2004 BMW 330I Electrical System Problems

Unknown

Two hours after I got to work one of my coworkers came running in the backroom, And told me my car was on fire.

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.

Mileage: 145,000

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

Mileage: 120,000

I PURCHASED THE CAR, I NOTICED THE HEADLIGHTS WHERE DIM. I WENT OUT AND GOT NEW BULBS FOR MY CAR. I DIDN'T HELP AT ALL! I CAN BARELY SEE AT NIGHT AND I HAVE TO USE TO FOG LIGHTS JUST TO BE ABLE TO DRIVE AT NIGHT. IT IS ALSO UNLAWFUL TO DRIVE WITH MY FOG LIGHTS ON. AFTER MUCH RESEARCH, IT SEEMS THAT THE ROOT CASE OF MY HEADLIGHT BEING AS DIM AS THEY ARE, DO TO THE REFLECTIVE BOWL BEING BURNT OUT IN THE HEADLIGHT IT UNIT. THE COST TO REPLACE THE LIGHTS IS INSANE $1000.00 FOR A SET, JUST TO BE ABLE TO SEE AT NIGHT. IT IS UNSAFE TO DRIVE AT NIGHT. IT IS SO BAD, THAT I OFTEN DON'T DRIVE AT NIGHT BECAUSE I DON'T WANT TO PUT MY SAFE IN A BAD SITUATION. *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

Mileage: 99,960

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

Mileage: 68,000

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

Mileage: 92,000

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

Mileage: 112,000

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

Mileage: 70,000