2003 BMW 330i Headlight Problems

Which parts fail

• Brake lights
  2
• Tail lights
  1

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

Mileage when the problem started

• Under 25k
  00%
• 25k–50k
  415%
• 50k–75k
  623%
• 75k–100k
  623%
• 100k–150k
  727%
• 150k+
  312%

Owner reports

Selected complaints filed with NHTSA by 2003 BMW 330i owners, lightly cleaned up (personal details are redacted by NHTSA).

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.

Tl* Takata recall. The contact owns a 2003 BMW 330i. The contact received notification of NHTSA campaign numbers: 11V438000 (exterior lighting), 14V428000 (air bags), and 15V318000 (air bags); however, the parts for the recall repairs were unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repairs. The contact stated that the air bag and seat belt warning indicators illuminated. The contact stated that the turn signal on the driver's side malfunctioned by blinking intermittently while in use. The contact called the hixson BMW and walker BMW dealers who both stated that the parts were not available for the repairs. The manufacturer was not made aware of the failures. The approximate failure mileage was 150,000. Parts distribution disconnect.

Tl* the contact owns a 2003 BMW 330i. While parked, the contact noticed that the tailgate light warning light was illuminated. The contact inspected the vehicle and noticed that the resistor cable and the outlet plug connected to the tail light wires were melted. The contact stated the turn signal and brake light failed intermittently and alternated functions. The vehicle was not taken to the dealer for diagnostics and was not repaired. The contact referenced NHTSA campaign id number: 11V438000 (exterior lighting:turn signal) but was not aware if the vehicle was included in the recall. The manufacturer was made aware of the failure and advised that the VIN was not included in the recall. The approximate failure mileage was 42,000.

Tl* the contact owns a 2003 BMW 330i. The contact stated that the service tail light symbol illuminated on the dashboard intermittently. The contact disconnected the plastic where the light bulb was located and found that the plastic was melted and corroded due to faulty wiring. The vehicle was taken to the dealer who informed the contact that there were no recalls and offered the contact a discount for the repairs. The manufacturer advised the contact that since his vehicle was no longer under warranty that they would not be able to provide any assistance. The current and failure mileage was 44,800.

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.

Around November 2009 I started to notice the unmodified factory xenon headlamps in our car seemed dim. Over the next year they seemed to dim considerably and after the recent end of daylight savings time resulted in a significant increase in my night-time driving, I have found the headlamps to provide nearly no projected light. Upon inspection of the light assembly I have discovered that BMW built these headlamps using a chrome-coated plastic reflector to direct the light forward to the road. It appears the design used placed the bulb too near the reflector or used plastic with inadequate temperature resistance and the bowl itself has gradually burnt to the point where it no longer reflects light. There has not been a fire at this point but the plastic appears to be failing structurally now (burn through) and I fear what would happen if I allowed it to progress further. …

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" . …

The zkw brand high intensity discharge (HID) / xenon headlights installed from the factory in to my 2003 BMW 330i degraded to a point where visibility at night was almost zero unless I drove with the high beams and/or fog lights on. Replacing the bulbs did not remedy the problem. The cause was burnt "reflector bowls" which are not replaceable. The whole headlight assembly must be replaced at $1000-1300 per side. I had the headlights repaired by a specialist (at a cost of nearly $700) as I was not ready to pay $2600 to replace the headlights with another set of zkw assemblies which would no doubt fail like every set of zkw headlamps installed in 2003-2004 330i sedans. I do not feel that headlights should be a 'wear and tear' item. They are obviously a critical safety component. …

Recently I bought a 2003 BMW 330i with xenon projector headlights. The low- and high-beam output of these lights is very poor, with very little usable light when driving on lit or unlit roads at night. Compared to standard halogen lamps on my other cars (1990 BMW 525i, 2004 Saturn ion) I would rate them at 40% and 30% output respectively, and both of the other cars use standard halogen lamps. Research on this issue found the headlamp reflector used by BMW for these lights (zkw branded) is made of plastic instead of metal and begins to overheat and melt over time, reducing light output and eventually failing completely. BMW does not offer replacement reflectors, plastic or otherwise, and the only option using manufacturer parts is to replace the entire unit at a cost of approximately $2000 (for the pair). …

Tl* the contact owns a 2003 BMW 330i. The vehicle was included in NHTSA campaign id number: 11V438000 (exterior lighting:brake lights) and was taken to the dealer for repairs. The technicians stated that the bulb housing would have to be replaced but would not be covered under the recall. The technician advised the contact that the recall repair would only cover the wiring harness, which connected to the taillight. The repair could not be performed unless the bulb housing was replaced. The replacement of the bulb housing was performed as well as the recall repair. The approximate failure mileage was 158,000. Updated 05/09/12 the consumer stated the repair was began without first informing him of the additional chargers for the additional parts not covered by the recall. …

Related recalls

NHTSA investigations

Headlight complaints in other 330i years