2003 BMW 325I Exterior lighting Problems

The xenon projector bowls in the headlight assembly on both sides of the vehicle have slowly been burning. The bowl is made of plastic and with the heat of the xenons burns the plastic creating not only a fire hazard but also greatly reduces the effectiveness of the headlight beam, rendering it almost useless. This is specific to the OEM manufacture of the headlight assembly, ZKW. This has also been well documented on various forums for these vehicles over the years.

NHTSA ID

11446729

Incident

Jan 4, 2022

THE PURPOSE OF THIS REQUEST IS TO GET BMW TO HONOR A REMEDY FOR TAILLIGHT DEFECT CAUSED AS A MANUFACTURING DEFECT. MY TAILLIGHT GROUNDING WIRES ARE CAUSING A SHORT ON TURNING SIGNALS. FURTHER RESEARCH INDICATED THIS HAS BEEN REPORTED NHTSA CAMPAIGN ID NUMBER: 11V438000. AFFECTED VEHICLES 325I - 2002-2005 BMW WILL NOT HONOR ITS PROPOSED REMEDY WITH NHTSA, CITING THE VIN HAS NOT BEEN IDENTIFIED IN RECALL. I CONTACTED BOTH DEALERSHIP IN STERLING VA AND CORPORATE BMW OF AMERICA (800-525-7417). BMW OF AMERICA WAS CONTACTED 7.15.2019. OPERATOR ANDREA EMPLOYEE # 6266 INFORMED ME THE CAR IS NOT COVERED UNDER REMEDY. MANUFACTURER: BMW OF NORTH AMERICA, LLC MFR'S REPORT DATE: AUG 25, 2011 NHTSA CAMPAIGN ID NUMBER: 11V438000 COMPONENT: EXTERIOR LIGHTING:TURN SIGNAL SUMMARY: BMW IS RECALLING CERTAIN MODEL YEAR 2002-2005 325I, 325XI, 330I, AND 330XI VEHICLES MANUFACTURED FROM SEPTEMBER 1, 2001, THROUGH MARCH 1, 2005. OVER TIME, RESISTANCE IN THE ELECTRICAL CONTACTS MAY CAUSE ONE OR MORE REAR LAMP FUNCTIONS (TAIL LIGHT, BRAKE LIGHT, AND/OR TURN-SIGNAL), WITHIN THE VEHICLE'S BODY PANEL, TO STOP WORKING. CONSEQUENCE: INTERMITTENT LIGHT OPERATION REDUCES THE ABILITY TO WARN OTHER MOTORISTS OF THE DRIVER'S INTENTIONS. THIS COULD CAUSE A VEHICLE CRASH WITHOUT WARNING. REMEDY: BMW WILL NOTIFY OWNERS, AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING OCTOBER 2011. OWNERS MAY CONTACT BMW CUSTOMER RELATIONS AND SERVICES AT 1-800-525-7417. THE RECALL IS FOR MODEL YEARS 2002-2005 OF THE 325I, 325XI, 330I AND 330XI CARS, THE MUNICH-BASED COMPANY SAID TODAY IN A POSTING ON THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S WEBSITE. LIGHTS INCLUDING TAIL, BRAKE AND TURN SIGNALS MAY ONLY WORK INTERMITTENTLY ON THE CARS, BMW TOLD THE AUTO-SAFETY REGULATOR.

NHTSA ID

11231883

Incident

Jul 15, 2019

MY REAR WINDOW AND THE ROOFTOP DONT WORK I CAN HEAR THE MOTORS BUT NOTHING HAPPENS A TECHNICIAN EXPLAIN THAT THE REGULATOR AND LINES ARE BROKEN ITS A COMMON THING ON MY MODEL HE SPECIFIED.

