROBLEM AND THEY COULD NOT HELP ME WITH THIS ISSUE BECAUSE THERE IS NO OPEN RECALL FOR THIS KNOWN PRODUCT AND SAFETY PROBLEM. *JS

THE VEHICLE CAME EQUIPPED FROM THE FACTORY WITH BI-XENON AUTO LEVELING HEADLIGHTS MANUFACTURED BY ZKW. THE LIGHT OUTPUT OF THE HEADLIGHTS IS BELOW ANY VEHICLE THAT I HAVE ENCOUNTERED ON THE ROAD. CARS THAT ARE OVER 20 YEARS OLD HAVE BRIGHTER HEADLIGHTS. I HAVE REPLACED THE BULBS AND IT HASN'T HELPED. LOOKING AT IT FURTHER, BROWN SCORCH MARKS ARE VISIBLE IN THE PROJECTOR WHEN THE HEADLIGHT IS ON. THE REAR OF THE PROJECTOR IS COMPLETELY BROWN AND BURNT. AT NIGHT, IT IS BECOMING VERY DIFFICULT TO SEE. AT THIS POINT I DON'T FEEL SAFE DRIVING THE VEHICLE. THIS PROBLEM IS GETTING PROGRESSIVELY WORSE. *TR

THE DRIVER'S SIDE SEAT BELT DOES NOT EXTEND FROM THE HOUSING. IT STOPS REPEATEDLY AND ONLY AFTER SEVERAL TRIES WILL IT EXTEND LONG ENOUGH TO BE LATCHED. THE SITUATION MAY CAUSE A DRIVER TO NOT USE SEAT BELTS AS THIS CAN TAKE A LONG TIME TO FINALLY EXTEND. I CONTACTED THE DEALER AND THEY SUGGEST IT MIGHT BE A MECHANICAL PROBLEM WHICH THEY ARE WILLING TO DIAGNOSE FOR $150 AND THEN FIX FOR AN UNKNOWN AMOUNT. IT WOULD THIS IS A POTENTIALLY SERIOUS SAFETY ISSUE. THERE HAS BEEN RECALLS FOR A SIMILAR PROBLEM IN OTHER BMWS BUT NOT THIS MODEL. FOR EXAMPLE, REFER TO NHTSA ITEM NUMBER: 10041411 AND NHTSA ITEM NUMBER: 10037487 *JS

AFTER PURCHASING MY 330I IN NORTH SALEM, NY, I SPENT ABOUT 30 HOURS DRIVING THE CAR HOME TO FLORIDA. I MADE IT HOME LATE AT NIGHT AND PULLED THE CAR INTO MY GARAGE. ONCE INSIDE, I NOTICED SMALL WISPS OF SMOKE EXITING THE HOOD, JUST ABOVE EACH HEADLIGHT. I OPENED THE HOOD AND SMELLED A FAINT BURNING PLASTIC SMELL. THROUGH ONLINE RESEARCH AND INVESTIGATION ON THE VEHICLE, I FOUND THE PROJECTOR HEADLIGHT REFLECTOR BOWLS WERE SEVERELY 'BURNT', SOMETHING VERY COMMON ON THESE STYLE HEADLIGHTS ON THIS CAR. I RESEARCHED MORE AND FOUND THAT THESE REFLECTORS WERE MADE OF PLASTIC, AND OVER TIME WOULD OVERHEAT AND BURN, LOSING THEIR REFLECTIVE COATING. THIS LOSS OF REFLECTIVE COATING EVENTUALLY LEADS TO SEVERELY DIMINISHED LIGHT OUTPUT. I RESEARCHED HOW TO REPLACE OR REPAIR THE LIGHTS, AND EVENTUALLY RETROFITTED NEWER METAL PROJECTOR BOWLS FROM A 2006+ BMW. THIS RETROFIT WHILE NOT PERMANENT, HAS HELPED. THIS IS A VERY SERIOUS PROBLEM. IN ADDITION TO THE LACK OF HEADLIGHT OUTPUT, THERE IS A SERIOUS FIRE HAZARD INVOLVED WITH THIS DESIGN FLAW. *TR

TL* THE CONTACT OWNS A 2004 BMW 325CI. THE CONTACT STATED THAT THE REAR VIEW MIRROR BECAME DISTORTED AND BEGAN TO LEAK. THE LIQUID BURNED THE GEAR SHIFT CONSOLE PLASTIC. THE DEALER STATED THE REAR VIEW MIRRORS AUTOMATIC DIMMER CONSIST OF A LIQUID. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 34,000. ....UPDATED 06/18/12 *BF THE CONSUMER STATED THE VEHICLE IS IN THE PROCESS OF BEING REPAIRED. UPDATED 06/21/12

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.

