2007 BMW 530XI

The front Xenon Headlight Wiring protective plastic coating has degraded and prematurely failed on both headlight assemblies. This caused headlight bulb shorting and poses a potential fire hazard in the front engine compartment of the vehicle. The wiring used in the headlight assemblies was not up to proper standards and failed. The wiring used in other areas of the engine bay seems to be okay. The internal headlight wiring appears to be supplied by the OEM Headlight Manufacturer (HELLA) and does not seem to be up to proper standards to prevent the plastic protective coating from failing over time. This should not be considered a "wear item" as electrical wiring is used throughout millions of much older vehicles without incident.

I DISCOVERED FAILURES OF MULTIPLE WIRES IN THE TAILGATE/REAR WINDOW WIRING HARNESSES. THROUGH RESEARCH ONLINE I HAVE FOUND THIS IS A COMMON PROBLEM WITH THIS VEHICLE OVER SEVERAL MODEL YEARS - 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. IT WOULD BE BEYOND THE CAPABILITIES OF ALL BUT A SKILLED MECHANIC WITH PROPER TOOLS. I DISCOVERED IT WHEN THE REMOTE LOCK/UNLOCK USING THE KEY FOBS FAILED. AS I INVESTIGATED I FOUND THE BROKEN WIRE, ALONG WITH SEVERAL OTHERS WITH BROKEN INSULATION, SOME WITH BROKEN COPPER STRANDS. *TR