NHTSA Complaint #10926533 — 2004 BMW 330CI

HEADLIGHT WIRING ON MY 2004 BMW 330CI DEGRADED PREMATURELY ACCELERATED BY HEAT AND HIGH VOLTAGE UNTIL IT CAUSED MY HEADLIGHT TO FAIL WHILE DRIVING ON THE INTERSTATE IN THE EARLY EVENING. THE SYMPTOM WAS CAUSED BY THE SUPPLY WIRES TO THE IGNITER LOSING THERE INSULATION AT STRESSED HARNESS ATTACHMENT POINT, ARCED OVER, AND CAUSED THE COPPER CONDUCTORS TO BECOME BRITTLE. THIS SYMPTOM WAS SEEN ON THE PROJECTOR ASSEMBLY WIRING AS WELL AS THE DAYLIGHT RUNNING LIGHT WHICH DID NOT EXHIBIT THE COPPER BREAKDOWN. INSULATION OF BOTH ASSEMBLIES CRUMBLED TO FLAKES WHEN TOUCHED AND RENDERED THE HEADLIGHT ASSEMBLY UNUSABLE. THIS FAULT COULD JUST AS EASILY CAUSE A FIRE IN THE HEADLIGHT ASSEMBLY DURING WHICH THE SPECIFIED HEADLIGHT FUSES MAY NOT PROVIDE PROTECTION TO THE ASSOCIATED VEHICLE SYSTEMS. THE ONLY PROVIDED SOLUTION FROM THE MANUFACTURER IS TO BUY A NEW ASSEMBLY FOR A COMPONENT WHICH SHOULD ONLY REQUIRE PERIODIC REPLACEMENT OF THE LAMPS WHEN THEY BURN OUT. FORTUNATELY MY CAR ALSO FLOOD LIGHTS WHICH HELPED TO LIGHT THE WAY WHEN THE HEADLAMP FAILED.