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.

- Los Angeles, CA, USA

The purpose of this request is to get BMW to honor a remedy for taillight defect caused as a manufacturing defect. My taillight grounding wires are causing a short on turning signals. Further research indicated this has been reported NHTSA campaign id number: 11V438000. Affected vehicles 325I - 2002-2005 BMW will not honor its proposed remedy with NHTSA, citing the VIN has not been identified in recall. I contacted both dealership in sterling va and corporate BMW of America (800-525-7417). BMW of America was contacted 7.15.2019. Operator andrea employee # 6266 informed me the car is not covered under remedy. Manufacturer: BMW of North America, llc mfr's report date: Aug 25, 2011 NHTSA campaign id number: 11V438000 component: Exterior lighting:turn signal summary: 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. Consequence: 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 is expected to begin during October 2011. Owners may contact BMW customer relations and services at 1-800-525-7417. The recall is for model years 2002-2005 of the 325I, 325xi, 330I and 330xi cars, the munich-based company said today in a posting on the National Highway Traffic Safety Administration's website. Lights including tail, brake and turn signals may only work intermittently on the cars, BMW told the auto-safety regulator.

- Sterling, VA, USA

My rear window and the rooftop dont work I can hear the motors but nothing happens a technician explain that the regulator and lines are broken its a common thing on my model he specified.

- North Hills, CA, USA

Brake lights on both sides gets stuck on once the pedal is pressed. This produces no error codes. I was told it could be the brake pedal pressure sensor switch. I changed this and it did nothing. This is very dangerous to other drivers because they are not sure if the car is braking as the light is always on and will burn out the bulbs and melt the housing if constantly on. This can be reproduced either while parked or in motion.

- Chicago, IL, USA

The contact owns a 2003 BMW 325ci. While operating the vehicle, smoke was present under the hood. Upon inspection, it was discovered that the smoke was coming from the fog lights. The contact later discovered that the fog lights, signal lights, high beams, and passenger side brake light were not operating. The cause of the failure was not diagnosed. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 120,000.

- Tehachapi, CA, USA

The zkw xenon headlights have a flaw in the plastic projector housing. The housing gets too hot and melts and the light output is severely restricted. This happens to 100% of the headlights made by this manufacturer and is a safety issue. The reflective coating on the headlights melts and the light can no longer be projected out correctly. The fog lights are now brighter then the headlights. The vehicle can no longer be safely driven at night. Spare parts are not available and the only fix is to replace the entire headlights at a cost of over $2000. There should be a recall to replace the headlights as this is a safety issue of not being able to see.

- Lincoln, NE, USA

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. NHTSA please help solve this safety related problem.

- Kenmore, WA, USA

The contact owns a 2003 BMW 325I. The contact stated that while driving approximately 20 mph, the rear brake lights failed to illuminate. The contact replaced the bulbs but the failure recurred several times. The vehicle was not diagnosed or repaired. The contact was made aware of recall NHTSA campaign id number: 11V438000 (exterior lighting), but did not receive notification. The manufacturer was not notified of the failure. The approximate failure mileage was 200,000.

- Branford, CT, USA

The contact owns a 2003 BMW 325xi. The contact stated that the headlights failed to function and were detached from the housing. The vehicle was taken to the dealer who stated that the housing compartment and bulbs needed to be replaced. The vehicle was not repaired. The failure mileage was 133,000.

- Mephis, TN, USA

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.

- Tucson , AZ, USA

There is limited light output from the xenon/hid headlight assemblies due to "melted" projector bowls from BMW. This is a serious safety defect that prevents end users from being able to see the road and objects ahead of them.

- Mission Viejo, CA, USA

The contact owns a 2003 BMW 325I. The contact stated that the rear passenger's side tail light failed. The contact replaced the bulb more than once but the failure recurred. The contact then learned of NHTSA campaign id number: 11V438000 (exterior lighting: Turn signal). The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in the recall. The failure and current mileage was 125,000.

- Oceano, CA, USA

Oem projector headlights burnt behind projector causing very dim lights.

- San Diego, CA, USA

The contact owns a 2003 BMW 325I. The contact stated that the brake lights and the turn signals failed. The contact checked the wiring harness and found that the harness was melted. The contact spoke with the manufacturer regarding NHTSA campaign id number: 11V438000 (exterior lighting: Brake lights), but was told that the vehicle was not included in the recall. The failure mileage was 105,000 and the current mileage was 110,000.

- El Paso, TX, USA

My tail lights and turn signals work for a while then quite working. The exact same symptoms as recall #11V438000 for the same type, model and year as my car, but BMW says my vehicle is not included.

- Indianapolis, IN, USA

The contact owns a 2003 BMW 325I. The contact stated that the rear passenger tail light failed. The contact replaced the bulb twice but the failure recurred. The contact mentioned that after inspecting the vehicle he noticed that there was a short in the electrical system. The contact was then informed of recall NHTSA campaign id number: 11V438000 (exterior lighting: Turn signal). The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in any recalls. The failure and current mileage was 100,000.

- Ewa Beach, HI, USA

The passenger side hid headlight fails to come on. This occurs randomly and seems to happen more frequently in the winter time when the temperature is colder and the air has more humidity. This is not a bulb issue in that I have replaced the bulb several times.

- Granite Bay, CA, USA

The warning light for my passenger side tail light has been going on and off for months as if there is a short in it. It stayed on permanently this month, showing a dimmer light than the working side tail light, so I had it checked when I had the oil changed at my BMW mechanic. He informed me there was a recall for tail light assemblies for my vehicle and told me to call the dealer to check the VIN number. I called the dealer last Friday, June 22, 2012 and was informed that my vehicle was part of the recall and that someone would call to make an appointment for the work. No one called, so I called again today and they said the VIN was not part of the open recall. The tail light is acting like the other tail lights that were recalled so I do not understand how it cannot be part of the recall.

- Baton Rouge, LA, USA

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.

- Los Altos, CA, USA

Due to the plastic bowels in the headlight projectors, which are chrome like lined, and the high heat of the hid bulbs, this chrome like coating has burned off making the light output of my hid head lights very dim. The outside of the bowels have gone from a chrome like coating to a bronze/caramel color/coating. This problem is very obvious. I have had other vehicles with hid headlights, and the light output of those cars is easily double or more, to the point where alot of times I have to drive with my fog lights on just to light the road up to be able to see well enough so that I don't have a accident. I have pictures I took of the discolored bowels im talking about on my phone that I would be able to send.

- Glenn Heights, TX, USA