NHTSA ID

11229396

Incident

Nov 27, 2018

DRIVING AT NIGHT HAS BECOME IMPOSSIBLE WITH OUT RISK. THE ZKW XENON HEADLIGHTS HAVE BECOME SO DIM THAT THE FOG LIGHTS NOW PROVIDE MORE ILLUMINATION. THE PROBLEM HAS BEEN TRACED TO BURNED/DISCOLORED PLASTIC REFLECTOR BOWLS ON BOTH SIDES WITH THE PASSENGER SIDE BEING SLIGHTLY WORSE. AFTER RESEARCH IT APPEARS THIS PROBLEM IS WIDE SPREAD IN ZKW HEADLIGHTS. THERE ARE SEVERAL REPORTS HERE AND IT APPEARS BMW ALSO REALIZED THE PROBLEM AND HAD ZKW SWITCH TO METAL REFLECTOR BOWLS ON NEWER MODELS YET OFFER NO SOLUTION OTHER THAN BUY COMPLETE HEADLIGHT ASSEMBLY'S TO THE TUNE OF $1200 A SIDE. MIGHT A POSSIBLE RECALL MOTIVATE BMW TO AT LEAST OFFER THE INDIVIDUAL PART. I UNDERSTAND THE VEHICLE IS ALMOST 13 YEARS OLD BUT TO TREAT A BLATANT SAFETY ISSUE LIKE THIS IS RIDICULOUS. NHTSA PLEASE HELP SOLVE THIS SAFETY RELATED PROBLEM.

NHTSA ID

10850908

Incident

Jan 15, 2016

Mileage

95,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I EQUIPPED WITH ZKW BI-XENON HEADLIGHTS. WHILE DRIVING 70 MPH, THE HEADLIGHTS DIMMED AND DIMINISHED THE CONTACT'S VISIBILITY. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO STATED THAT THE HEADLIGHTS NEEDED TO BE REPLACED. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 80,000.

NHTSA ID

10733246

Incident

Jul 5, 2015

Mileage

80,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE REAR BRAKE LIGHTS FAILED TO ILLUMINATE. THE CONTACT REPLACED THE BULBS BUT THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT WAS MADE AWARE OF RECALL NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING), BUT DID NOT RECEIVE NOTIFICATION. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 200,000.

NHTSA ID

10660459

Incident

Aug 15, 2012

Mileage

200,000 mi

MY CURRENT VEHICLE IS A 2003 BMW 325I WITH BI-XENON HEADLIGHTS MANUFACTURED BY ZKW. OVER THE LAST YEAR OR TWO, THE LIGHT OUTPUT FROM THE XENON HEADLIGHTS HAD DROPPED TO THE POINT WHERE I GET ALMOST NO NOTICEABLE ILLUMINATION OF THE ROAD AT NIGHT (IN AVERAGE CITY LEVELS OF STREET ILLUMINATION). I TURNED TO USING MY FOGLAMPS TO BE ABLE TO SEE ANYTHING. MECHANIC INSPECTED THE HEADLIGHT ASSEMBLY AND THE UPPER PORTION OF THE PROJECTOR BOWLS ARE BURNED. THEY ARE MADE OF PLASTIC AND PAINTED WITH REFLECTIVE PAINT, BUT THE UPPER ~60% OF THE BOWL IS NOW BROWNED AND NONREFLECTIVE. THIS IS DUE TO AN INABILITY OF THE PAINT TO WITHSTAND THE HIGH TEMPERATURES GENERATED BY THE XENON BULBS. ALSO, THIS SEEMS TO BE COMMON TO MANY/ALL ZKW BRAND HEADLIGHTS UTILIZED IN 2003-2004 MODEL YEARS OF 3 SERIES (E46) BMW VEHICLES, ACCORDING TO POSTINGS ON THE BMW-OWNER FORUMS. REFLECTOR BOWLS CAN NOT BE PURCHASED AND REPLACED SEPARATELY AND THE ENTIRE HEADLAMP ASSEMBLY MUST BE REPLACED AT A COST OF APPX $2400. ZKW HAS CHANGED THE DESIGN SO THERE IS SUFFICIENT EVIDENCE TO SUGGEST THAT THEY AND BMW ARE AWARE OF THE DESIGN FLAW AND RESULTING SAFETY HAZARD. *TR