BONJOUR, LES RFLECTEURS ZKW DE MES FEUX XNON SONT BRULS. MES FEUX N'CLAIRENT PLUS. *TR

TL* THE CONTACT OWNS A 2004 BMW 330CI. WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED AND THE ENTIRE INSTRUMENT PANEL ILLUMINATED. THE CONTACT HAD TO COAST THE VEHICLE ONTO THE EMERGENCY LANE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO STATED THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE SIMILAR FAILURE OCCURRED TWICE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. THE VIN WAS UNAVAILABLE.

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

THE HEADLIGHTS OF THE CAR GET PROGRESSIVELY DIMMER OVER TIME. CHANGING HEADLIGHT BULBS (XENON HID D2S 4300K) DOES NOTHING BECAUSE THE REFLECTIVE COATING ON THE HEADLIGHT BOWLS HAS MELTED / BURNT OFF. THERE IS A SCENT OF HOT PLASTIC WITH THE HEADLIGHTS RECENTLY ON AND PROTECTIVE COVERS REMOVED. THE HEADLIGHT BOWLS APPEAR DARKLY CHARRED JUST ABOVE THE BULB AREA. *TR

IT APPEARS THAT A DESIGN DEFECT HAS CAUSED HOUSINGS FOR BI-XENON HEADLIGHTS TO BE SUBJECT TO HEAT STRESS, RESULTING IN DISCOLORATION AND CRACKING. AS A RESULT VISIBILITY DURING NIGHTTIME DRIVING IS SIGNIFICANTLY IMPACTED WHEN USING BOTH LOW-AND HIGH-BEAMS. APPROXIMATE COST FOR REPLACEMENT PARTS IS IN EXCESS OF $2,000, NOT INCLUDING LABOR. *TR

PURCHASED A USED 2004 BMW 330I. THE HEADLIGHT OUTPUT IS VERY DIM, AND UPON RESEARCH INTO THE MATTER, HAVE LEARNED THAT THE SUPPLIED ZKW HEADLIGHT ASSEMBLIES CONTAIN PLASTIC REFLECTOR BOWLS THAT ARE PRONE TO MELTING AND/OR BURNING. I INSPECTED MY HEADLIGHT ASSEMBLIES AND FOUND THIS TO BE THE CASE. THE REFLECTOR BOWLS IN MY HEADLIGHTS ARE BURNT, AND CONSEQUENTLY MY HEADLIGHTS ARE NOT NEARLY AS BRIGHT AND EFFECTIVE AS THEY SHOULD BE. THIS IS A SAFETY HAZARD - NIGHTTIME VISIBILITY IS SOMETHING THAT SHOULD BE TAKEN SERIOUSLY BY A MANUFACTURER. *TR

MY 2004 BMW 330 EQUIPPED WITH BI-XENON HEADLIGHTS IS EXPERIENCING GREATLY REDUCED LIGHT OUTPUT. UPON RESEARCH ON BMW FORUMS, THE PROBLEM IS DUE TO PLASTIC REFLECTORS IN THE LIGHT HOUSING MANUFACTURED BY ZKW. THIS IS A SAFETY ISSUE AS THE LIGHT OUTPUT DECREASES SLOWLY OVER TIME AS THE HEAT FROM THE XENON BULB BURNS THE COATING OFF THE REFLECTOR AND LEAVES A BURNT AMBER COLOR AS THE PLASTIC DEGRADES. BMW REFUSES TO REPLACE THE DEFECTIVE PART UNDER GOODWILL OR CPO WARRANTY, AND CLASSIFIES IT AS A WEAR ITEM, WHICH IS INCORRECT. BULBS ARE WEAR ITEMS, NOT ANY NON-MOVING PART IN THE HOUSING. THIS IS A SERIOUS SAFETY ISSUE, ESPECIALLY FOR OWNERS WHO ARE NOT AWARE DUE TO THE GRADUAL DEGRADATION OF LIGHTING QUALITY. *TR

