2008 BMW 535I

INSULATION CRUMBLING ON ALL WIRING INSIDE BOTH HEADLIGHT (DRIVER AND PASSENGER SIDES) UNITS RESULTING IN MALFUNCTIONING HEADLIGHTS, RUNNING LIGHTS, AND MARKER LIGHTS. UNFORTUNATELY, A COMMON PROBLEM AND A HUGE SAFETY CONCERN. ISSUE IS EXACERBATED BUT NOT CAUSED BY HEAT. INSULATION ON WIRING TO NAVIGATION, RADIO/MEDIA PLAYER, CLIMATE CONTROL UNIT, OR CCC (CAR COMMUNICATION COMPUTER), CRUMBLING CAUSING MALFUNCTIONS TO OCCUR IN ALL THE ABOVE SECTIONS. I SUSPECT MUCH OF THE CAR'S WIRING TO BE IN SIMILAR, POOR CONDITION. I HAVE READ THAT MANY EUROPEAN CARS FROM THE '80S, '90S THROUGH THE FIRST TEN OR SO YEARS OF THE 21ST CENTURY USED A SOY BASED, BIODEGRADABLE WIRE INSULATION AS PART OF A "GREEN MOVEMENT". THIS EARLY IMPLEMENTATION OF SAID WIRE DOES NOT LAST MUCH LONGER THAN 10 YEARS, MUCH LESS THAN THAT WHEN EXPOSED TO HEAT. PLEASE SEE: HTTPS://WWW.BIMMERFORUMS.COM/FORUM/SHOWTHREAD.PHP?2132684-HEADLIGHT-WIRE-JACKETS-JUST-FLAKE-OFF HTTPS://5SERIES.NET/FORUMS/E60-DISCUSSION-2/HEADLIGHT-WIRING-OUTER-JACKET-DETERIORATING-139655/ HTTP://WWW.PEACHPARTS.COM/SHOPFORUM/OFF-TOPIC-DISCUSSION/330631-CAN-YOU-BELIEVE-BMW-STILL-USING-BIODEGRADEABLE-WIRING-INSULATION.HTML HTTP://WWW.MERCEDESDEFECTS.COM/2008/04/WIRE-HARNESS-DEFECT.HTML HTTPS://RENNLIST.COM/FORUMS/PORSCHE-CAYENNE-FORUM/733521-BRITTLE-WIRING-INSULATION.HTML THERE ARE MANY, MANY MORE THREADS SUCH AS THESE ON THE WEB. THERE ARE THOUSANDS OF CARS ON THE ROAD LIKE THIS. THE MANUFACTURERS KEEP PRODUCING VEHICLES WITH THIS TYPE OF WIRING. IT'S WONDERFUL THAT THE INSULATION DEGRADES. IT'S ABSURD TO START BIODEGRADING WHEN THE CAR IS JUST FIVE OR SO YEARS OLD.

THE WIRE INSULATION INSIDE THE HEADLAMP HOUSING BECOMES BRITTLE AND CAN SHORT OUT. THEY CAN FLICKER OR GO OUT. IF BOTH LEFT AND RIGHT EXPERIENCE A SHORT, A DRIVER CAN BE LEFT DRIVING AT NIGHT WITHOUT HEADLIGHTS. THIS CAN RESULT IN DEADLY ACCIDENTS. THIS HAS HAPPENED TO MY RH HEADLIGHT. THE ISSUE HAS LONG BEEN KNOWN AND COMPLAINTS ARE POSTED ALL OVER BMW FORUMS. REPLACEMENT HEADLAMPS ARE IN EXCESS OF US$900 EACH LEAVING MANY CAR OWNERS TO GO WITH DEFECTIVE HEADLAMPS. I WAS DRIVING MY CAR TONIGHT WHEN THE RH LAMP WENT OUT FOR A FEW MOMENTS DUE TO THE WIRING SHORT. I CAN ONLY IMAGINE HOW IT WOULD HAVE BEEN IF BOTH WENT OUT. I DON'T HAVE PHOTOS OR VIDEO EVIDENCE.

WIRE INSULATION INSIDE THE HEADLIGHT HOUSING IS FALLING AWAY LEAVING BARE WIRES. CURRENTLY ONLY AFFECTING THE DRL. SEARCHING BMW FORUMS - THIS IS NOT AN UNCOMMON PROBLEM. THIS IS A DANGEROUS CONDITION BEING THAT THE HEADLIGHTS COULD FAIL AT ANY TIME. REPLACEMENT IS PROHIBITIVELY EXPENSIVE AT MORE THAN $700 PER UNIT. WITH THE NUMBER OF COMPLAINTS THAT I HAVE SEEN IN ON-LINE FORUMS, I FEEL THIS SHOULD WARRANT A SAFETY RELATED RE-CALL. THANK YOU IN ADVANCE FOR YOUR TIME.