NHTSA ID

10610030

Incident

Jan 31, 2014

Mileage

130,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT THE REAR PASSENGER'S SIDE TAIL LIGHT FAILED. THE CONTACT REPLACED THE BULB MORE THAN ONCE BUT THE FAILURE RECURRED. THE CONTACT THEN LEARNED OF NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: TURN SIGNAL). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE FAILURE AND CURRENT MILEAGE WAS 125,000. *TR

NHTSA ID

10551392

Incident

Feb 6, 2013

Mileage

125,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT THE BRAKE LIGHTS AND THE TURN SIGNALS FAILED. THE CONTACT CHECKED THE WIRING HARNESS AND FOUND THAT THE HARNESS WAS MELTED. THE CONTACT SPOKE WITH THE MANUFACTURER REGARDING NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: BRAKE LIGHTS), BUT WAS TOLD THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE FAILURE MILEAGE WAS 105,000 AND THE CURRENT MILEAGE WAS 110,000.

NHTSA ID

10494486

Incident

Jul 2, 2012

Mileage

105,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT THE REAR PASSENGER TAIL LIGHT FAILED. THE CONTACT REPLACED THE BULB TWICE BUT THE FAILURE RECURRED. THE CONTACT MENTIONED THAT AFTER INSPECTING THE VEHICLE HE NOTICED THAT THERE WAS A SHORT IN THE ELECTRICAL SYSTEM. THE CONTACT WAS THEN INFORMED OF RECALL NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: TURN SIGNAL). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS. THE FAILURE AND CURRENT MILEAGE WAS 100,000.

NHTSA ID

10478591

Incident

Sep 28, 2012

Mileage

100,000 mi

THE WARNING LIGHT FOR MY PASSENGER SIDE TAIL LIGHT HAS BEEN GOING ON AND OFF FOR MONTHS AS IF THERE IS A SHORT IN IT. IT STAYED ON PERMANENTLY THIS MONTH, SHOWING A DIMMER LIGHT THAN THE WORKING SIDE TAIL LIGHT, SO I HAD IT CHECKED WHEN I HAD THE OIL CHANGED AT MY BMW MECHANIC. HE INFORMED ME THERE WAS A RECALL FOR TAIL LIGHT ASSEMBLIES FOR MY VEHICLE AND TOLD ME TO CALL THE DEALER TO CHECK THE VIN NUMBER. I CALLED THE DEALER LAST FRIDAY, JUNE 22, 2012 AND WAS INFORMED THAT MY VEHICLE WAS PART OF THE RECALL AND THAT SOMEONE WOULD CALL TO MAKE AN APPOINTMENT FOR THE WORK. NO ONE CALLED, SO I CALLED AGAIN TODAY AND THEY SAID THE VIN WAS NOT PART OF THE OPEN RECALL. THE TAIL LIGHT IS ACTING LIKE THE OTHER TAIL LIGHTS THAT WERE RECALLED SO I DO NOT UNDERSTAND HOW IT CANNOT BE PART OF THE RECALL. *TR

NHTSA ID

10463612

Incident

Jun 12, 2012

Mileage

122,426 mi

LOW BEAM REFLECTORS ON 2003 ZKW HID XENON HEADLIGHTS WAS BURN AND SCORCHED AND POSTED AS A FIRE RISK. THE SCORCHED REFLECTOR ALSO REDUCE THE LOW BEAM LIGHT OUTPUT AND POSTS AS A DRIVING HAZARD. *TR

NHTSA ID

10456624

Incident

May 1, 2009

Mileage

55,000 mi

2003 BMW 325I. CONSUMER REQUESTS REIMBURSEMENT FOR RECALL REPAIRS PRIOR TO RECALL NOTIFICATION. *TGW THE CONSUMER STATED THE VEHICLE WAS SERVICED SEVERAL TIMES, TO CORRECT THE PROBLEM REGARDING THE REAR LAMPS. THE CONSUMER STATED SINCE SEVERAL OF THE REPAIRS WERE DONE PRIOR TO THE TIME FRAME ESTABLISHED BY THE RECALL, SHE WAS ONLY REIMBURSED PARTIALLY. RECALL# 11V438000. *JB