MY VEHICLE IS A BMW 325, 2004 AND I HAVE HAD ISSUES WITH MY REVERSE. WHEN I PLACE MY CAR IN REVERSE, IT DOES NOT MOVE. I HAVE READ OF SEVERAL ISSUES PERTAINING TO THIS PROBLEM IN BMW VEHICLES FROM 2000 - 2005. MOREOVER, I UNDERSTAND THAT THERE WAS A CLASS ACTION LAW SUIT THAT WAS SETTLED IN NJ. I WOULD LIKE TO UNDERSTAND IF THE NHTSA IS PURSUING AND INVESTIGATION INTO THIS MATTER. *TR

THE VEHICLE HAD BEEN PARKED APPROXIMATELY 15-20 MINUTES WHEN WE WERE ALERTED BY THE FIRE ALARM IN OUR CONDO BUILDING. UPON EVACUATING THE BUILDING, WE WERE TOLD THAT OUR 2004 BMW 325I WAS ON FIRE. WE STILL HAVE NOT BEEN GIVEN ANY SPECIFIC CAUSE FOR THE FIRE, EXCEPT THAT IT WAS PROBABLY ELECTRICAL IN NATURE. SPECIAL AGENTS FROM OUR INSURANCE COMPANY WERE ALSO CALLED IN, WHO, IN TURN, CALLED IN TWO MORE EXPERTS. EVIDENCE WAS BAGGED AND THE CAR WAS SHRINK WRAPPED TO BE TAKEN TO A LOT WITH AT LEAST THREE OTHER BMW'S WHICH HAD ALSO CAUGHT FIRE WHILE PARKED. THIS IS ONE OF THE MOST FRIGHTENING THINGS TO EVER HAPPEN TO US. WE ARE POSTING THIS HOPING IT CAN HELP THIS FROM HAPPENING TO ANYONE ELSE. *TR

THE XENON PROJECTOR BOWLS ARE MADE OF PLASTIC, WHICH EVENTUALLY BURNS. THIS DIMINISHES THE LIGHT OUTPUT SO DRASTICALLY THAT IT IS INCREDIBLY DIFFICULT TO SEE AT NIGHT. THE "BURNING" OF THE PLASTIC BOWL ALSO SEEMS LIKE IT MIGHT CAUSE THE BOWL ITSELF TO MELT OR CATCH FIRE. *TR

THE CONTACT OWNS A 2004 BMW 330I. THE CONTACT STATED THAT THE HEADLIGHTS FAILED. THE HEADLIGHTS DOES NOT GIVE ENOUGH LIGHT. THE DEALER WAS CONTACT AND THEY ADVISED THAT THE HEADLIGHT REFLECTIVE PLASTIC HOLDER MELTED AND CAUSES THE LIGHT TO BE LOW. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 124,000. LI

BI-XENON HEADLAMP PROJECTOR BACK-BOWLS ARE MADE OUT OF PLASTIC AND HAVE HAD THEIR REFLECTIVE COATING BURNT OFF OF THEM FROM NORMAL HEADLIGHT USAGE. DUE TO THE LACK OF REFLECTIVITY ON THE PROJECTOR BOWLS MY HEADLIGHTS HAVE BECOME SIGNIFICANTLY MORE DIM OVER TIME AS MORE OF THE REFLECTIVE COATING IS BURNING OFF. IT HAS BECOME HARDER AND MORE DANGEROUS TO DRIVE AT NIGHT DUE TO THE SEVERE LACK OF LIGHT MY HEADLIGHTS NOW PRODUCE. *TR

FRONT OPTIONAL HID (XENON) HEADLAMPS WERE NOTICED A BEING EXTREMELY DIM. THE HEADLIGHT HAS A REPLACEABLE PLASTIC LENS. LENS WAS FIRST POLISHED AND THEN WHEN NO LIGHT IMPROVEMENT WAS OBSERVED, BOTH LENSES WERE REPLACED. LIGHT OUTPUT REMAIN VERY POOR. BULB WERE ORDERED TO REPLACE ORIGINAL HOWEVER WHEN BEGINNING TO REPLACE THE BULBS IT WAS NOTICED THAT THE BOWL HAD AN OBSERVED SCORCH OR BURNED SPOT ON THE PROJECTOR BOWL AND I CEASED CHANGING THE BOWL. AFTER READING FORUMS IT APPEARS THIS IS A COMMON MANUFACTURING DEFECT INVOLVING A SAFETY ITEMS THAT REDUCES VIABILITY AND MAY POSSIBLY BURN THROUGH ON THIS MODEL YEAR WITH THIS OPTION. A PHOTO IS AVAILABLE IF NECESSARY. *TR

