2006 BMW 530XI

The insulation on the internal wiring of the headlight (left and right) have fallen off the wiring leaving sections of conductor exposed creating shorts in the lighting system. This is a known problem in the BMW community (owners and BMW) since at least 2011. This is due to the use of bio-degradable wiring by BMW that breaks down prematurely. Replacement headlight assemblies (high intensity discharge Xenon) are over $1,000 each. Both halogen high beam lights are inoperable which reduces driver vision at night on suburban roadways. Re-wiring with correctly specified wiring is possible but requires specific skills and experience. This is a known problem which BMW has hoped would go away as few of their cars of this age are on the road. This risk assessment driven policy should not shield BMW from fully addressing their failures in material selection which impact safe use of their cars.

Inside headlight wiring insulation became brittle and falls off leading to potential shorts and equipment failure. Additional wiring throughout engine compart shows similar degradation and failure. Split wire housing to protect wires from engine heat also show signs of decay, exposing wires to excess heat and inducing failure of insulation. This is not a turbocharged engine and has lower engine compartment temperatures. This problem started 7-8 years ago and has gotten worse.

AFTER A RECENT HEAVY RAIN THE VEHICLE ELECTRICAL DASHBOARD INSTRUMENTS WERE ERRATIC, THE REAR HATCH OPENING/CLOSING MECHANISM FAILED, AND ULTIMATELY THE REAR AIR SUSPENSION FAILED WITH THE CAR SITTING ON THE REAR BOTTOMING STOPS CAUSING DIFFICULTY IN CONTROLLING THE VEHICLE DUE TO THE SEVERE BOUNCING. FURTHER INVESTIGATION REVELED STANDING WATER IN THE SPARE TIRE AND BATTERY/ELECTRICAL AREAS AT THE REAR OF THE CAR.

TL* THE CONTACT OWNED A 2006 BMW 530XI. WHILE DRIVING APPROXIMATELY 25 TO 30 MPH, THE VEHICLE HAD AN ABNORMAL ODOR. THE CONTACT PULLED THE VEHICLE OVER AT A FUEL STATION, OPENED THE TRUNK, AND NOTICED FLAMES. THE FIRE WAS EXTINGUISHED BY A PATRON. A POLICE REPORT WAS NOT FILED. THE VEHICLE WAS DESTROYED AND TOWED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBERS: 12V126000 (ELECTRICAL SYSTEM) AND 08V384000 (AIR BAGS). THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 93,000. UPDATED 11/02/16*LJ *TR

RECALL CAMPAIGN NO. 12V-126: BATTERY CABLE INSULATED BULKHEAD CONNECTOR THE ISSUE INVOLVES A BATTERY CABLE BOLT CONNECTION IN THE TRUNK. SPECIFICALLY, THIS BOLT CONNECTION IS SECURED TO THE TRUNK FLOOR PANEL BY AN INSULATED BULKHEAD CONNECTOR. THE INSULATED BULKHEAD CONNECTOR MAY HAVE BEEN INCORRECTLY ATTACHED TO THE TRUNK FLOOR PANEL. OVER TIME, THIS CAN LEAD TO A LOOSENING OF THE BOLT CONNECTION AND CAUSE AN OVERHEATING CONDITION - EXACTLY SAME THING HAPPEND TO ME

TL* THE CONTACT OWNS A 2006 BMW 530XI. THE CONTACT STATED THAT SMOKE EMITTED INTO THE VEHICLE FROM THE REAR WITHOUT WARNING. THE CONTACT WAS ABLE TO PULL THE VEHICLE OVER AND NOTICED FLAMES COMING FROM THE TRUNK OF THE VEHICLE. THE CONTACT WAS ABLE TO EXTINGUISH THE FLAMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 12V126000 (ELECTRICAL SYSTEM). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE. PARTS DISTRIBUTION DISCONNECT.

FAILURES OF MULTIPLE WIRES/ELECTRICAL COMPONENTS IN THE TAILGATE/REAR WINDOW WIRING HARNESSES. SEARCH FOR BMW E61 TAILGATE WIRING PROBLEMS. THE FAILURES ARE CAUSED BY A POOR DESIGN WHERE THE WIRES ENTERING THE HINGE GUIDES (4) FOR THE GLASS AND TAILGATE ARE REPEATEDLY FLEXED AT A SHARP ANGLE UNTIL THE INSULATION, THEN THE COPPER WIRE BREAKS. SAFETY ISSUES - POSSIBLE ELECTRICAL SHORT CIRCUIT LEADING TO FIRES (HIGHEST LOAD IS FOR REAR DEFROSTER); LIGHTING FAILURES (REAR HIGH BRAKE LIGHT, LICENSE PLATE LAMPS AND OTHERS); REDUCED VISIBILITY DUE TO LOSS OF WIPER/WASHER/DEFROSTER; REAR GLASS LATCH OPENING WHILE UNDERWAY, POSSIBLY RESULTING IN LOSS OF CARGO OR INGRESS OF EXHAUST FUMES. THIS IS NOT AN EASILY REPAIRED PROBLEM AND HAS COST OVER $2000 SO FAR. I'M WORRIED ABOUT DRIVING THIS CAR AS IT IS THE MAIN TRANSPORTATION FOR MY CHILDREN AND THEIR FRIENDS.I DISCOVERED IT WHEN THE REMOTE LOCK/UNLOCK USING THE KEY FOBS FAILED, THE TRUNK INOPERABLE AND UNCLOSEABLE, THE RADIO STOPPED WORKING, THE LIGHTS IN THE REAR OF THE CAR STAYED ON PERMANENTLY AND I HAD TO DRIVE HOME ONE NIGHT WITH THE TRUNK WIDE OPEN BECAUSE THE WIRING HAD STOPPED WORKING AND IT COULD NOT BE CLOSED. AS I INVESTIGATED I FOUND MANY BROKEN GROUND WIRES, ALONG WITH SEVERAL OTHERS WITH BROKEN INSULATION, SOME WITH BROKEN COPPER STRANDS ETC. I HAVE ALREADY HAD THE RIGHT AND LEFT WIRE HARNESSES REPLACED AT AN INDEPENDENT DEALER FOR ABOUT $2200. THIS IS A SAFETY ISSUE AND I'M WORRIED THAT MORE WILL COME. *TR