2003 BMW 330I: headlights failing or too dim

Filed Nov 13, 2015 · Lights · 100,000 miles · NY

The low beam reflectors on 2003-2004 zkw hid headlights were made of some material that degraded when subjected to the heat produced by oem xenon bulbs. This results in a significant decrease in light output as the reflector became scorched. I don't know the exact ins and outs, but I would imagine that bmw and zkw were and are aware of the defect as the newer, redesigned headlights do not suffer from this problem.

Filed Oct 9, 2015 · Lights · 150,000 miles · CA · fire

Tl* the contact owns a 2003 bmw 330i. While driving approximately 65 MPH, the passenger side headlight caught fire. The contact extinguished the fire. The vehicle was taken to an independent mechanic where it was diagnosed that the headlight needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of failure. The approximate failure mileage was 150,000. The VIN was not available.

Filed Sep 25, 2014 · Lights · 114,000 miles · WI

This car suffers from the known burnt xenon low beam bowls, its impossible to see anything at night and is not safe. This needs to be recalled by bmw immediately, headlights have been adjusted properly and new bulbs were put in and does not cure the problem. Its very common for these xenon headlights to have this problem in alot of 2003+ bmw 3 series.

Filed Sep 18, 2014 · Lights · 83,482 miles · UT

Bi-xenon headlights manufactured by zkw have a serious design defect. After only 80,000 miles, the headlights are almost completely ineffective at night time. Upon inspection, the reflective bowl in the headlight assembly was burnt, blackened and melted. Not only is this a safety issue for driving at night, but it could potentially be a fire hazard. Upon doing some research, this appears to be a serious problem, evidenced by many complaints on various bmw message forums. Something needs to be done about this before it leads to fire or accident.

Filed Jul 24, 2014 · Lights · 96,000 miles · CT

Xenon headlights. Dim to dark at best. Work when they want.

Filed Nov 14, 2013 · Lights · 90,000 miles · TX

I'm contacting you to express my frustration with the quality of the bmw xenon headlight. The xenon low beams started to dim and are now useless. Through google I found out that this is a very common problem since the plastic reflector/projector bowls just burn out. The light output is now too low to be safe at night. Http://www.zhpmafia.com/forums/showthread.php?3625-zkw-reflector-recall-open-nthsa-investigation&s=b19d0df67f3afe70ac7ad8205496e414.

Filed Mar 1, 2013 · Lights · MA

The headlights on the car seems to be very dim. The amount of light that comes out of the headlights looks slightly brown and pretty dark as compared to many other cars on the road. I believe that the headlights were designed with plastic and which case the bulb would cause things to burn over time.

Filed Oct 12, 2012 · Electrical, Lights · 120,000 miles · NC

About 2 or so years ago I started to notice my night driving was becoming unpleasant and unsafe due to the fact that my headlights were losing output. After replacing the plastic lenses new from bmw I then went on to buying new bulbs thinking that would make a diff. It didn't. 10-12-12 today my lights are yellow/foggy on the inside like smoke has made the lenses opaque and my output is barely seen, I looked on the back where the bulb is inserted and it sure looks brown in there, I get more light reflected on the ground when I turn my turn signals than I do on the headlights. After going online and searching, my car came from factory with a defect zkw xenon headlight system, which 99% of the zkw headlight owners of e46 sedans found online have the same issue, all you have to do is google "e46 zkw burnt bowls" . I have a 4 month old little girl, I cannot imagine driving with her in the car on a rainy night and my concern is now my baby. I can send you pictures if needed please, thank you for reading and I appreciate your help.

Filed Sep 21, 2012 · Lights · 46,000 miles · TX

Car is equipped with optional, factory-installed, bi-xenon headlamp assemblies made by zkw. The projector bowls inside, which greatly magnify the light output of the bulb, are made of a plastic that cannot handle the heat of the xenon bulb. As a result, the reflective surface burns and turns brown. In doing so, the light output is greatly reduced to a dangerous level. This problem affects both high and low beam operation. Situation gets progressively worse over time. The plastic bowls are not sold separately, therefore the only solution is to purchase new headlamp assemblies, at an approximate cost of $1,900 for the pair.

Filed May 13, 2012 · Lights · 125,000 miles · TN

Burned headlight reflector bowl on 2003 "zkw" headlight housings. Headlamp output severely diminished. Also equipped on 03-05 3-series.

Filed Feb 25, 2012 · Lights · 108,000 miles · KS

I have encountered a failure of the factory xenon headlamp assembly. I have had reduced visibility as a result of a burnt bulb housing that did not make itself readily apparent. Because there is no remedy outside of replacing the poorly designed housing, I have a concern of the safety of myself, my occupants, and others on the road. A failed bulb is understandable maintenance. A failed headlamp assembly due to burning and cracking the plastic lens from so much heat is not. This is a poor design, and should warrant a recall.

Filed Nov 13, 2011 · Electrical, Lights · 72,577 miles · CA

Intermittent failure of driver and passenger side tail light assembly due to burnt connector pins and connector housing. Inadequate connector/wire rating. Should be subject of a recall from a responsible car manufacturer. Unsafe to drive in the dark. Blemish on the ultimate driving machine. Intermittent failure of the mostly passenger side head light. Occasional failure of the driver side head light. Normally the light bulb would require replacement, but often the whole lighting unit is considered failing by the dealer. Cost of replacement is extremely high.