I WOULD LIKE TO BRING TO ATTENTION OF NHTSA THAT MY CAR'S REAR COIL SPRINGS CRACKED DUE TO RUST. I CAME TO KNOW ABOUT IT WHEN I TOOK THE CAR FOR OIL CHANGE AT BRIDGEWATER NJ BMW DEALERSHIP. I GOT THE PART REPLACED BY A CERTIFIED INDEPENDENT MECHANIC AS THE DEALER'S QUOTE WAS WAY HIGH. I HAVE THE REMOVED PART IF NHTSA WANT?S FOR ANALYSIS. I HAVE DONE SOME ONLINE SEARCH ON THIS ISSUE AND FOUND IT TO BE A COMMON PROBLEM DUE TO KIND OF PAINT AND COATING BEING USED FOR THE SPRINGS. I BELIEVE THIS IS A QUALITY OF WORKMANSHIP ISSUE AND SHOULD BE ADDRESSED BY A RECALL AND REQUEST NHTSA TO URGE BMW NA TO LOOK INTO THIS MATTER AND TAKE NECESSARY STEPS TO IMPROVE THE QUALITY OF THE COMPONENT IN QUESTION AS IT IS A HUGE SAFETY ISSUE AS WELL. *TR

THE BI-XENON PROJECTOR HEADLIGHTS ON MY CAR DO NOT PRODUCE THE FOCUSED LIGHT THAT THEY DID WHEN THE CAR WAS PURCHASED. INVESTIGATION HAS PRODUCED EVIDENCE THAT THE PLASTIC XENON REFLECTOR BOWLS HAVE LOST THEIR REFLECTIVE MATERIAL AND THAT THE PLASTIC REFLECTOR BOWL IS NOW DETERIORATED AND BROWN. THE PATTERN OF WHERE THE REFLECTIVE MATERIAL HAS DISAPPEARED INDICATES THAT THE VAPOR DEPOSITED REFLECTIVE MATERIAL HAS FAILED DUE TO THE HEAT GENERATED BY THE HEADLIGHT BULB. OTHER HEADLIGHTS IN THE BMW 3 SERIES LINE HAVE METAL BOWLS AND DO NOT DISPLAY THE SAME PROBLEM. I'VE SPOKEN TO MY BMW DEALER AND BMW OF AMERICA AND REGISTERED A COMPLAINT BUT RECEIVED NO ASSISTANCE. IF THE PROJECTOR BOWLS WERE AVAILABLE AS REPLACEMENT ITEMS I WOULDN'T BE AS UN-HAPPY UNFORTUNATELY THAT'S NOT THE CASE AND TO RECTIFY THE PROBLEM IT REQUIRES THE CUSTOMER TO PURCHASE HEADLIGHT ASSEMBLIES AT AROUND $1200.00 PER SIDE. AS I AM AN ENGINEER BY PROFESSION I WOULD CONSIDER THIS A DESIGN DEFECT DUE TO A POOR CHOICE OF MATERIAL CAPABILITIES AND/OR MATERIAL COMPATIBILITIES. I CONSIDER THIS TO BE A SAFETY ISSUE DUE TO THE FACT THAT THIS OCCURS OVER TIME LEAVING THE OWNER OPERATOR WITH SLOW DETERIORATION OF LIGHT QUALITY. I WOULD APPRECIATE YOUR ASSISTANCE IN HOLDING BMW RESPONSIBLE FOR THE SAFETY OF THEIR CUSTOMERS AND OTHERS ON THE OUR HIGHWAYS. I HAD NOTICE THE REDUCED LIGHT QUALITY BUT WAS BLAMING IT ON THE CONDITION OF MY HEADLIGHT LENSES. BUT AFTER HAVING MY HEADLIGHT LENSES RECONDITIONED THE LIGHTING CONDITION CONTINUED. LEAVING ME TO INVESTIGATE AND FIND THAT THIS IS A COMMON ISSUE WITH OTHER BMW 3 SERIES AUTOMOBILES. *TR

TL* THE CONTACT OWNS A 2004 BMW 325I. WHILE EXAMINING THE VEHICLE, THE CONTACT NOTICED THAT THE REAR VIEW MIRROR WAS LEAKING INSIDE OF THE GLASS, DISTORTING THE CONTACTS VIEW. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS INFORMED THAT THE REAR VIEW MIRROR NEEDED TO BE REPLACED DUE TO LEAKING GAS. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 72,000.

TL* THE CONTACT OWNS A 2004 BMW 330CI. WHILE DEPRESSING THE BRAKE PEDAL, THE CONTACT NOTICED THE REAR DRIVER SIDE BRAKE LIGHT WOULD ONLY ILLUMINATE PARTIALLY. 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 CONVERTIBLE MODELS WERE NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.

