Which parts fail
Components named in complaints (headlights, tail lights, turn signals, interior lights).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 BMW 325i owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2004 BMW 325i. The contact stated that the rear exterior lights became inoperable as the rear taillight warning light illuminated. The contact stated that upon inspection around the connector and the panel, there were scorch marks and the connectors coating was completely melted off. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and the VIN was not included in NHTSA campaign number: 11V438000 (exterior lighting). The failure mileage was approximately 190,000.
Car sitting in driveway of primary residence for several days after repeated heavy rains and hurricanes and spontaneously caught fire. Fire was self extinguished but started in dash on left side of steering wheel centered on the head-light control module.
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.
Tl* the contact owns a 2004 BMW 325i. The contact stated that the ground wires were overheating, melting the plug and causing the tail lights to malfunction. The vehicle was not taken to the dealer. The manufacturer was made aware of the failure but did not offer any assistance since the vehicle was not included in any recalls. The vehicle was not repaired. The failure mileage was 117,000 and the current mileage was 120,000.
Tl* the contact owns a 2004 BMW 325i. The contact stated that the vehicle emitted a strong burning odor while it was parked. While inspecting the vehicle, the contact found that the front driver's headlight cable was on fire. The fire department was called but a fire report was not filed. The vehicle was not repaired. The manufacturer was not made aware. The approximate failure and current mileage was 60,000.
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.
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.
Tl* the contact owns a 2004 BMW 325i. The contact stated that the turn signals and the headlights failed to activate. The vehicle was taken to a dealer where it was diagnosed that the light module needed to be replaced. The vehicle was repaired. The manufacturer was not made aware of the failure. The failure mileage was 202,000. Updated 4/7/15
I have a major BMW problem. It currently has a service bulletin # si b 63 03 06 lights but BMW will not fix this out of warranty even though they knew about this when my car was under warranty and I was supposed to get full services. I want a formal investigation.
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.
Related recalls
Exterior lighting › Turn signal
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…
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.
NHTSA investigations
Rear lamp illumination
Odi has received complaints from consumers stating that their tail light assembly is not properly illuminating.the tail light assembly consists of a turn signal lamp, a tail lamp and a brake lamp.the complainants have indicated that the issue is with an 8 pin connector and associated ground wiring.these components are allegedly overheating and melting due to excessive electrical current that runs through the…
Rear Lamp Illumination
In a letter submitted to the Office of Defects Investigation (ODI) dated August25, 2011, BMWindicated that it will conduct a voluntary recall campaign to remedy the subject vehicles.The issue involves the rear lamps in the vehicles body panel.Through normal vehicle use over time, the rear lamps ground wiring and associated 8-pin connector can experience an increase of the resistance at the electrical contact…
Rear lamp illumination
In March 2009, the office of defects investigation (odi) received a petition from mr. Mark peters requesting an investigation of rear lamp failure in model year 2002-2005 BMW 3-series vehicles.an information request letter was sent to BMW in April 2009, and odi received BMW's response in June 2009.the tail lamp assembly contains lighting for the brake lamps, tail lamps, and turn signals.a technical service bulletin…
Headlight complaints in other 325i years
Frequently asked questions
How common are headlight problems on the 2004 BMW 325i?
NHTSA has 44 complaints about the lights of the 2004 BMW 325i, 30% of the model year's 147 complaints. The component named most often is brake lights (1 mentions).
Is there a recall for 2004 BMW 325i headlight problems?
Yes — NHTSA recall 11V-438 (turn signal, Aug 26, 2011). Recall repairs are free at authorized dealers.
At what mileage do 2004 BMW 325i headlight problems start?
Half of the complaints with a recorded mileage happened before about 79,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 5 fires and 0 injuries to lights problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.