2002 BMW 325i Headlight Problems

Which parts fail

• Brake lights
  6
• Tail lights
  4
• Headlights
  1
• Turn signal
  1

Components named in complaints (headlights, tail lights, turn signals, interior lights).

Mileage when the problem started

• Under 25k
  26%
• 25k–50k
  39%
• 50k–75k
  927%
• 75k–100k
  721%
• 100k–150k
  824%
• 150k+
  412%

Owner reports

Selected complaints filed with NHTSA by 2002 BMW 325i owners, lightly cleaned up (personal details are redacted by NHTSA).

Tl* the contact owns a 2002 BMW 325i. While operating the vehicle, the rear lights would not operate. After replacing the light bulbs, the failure continued. While changing the light bulbs, it was discovered that the light assembly was burned and charred. The manufacturer was not notified of the failure. The vehicle was not included in NHTSA campaign number: 11V438000 (exterior lighting). The contact stated that the vehicle experienced the same failure listed in the recall. The failure mileage was 82,000.

Brake light failure came on in my 2002 bmw325i. I went out to look for the failed bulb, but the brake lights were all working. I noticed that the left side, rear lights were much dimmer than the right side. I went to the mechanic and he showed me a burnt wire and molten plastic connector from the rear light cluster. He said that this is a known problem with this car because BMW did not provide enough ground to the cluster and overtime the extra heat generated by the current will burn the wire and connector. At other times, he said, the connector will short the gnd pin to the pins around it and causes small fires. BMW has a sib number 63 03 06 out for this problem and they have the guts to charge customers $400 to repair their own mistake. I think this is a serious safety violation and I believe that BMW should be held accountable by fixing all the cars out there with this known defect. …

2002 BMW 325i, turn signal failure resulting in small fire. 1- symptoms: car turn signal failure warning light illuminated. 2- upon removal of housing I noted that the light operated intermittently which caused me to investigate further. Upon removal of the plug or wiring harness I noted that the brown wire showed evidence of melting of both wire and metal male plug end with black residue. A simple internet search revealed that BMW issued sib number 63 03 06 to mechanics. I have not found a recall for this hazardous failure, however, did find a forum where several owners noted the same failure. Internet address to this forum is: http://www.aboutautomobile.com/complaint/2002/BMW/325i/exterior+lighting 3- I have not corrected the failure but plan on investigating the procedure to replace the harness. …

Tl* the contact owns a 2002 BMW 325i. The contact stated that the vehicle was included in the recall associated with NHTSA campaign id number 11V438000 (exterior lighting:brake lights). The vehicle was taken to an authorized dealer and the contact was informed that the recall repairs would be performed, but it was up to the consumer to replace the brake light housing assembly that was burned as a result of the failure. The manufacturer was made aware of the failure and also stated that it was up to the consumer to replace the housing assembly. The failure mileage was 109,000.

Tl* the contact owns a 2002 BMW 325i. The contact stated that the rear driver's side brake light had become very dim. In addition, the brake light warning light illuminated on the instrument panel. The contact looked at the light and noticed that there were wires that had become melted. The vehicle was taken to the manufacturer where they advised the contact that the vehicle was not included in NHTSA campaign id number: 11V438000 (exterior lighting:turn signal). The vehicle was not repaired. The manufacturer was notified. The failure mileage was 154,000.

Tl* the contact owns a 2002 BMW 325i. The contact was driving 30 MPH when he smelled a burning odor. The contact was advised by another driver that the exterior tail lights had failed.the contact then disconnected the wires for the tail lights. The vehicle was taken to the dealer who stated they have to replace the complete wiring harness at the owners expense of $1,300. The vehicle was then taken to a local mechanic who repaired the tail lights. The manufacturer was not notified. The failure mileage was 130,000.

Tl* the contact owns a 2002 BMW 325i. When the brake pedal was engaged at any speed, the exterior lighting failed. The failure recurred numerous times. The contact mentioned that the message board displayed "exterior lighting for the rear right side". The dealer and manufacturer were notified of the failure. The VIN was not included in NHTSA campaign number: 11V438000 (exterior lighting). The vehicle was not diagnosed nor repaired. The vehicle was not repaired. The approximate failure mileage was 55,000.

Tl* the contact owns a 2002 BMW 325i purchased new in 2002. The tail lights and the driver- side headlight on the vehicle failed intermittently. A technician from the dealer noticed that the wire for the headlight assembly and the ground wire had burned. The dealer advised replacing the entire head light assembly at an expense of $600. No repairs were made. The failure and current mileages were under 70,000. The VIN was unavailable.

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 2002 BMW 325i. The contact stated that the light bulb socket and wiring melted. The vehicle was repaired under NHTSA campaign id number: 11V438000 (exterior lighting: brake lights) but did not include the replacement of both light bulb socket assemblies. The manufacturer was notified of the problem. The approximate failure mileage was 169,751.

Related recalls

NHTSA investigations

Headlight complaints in other 325i years