HEADLIGHTS HAVE GRADUALLY LOWERED LIGHT OUTPUT TO THE POINT THAT THE VEHICLE IS UNSAFE TO OPERATE IN DARK CONDITIONS. THIS CONDITION HAS APPARENTLY HAPPENED TO MANY OTHER VEHICLES OF THE SAME MAKE AND MODEL, AND MAY HAVE SOMETHING TO DO WITH THE LOW BEAM REFLECTORS ON 2003-2004 ZKW HID HEADLIGHTS WERE MADE OF SOME MATERIAL THAT DEGRADED WHEN SUBJECTED TO THE HEAT PRODUCED BY OEM XENON BULBS. *TR

THE ZKW PROJECTOR BOWLS ARE BURNED OUT ON THE HEADLIGHT FIXTURES, REDUCING LIGHT OUTPUT AND VISIBLITY. AFTER SOME RESEARCH, IT IS EVIDENT THAT THIS IS NOT AN ISOLATED INCIDENT. BMW NEEDS TO ADDRESS THIS SAFETY ISSUE. *TR

TL* THE CONTACT OWNS A 2004 BMW 330I. THE CONTACT STATED THAT THE VEHICLE WAS PARKED AND HE NOTICED THAT THE LOW BEAM HEADLIGHTS WERE ILLUMINATED WITH AN INADEQUATE AMOUNT OF BRIGHTNESS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSIS AND THE TECHNICIAN STATED THAT THE PLASTIC REFLECTOR BOWLS WERE POORLY DESIGNED. THE TECHNICIAN ALSO STATED THAT THESE BOWLS MELTED OVER AN EXTENDED PERIOD OF TIME DUE TO HEAT EXPOSURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 56,000. THE VIN WAS UNAVAILABLE.

THE XENON PROJECTOR ASSEMBLY IS MADE OUT OF PLASTIC AND IS BURNING/MELTING. THE LIGHT OUTPUT IS ROUGHLY 20% OF THE ORIGINAL. *TR

THE DRIVER'S SIDE REAR TAIL LIGHT ASSEMBLY FAILED. RECEIVED A WARNING INDICATOR LIGHT ON THE DASH PANEL. REPLACING THE BULBS IN THE ASSEMBLY FAILED TO CORRECT THE PROBLEM. RESEARCHING THIS ISSUE I DISCOVERED THERE HAS BEEN AN EQUIPMENT RECALL FOR FAILED TAIL LIGHT ASSEMBLIES. *TR

THE VEHICLE CAME EQUIPPED FROM THE FACTORY WITH BI-XENON AUTO LEVELING HEADLIGHTS MANUFACTURED BY ZKW. THE PAST COUPLE MONTHS, THE LIGHT OUTPUT HAS STEADILY DECREASED. LOOKING AT IT FURTHER, BROWN SCORCH MARKS ARE VISIBLE IN THE PROJECTOR WHEN THE HEADLIGHT IS ON. ON THE DRIVER'S SIDE, THERE IS ALSO DISTORTION IN THE UPPER HALF OF THE PROJECTOR WHICH LOOKS ALMOST AS IF THE TOP HALF OF THE PROJECTOR HAS MELTED AND DISTORTED. THE LIGHT OUTPUT FROM THE PROJECTORS HAS BEEN REDUCED TO A THIN BEAM OF LIGHT RIGHT BELOW THE CUTOFF, WITH THE DRIVER'S SIDE BEING WORSE THAN THE PASSENGER. PARKED 6 FEET AWAY FROM A WALL, THIS STRIP OF LIGHT EXTENDS ONLY ABOUT 8-12" BELOW THE CUTOFF, PUTTING OUT VIRTUALLY NO LIGHT BELOW THAT. AT NIGHT, IT IS BECOMING VERY DIFFICULT TO SEE WITH NO LIGHT IN THE FOREGROUND; THIS PROBLEM IS GETTING PROGRESSIVELY WORSE. *TR

TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT STATED THAT THE HEADLIGHTS BECAME ABNORMALLY DIM, MAKING IT VERY DIFFICULT FOR THE CONTACT TO SEE THE ROAD AND OTHER VEHICLES. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS WHERE THEY ADVISED HIM THAT THE HEADLIGHT REFLECTOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 80,000. THE CURRENT MILEAGE WAS APPROXIMATELY 100,000. THE VIN WAS UNAVAILABLE.