2003 BMW 325I: headlights failing or too dim

Filed Jan 8, 2022 · Lights · CA

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.

Filed Mar 21, 2016 · Lights · 95,000 miles · WA

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. The federal safety agency please help solve this safety related problem.

Filed Jul 10, 2015 · Lights · 80,000 miles · CA

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.

Filed Jul 12, 2014 · Lights · 130,000 miles · AZ

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.

Filed Apr 26, 2012 · Lights · 55,000 miles · CA

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.

Filed Dec 29, 2011 · Lights · 67,000 miles · PA

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.

Filed Mar 10, 2011 · Lights · 75,000 miles · TX

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. After researching this problem on online forums, I examined the headlights myself and found that the upper portion of the projector bowls seem burned. They are made of plastic and painted with reflective paint, but the upper ~40% of the bowl is now browned and nonreflective. Apparently 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. For now, I have tried to remedy this by lining the burnt portion of the bowl with aluminum foil and can now notice some illumination of the road at night. This further argues that the burning/loss of reflective coating is what causes the loss of light output.

Filed Aug 10, 2010 · Lights · 72,000 miles · CA

The zkw brand of high intensity discharge (hid) headlights equipped in the 2003-2004 e46 model 3 series bmw sedan have a plastic reflector bowl in the projector that has the tendency to have the chrome reflective plating burnt off rendering the headlights all but useless. This makes it dangerous to drive at night because you can barely see the road. The only remedy to this is to replace the entire headlight assemblies for $1200 per side, which is unacceptable for non wear item to occur when the vehicle is between 5 to 7 years old, averaging 50k to 90k miles.

Filed Jul 5, 2010 · Electrical, Lights · IA

We own a bmw 325i series 2003 sedan. While my daughter started the car she noted the left headlight went out on the driver's side of the car. She was only around 4 blocks away so proceeded to drive home and during the drive she experienced her brakes grabbing and steering difficulties. All the dashboard indicator lights came on. We took the car that night to bmw to drop off for evaluation. The service manager stated that the xenon headlight failed and took at the steering system panel and had to be all rewired. He said they had never seen this happen before. I am concerned this is a safety concern in the wiring of the xenon headlight to effect a steering panel when the headlight goes out. The effect on the steering panel is immediate and gives no time to replace the headlight without further damage to the car. The cost to repair was 1800.00. This is very concerning. 2 months later the blinker headlight next to the xenon headlight fell completely out of the car held by a wire while my daughter was driving on the highway. It seems like there is an issue with the bmw 325i series headlights that to me is a great safety concern for those driving. I would appreciate your follow up to the make and model. I would be glad to provide my name for you to obtain copies of the service records on these events from our bmw dealership. Thank you.

Filed Feb 11, 2010 · Lights · 40,000 miles · MN

The right front headlight will go off sporadically and right rear tail light goes off. The dealer could not correct the headlight problem. The tail light problem began while car was in warranty. Now to correct taillight problem there is update kit which they want me to pay. Since taillight problem began in warranty bmw should cover cost.

Filed Jan 21, 2010 · Engine, Lights · 90,000 miles · GA

Own a bmw 3251, rear end started making popping noise when put in reverse and when turning curves. When on interstate rear end locked up while driving causing my car to skid through all lanes of traffic. After having car inspected the rear end had broke, we replaced the rear end. Also having trouble with head lights staying on and blinkers. Right rear tail light over heated and burnt items in trunk. Radiator has broke and driverside window regulator and clutch fan.

Filed Sep 11, 2007 · Body, Electrical · 37,763 miles · PR

Four times since I buy a 2003 bmw 325i , I have to get the auto to guarantee service for replacement of the struct front bushing, now , after replace them at 32,000 miles about four month ago, my car at 37,000 miles request a new bushings. They said me that bmw was no longer replace them by guarantee because of the road conditions in puerto rico. When I buy the car I paid for a guarantee and I think that is impossible that a car like this , the ultimate drive machine require every four month to replace that parts. They should install a good reinforced genuine parts and not a remanufactured. I always try to avoid the holes, but I ask when it's raining it start a red light that indicated " please avoid this hole" . *tr the dealer stated replaced lens and cover disc for both headlights, noises coming from both rear shock absorbers, replacing alternator drive belt tensioner, tensioner and pulleys, and removing and installing left or right rubber strip. Updated 10/24/07