NHTSA ID

10449879

Incident

Jan 25, 2003

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT THE REAR PASSENGER SIDE TAIL LIGHT WOULD FAIL INTERMITTENTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS ADVISED THAT THE VEHICLE WAS FUNCTIONING AS DESIGNED. THERE WAS A SMALL ELECTRICAL FIRE FROM THE TAIL LIGHTS. THE MANUFACTURER WAS CONTACTED, BUT DENIED ASSISTANCE WITH THE REPAIR BECAUSE THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING:TAIL LIGHTS . THE FAILURE MILEAGE WAS 53,000 AND THE CURRENT MILEAGE IS 94,000. THE CONSUMER STATED THE INTERMITTENT ISSUE WITH THE TAIL LIGHTS WAS IGNORED FOR MANY YEARS. UPDATED 02/23/12

NHTSA ID

10448203

Incident

Dec 1, 2008

Mileage

53,000 mi

PURCHASED VEHICLE NEW WHILE I WAS STATIONED WITH THE US AIR FORCE IN GERMANY, TO MY UNDERSTANDING IT WAS MADE IN GERMANY UNLIKE MOST 325'S AT THE TIME. IT WAS PRODUCED UNDER US SPECIFICATIONS AS I'D PLANNED TO BRING IT BACK TO THE STATES. I HAVE CONTINUOUSLY HAD PROBLEMS OVER THE YEARS WITH THE EXTERIOR LIGHTING TURN SIGNAL ACTING INTERMITTENTLY AS MENTIONED IN RECALL NHTSA CAMPAIGN ID NUMBER: 11V438000. HOWEVER, AFTER CONTACTING MY LOCAL BMW DEALER, AND BMW N.A., THEY HAVE INFORMED ME MY VIN ISN'T COVERED UNDER THE RECALL. I BELIEVE I MAY HAVE SLIPPED THROUGH THE CRACKS AS A VIN IDENTIFIED IN THE RECALL AS MY BMW WAS PRODUCED OUTSIDE THE NORMAL CHANNELS OF BMWS AFFECTED IN NORTH AMERICA. I BELIEVE THIS BECAUSE MY VEHICLE EXHIBITS THE EXACT CHARACTERISTICS OF THE RECALL IN QUESTION. I WOULD LIKE MY VIN INCLUDED ON THE RECALL AS EVEN TODAY DRIVING THE VEHICLE THIS MORNING I DIDN'T FEEL SAFE BECAUSE THE TURN SIGNAL IS INTERMITTENT. *TR

NHTSA ID

10447909

Incident

Feb 14, 2012

Mileage

154,000 mi

TAIL LIGHTS CONTINUE TO FAIL ON THIS MODEL. CALLED THE MANUFACTURER, BMW, AND THEY SAID THAT EVENTHOUGH A RECALL EXISTS FOR 2003 BMW 325I MODELS FOR TAIL LIGHT FAILURE (ID NO. 11V4380000), MY VIN NUMBER DID NOT CORRESPOND TO PRODUCTION RUN FAILURES UNDER RECALL. *TR

NHTSA ID

10443539

Incident

Jan 3, 2005

Mileage

12,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT THE REAR TAIL LIGHT FAILED. THE CONTACT EXAMINED THE VEHICLE AND FOUND THAT THE REAR TAIL LIGHT WIRES WERE BURNED. THE MANUFACTURER WAS CONTACTED AND ADVISED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING:TURN SIGNAL). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 60,000 AND THE CURRENT MILEAGE WAS 161,000.

