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.
BMW 325I headlights problems
50 of the 1,367 owner complaints about the BMW 325I describe headlights failing or too dim, most of them for the 2004 model year.
- owner complaints
- 50
- worst model year
- 2004
- typical repair cost reported
- $1,200
- typical mileage
- 80,000
Is there a fix? There are 2 recalls for this area of the car. See below
By model year
Often reported together
Fire or smoke 2Wipers 1Sunroof shattered 1Power windows 1Overheating 1Airbag light 1
What owners say
The reflector bowl on the headlights burns, creating a severely decreased output. This is an issue known by many people in the bmw community. Https://www.bimmerfest.com/threads/e46-zkw-reflector-recall-open-the federal safety agency-investigation.552978/
2006 bmw 325i the biodegradable wiring has deteriorated causing the directional and headlamps to fail resulting in expensive repairs and jeopardizes the safety of the drivers of the vehicle while in use.
Tl* the contact owns a 2004 bmw 325i. The contact stated that the headlights failed. The contact inspected the vehicle and found that the headlight housing material was deteriorated and prevented the headlights from providing adequate illumination. The dealer and manufacturer were not contacted. The vehicle was not diagnosed or repaired. The failure mileage was 140,000.
Headlights have lost brightness and coverage and do not illiuminate the road properly. Vehicle is equipped with hid xenon lights package and when new were extremely bright but now are very dim. Original equipment with no modifications or accidents.
Tl* the contact owns a 2004 bmw 325i. While operating the vehicle, the low beam headlights became dim and it was difficult to view the road. The vehicle was taken to the dealer where it was diagnosed that the zeon projector in the headlight assembly failed. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 100,000.
Hid (xenon) headlights very dim. Can barely tell they are on when driving at night. (the fog lights are much brighter than the headlights). Creates a dangerous situation when driving at night. Headlight assemblies manufactured by zkw. The reflective material deteriorates inside the headlight assembly leading to very poor light output. Issue has been reported over and over. I guess it's not important enough until somebody dies because of the issue, that is if that hasn't already happened....the ridiculous cost of fixing the issue compounds the problem. Sorry I don't have an extra $2,000.00 laying around to replace my defective headlights. Come on bmw step up to the plate and fix the problem you're very well aware of, please.
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.
Passenger side headlight bulb on zkw labeled headlight assembly melted reflector badly. Removed headlight bulb due to chance of catching fire. Headlight reflector damaged beyond repair and unable to mount headlight bulb. Issue noticed while driving on interstate where passenger headlight started loosing brightness and shining towards right side of vehicle. Pulled over and smelled burning plastic. Housing is black from burning.
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.
Related recalls
Exterior lighting: turn signal
- What is wrong
- 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.
- Risk
- 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 began on february 15, 2012. Owners may contact bmw customer relations and services at 1‑800‑525‑7417.
Recall number 11V438000 · Recall details
Exterior lighting: brake lights: switch
- What is wrong
- The brake light switch can fail allowing the switch to remain in the "brake lights off" position or in the "brake lights on" position.
- Risk
- If this happens, the brake lights either will not operate or will be continuously on, regardless of brake pedal position. Following drivers would not be able to determine whether the vehicle is stopping, increasing the potential for a vehicle accident.
- Remedy
- Dealers will replace the existing brake light switch with a newly designed switch.
Recall number 96V111000 · Recall details
Questions about the BMW 325I headlights
Which BMW 325I years have headlights failing or too dim problems?
The model years with the most reports are 2004 (14 complaints), 2003 (13 complaints) and 2006 (8 complaints).
How much does it cost to fix headlights failing or too dim on the BMW 325I?
Owners who mentioned a price put the repair at about $1,200 (median of 8 complaints that include a dollar amount). Costs vary with mileage, warranty and where the work is done.
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