2006 BMW 325CI — Problems, Recalls & Safety Data

Internal Adaptive bi-xenon headlight wiring insulation flaking off exposing bare wire, thus causing headlight to fail

The headlights in my car both went out because of this wiring issue. The wiring insulation inside the headlight is very prone to cracking and subsequently breaking which causes the headlight to not function. I have repaired this issue myself on both headlights for almost every wire going into the igniter. No headlights is a major safety issue at night, and due to the cracking along all of the wiring, it could go out at any time again. I had this issue looked at by the dealership and they tried to sell me new bulbs instead. In the picture you can see the 3 repaired wires already and the 4th needed repair, the black wire, got severed.

The contact owns a 2006 BMW 325CI. The contact stated while stopped at a traffic light, she became aware of smoke coming from under the hood and the odor of something on fire. The vehicle had overheated on several occasions. There were no warning lights illuminated. The vehicle was towed to a dealer who diagnosed the vehicle with PCV valve heater failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 142,000.

TL* TAKATA RECALL. THE CONTACT OWNS A 2006 BMW 325CI. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 20V018000 (AIR BAGS) HOWEVER, THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. BMW OF LOUISVILLE (2200 BLANKENBAKER PKWY, LOUISVILLE, KY 40299, (502) 287-1501) WAS CONTACTED AND CONFIRMED THAT THE PART WAS NOT AVAILABLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

DRIVERS SIDE LOW BEAM STARTED FLASHING WHEN CAR HIT BUMPS AND WHILE TURNING THE STEERING WHEEL TO THE RIGHT. OPENED BULB ACCESS COVER TO CHECK THE BULB AND FOUND THAT THE MAJORITY OF THE WIRING INSIDE THE HEADLIGHT ASSEMBLY HAS HARDENED AND FLAKING INSULATION, EXPOSING BARE COPPER WIRE AND ALLOWING IT TO SHORT OUT. REMOVED THE HEADLIGHT ASSEMBLY FOR A MORE THROUGH INSPECTION AND DISCOVERED THE SAME DAMAGE ON THE HIGH BEAM WIRING AND DETERIORATION ON THE ENTIRE WIRING HARNESS INSIDE THE LIGHT. SERIOUS SAFETY RISK AS WELL AS FIRE RISK.