NHTSA ID

10443199

Incident

Jan 2, 2006

Mileage

60,000 mi

XENON HEADLIGHT REFLECTORS ARE MELTING/BURNING CAUSING A SIGNIFICANT REDUCTION IN LIGHT OUTPUT. VERY SIMPLE PROBLEM FOR WHICH THERE IS NO FIX OTHER THAN TO PURCHASE NEW HEADLIGHT ASSEMBLES FOR $2,000. SEEMS TO AFFECT ALL XENON HEADLIGHTS PRODUCED BY ZWK FOR THE 2002-2004 3 SERIES BMW. *KB

NHTSA ID

10441640

Incident

Dec 29, 2011

Mileage

67,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT WAS DRIVING 20 MPH WHEN THE TURN SIGNAL FAILED TO ILLUMINATE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE DEALER CONFIRMED THAT THE TURN SIGNAL WIRING AND THE BRAKE LIGHTS BURNED OUT. THE MANUFACTURER WAS CONTACTED WHERE THEY ADVISED THAT THE VEHICLE QUALIFIED FOR REPAIRS UNDER NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: TAIL LIGHTS), BUT THE CONNECTOR WAS NOT INCLUDED. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNAVAILABLE. THE FAILURE AND THE CURRENT MILEAGES WERE 110,000.

NHTSA ID

10440210

Incident

Dec 14, 2011

Mileage

110,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. WHILE MAKING A RIGHT TURN AT APPROXIMATELY 5 MPH, THE TURN SIGNAL LIGHTS FAILED TO ILLUMINATE. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: TURN SIGNAL) BUT WAS ADVISED BY THE MANUFACTURER THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 78,600.

NHTSA ID

10439059

Incident

Nov 24, 2011

Mileage

78,600 mi

RIGHT TAILLAMP FAILURE AND LEFT TAILLAMP INTERMITTENT OPERATION. ELECTRICAL SYSTEM REPAIR: RIGHT REAR TAILLAMP CONNECTOR AND BULB CARRIER CORRODED. DEALER REPLACED PIGTAIL HARNESS AND BULB CARRIER WITH UPDATED DESIGN: SOCKET HOUSING, TERMINAL, CONTACT, CABLE CONNECTOR, HOSE, INSULATION HOUSING, FLAT CONTACT, CABLE SOCKET AND BULB SOCKET. *TR

NHTSA ID

10438169

Incident

Jul 3, 2010

Mileage

75,172 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT WAS DRIVING APPROXIMATELY 25 MPH AND WHEN THE BRAKE PEDAL WAS ENGAGED, THE DRIVER SIDE TAIL LIGHT INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL INTERMITTENTLY CAUSING THE REAR DRIVER SIDE TAIL LIGHT TO BECOME INOPERABLE. THERE WAS A RECALL RELATED TO THE SIMILAR DEFECT UNDER NHTSA CAMPAIGN ID NUMBER 11V438000 (EXTERIOR LIGHTING: TAIL LIGHTS). THE VIN WAS NOT INCLUDED IN THE RECALL AND THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.

NHTSA ID

10434793

Incident

Oct 1, 2011

Mileage

130,000 mi

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT BOTH REAR TAIL LIGHTS FAILED. THE CONTACT WAS ADVISED OF A RECALL UNDER NHTSA RECALL CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: TAIL LIGHTS) BY HIS MECHANIC. THE MANUFACTURER WAS CONTACTED BUT ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE CURRENT MILEAGE VEHICLE WAS 90,000 AND THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10432782

Incident

Oct 21, 2011

TL* THE CONTACT OWNS A 2003 BMW 325I. THE CONTACT STATED THAT THE EXTERIOR TAIL LIGHTS BURNED THROUGH THE HOUSING HARNESS. THE VEHICLE WAS TAKEN TO THE DEALER WHO ADVISED THE CONTACT THAT HIS VIN WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: TAIL LIGHTS). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE WHO OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 60,250.

NHTSA ID

10430854

Incident

Sep 19, 2011

Mileage

60,250 mi

THE REAR STOPLIGHTS, TAILLIGHTS, AND TURN SIGNALS HAVE FAILED ON MULTIPLE OCCASIONS. *TR

NHTSA ID

10430140

Incident

Oct 15, 2009