2003 BMW 325i Headlight Problems

Which parts fail

• Headlights
  3
• Tail lights
  2
• Turn signal
  2
• Brake lights
  1

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

Mileage when the problem started

• Under 25k
  25%
• 25k–50k
  820%
• 50k–75k
  820%
• 75k–100k
  1128%
• 100k–150k
  923%
• 150k+
  25%

Owner reports

Selected complaints filed with NHTSA by 2003 BMW 325i owners, lightly cleaned up (personal details are redacted by NHTSA).

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.

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.

Tl* the contact owns a 2003 BMW 325i. The contact stated that the rear passenger side tail light would fail intermittently. The vehicle was taken to the dealer where the contact was advised that the vehicle was functioning as designed. There was a small electrical fire from the tail lights. The manufacturer was contacted, but denied assistance with the repair because the VIN was not included in NHTSA campaign id number: 11V438000 (exterior lighting:tail lights . The failure mileage was 53,000 and the current mileage is 94,000. The consumer stated the intermittent issue with the tail lights was ignored for many years. Updated 02/23/12

Tl* the contact owns a 2003 BMW 325i. The contact was driving 20 MPH when the turn signal failed to illuminate. The vehicle was taken to the dealer where the dealer confirmed that the turn signal wiring and the brake lights burned out. The manufacturer was contacted where they advised that the vehicle qualified for repairs under NHTSA campaign id number: 11V438000 (exterior lighting: tail lights), but the connector was not included. The vehicle was not repaired and the VIN was unavailable. The failure and the current mileages were 110,000.

Tl* 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.

Tl* the contact owns a 2003 BMW 325i. The contact stated that the rear tail light failed. The contact examined the vehicle and found that the rear tail light wires were burned. The manufacturer was contacted and advised that the VIN was not included in NHTSA campaign id number: 11V438000 (exterior lighting:turn signal). The vehicle was not repaired. The failure mileage was 60,000 and the current mileage was 161,000.

Tl* the contact owns a 2003 BMW 325i. The contact stated that the exterior tail lights burned through the housing harness. The vehicle was taken to the dealer who advised the contact that his VIN was not included in the recall associated with NHTSA campaign id number: 11V438000 (exterior lighting: tail lights). The manufacturer was notified of the failure who offered no assistance. The failure mileage was 60,250.

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.

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. …

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. …

Related recalls

NHTSA investigations

Headlight complaints in other 325i years