2004 BMW 330I Electrical System Problems

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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.

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...

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

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...

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...

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...

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