I HAVE A 2008 535I (E60) W/55K MILES, IN OTHERWISE PERFECT CONDITION WITH NO AFTERMARKET ALTERATIONS. WHILE DRIVING CAR IN THE HIGHWAY, I HAD A PARKING LIGHT ALERT/ERROR THAT MY PARKING LIGHT WAS OUT. AFTER ARRIVING TO MY HOME I INSPECTED MY HEADLIGHT ASSEMBLY. THE ANGEL EYES ON BOTH LEFT AND RIGHT HEADLIGHT SHOWED COMPLETELY BARE WIRES ON BOTH SIDES OF THE BULB CONNECTORS, ON BOTH SIDES OF THE CAR. I FOUND FLAKING INSULATION AND BARE WIRES EVERYWHERE THE INNER SEALED HEADLAMP ASSEMBLY!!!. THE MORE I TOUCHED THE WIRES, THE MORE INSULATION FLAKED OFF, ALMOST LIKE A POWDER. I'VE NEVER SEEN ANYTHING LIKE IT. DEFINITELY A FIRE HAZARD!!!! *TR

I ORDERED NEW LIGHT BULBS TO CHANGE OUT MY HALO ANGEL BULB LIGHTS (RUNNING PARKING LAMPS) .WHICH SAID THEY WERE OUT ON MY SCREEN INSIDE OF THE BMW . WHEN I TWISTED OFF THE HOUSING CAP IN THE BACK ,THE WIRING INSIDE OF MY HEADLIGHT HOUSING WHICH TURNS ON MY PARKING LIGHTS LEFT AND RIGHT IS TOTALLY DEGRADED AND FLAKED OFF ,THE COPPER CABLES WERE TOUCHING EVERYWHERE .I READ THIS IS BECAUSE GERMANY USE BIODEGRADABLE MATERIAL BUT THIS IS A VERY DANGEROUS FIRE HAZARD FOR DRIVING ON THE HIGHWAYS AND ROAD IN FLORIDA . WE AS 5 SERIES OWNERS FOR THESE YEARS NEED A RECALL OF NEW HARNESS WITH BETTER WIRING .EVEN IF YOU BUY A NEW HOUSING IT WILL DO THE SAME THING IN 4 YEARS GUARANTEED . YOU WOULD HAVE TO FIND SOME ONE TO REWIRE IT WITH THE SAME CABLES FORD USES SO IT CAN LAST 20+ YEARS . PLEASE FIX. *TR

MY 2008 BMW 535I HEADLIGHT WENT OUT AND I TOOK IT TO A CERTIFIED MECHANIC TO CHANGE THE HEADLIGHT BULB, HE TOOK OUT THE HEADLIGHT AND SHOWN TO ME THE WIRING IN BOTH HEADLIGHTS HAVE FLAKED OFF AND HAD PRESENTED A FIRE HAZARD SITUATION WHICH CAUSED THE FUSE THE BLEW. I RESEARCHED THE BMW FORUMS AND FOUND LOTS OF PEOPLE WITH THE SAME ISSUE, HENCE, IT IS NOT AN OUTLIER. I CONTACTED BMW USA AND THEY REFUSED TO REMEDY THE SITUATION. I WAS TOLD BY THEM THAT THE VEHICLE IS OUT OF WARRANTY AND THAT THE VEHICLE MILEAGE WAS PAST THE HEADLIGHT WIRING SHOULD NOT GO BAD IN 8 YEARS AND THEY WERE RUDE AND TOLD ME THEY WILL NOT PAY FOR IT. I ALSO LEARNT THAT MOST OF THESE HEADLIGHT WIRES IN THE E60 FLAKED OFF WITHIN 50K MILES AND ARE NOT DISCOVERED UNTIL A SHORT OR BLOWN BULB. HELLA (THE MANUFACTURER OF THE HEADLIGHT) SAID IT IS NOT THEIR PROBLEM SINCE THE MAKE THE HEADLIGHTS TO BMW SPECIFICATIONS.

WIRING FOR DAYTIME RUNNING LIGHT MELTED ALL WIRING INSULATION OFF. I GOT A SHOCK WHILE REPLACING THE BULB BEFORE I REALIZED THERE WAS NO INSULATION LEFT. TO REPLACE THE LIGHT FIXURE IT IS IN EXCESS OF $1,500 EACH AND BOTH HAVE ALL INSULATION MELTED OFF THEIR WIRES. THE BULBS DO NOT STAY ON AND WE'RE HAVING DIFFICULTY GETTING A VALID NH INSPECTION STICKER.

HEADLIGHT ALMOST CAUGHT ON FIRE. STARTED CAR AND AS I WAS BACKING OUT OF GARAGE I SMELLED A BURNING SMELL AND THEN RECEIVED A DRIVERS SIDE BULB OUT ERROR INDICATION. WHEN I RETURNED TO THE HOUSE I LOOKED AT THE HEADLIGHT AND NOTICED THE INNER LENS HAD FALLEN AWAY INSIDE THE HOUSING. I BEGAN TO EXAMINE THE HEADLIGHT CLOSER AND DISCOVERED A LOT OF WIRES THAT WERE BASICALLY ROTTEN. MEANING THERE WAS NO INSULATION WHAT SO EVER TO PROTECT AGAINST A SHORT IF THE WIRES MADE CONTACT. I EXAMINED THE PASSENGER SIDE HEADLIGHT ONLY TO FIND THE EXACT SAME CONDITION WITH THE WIRING, LARGE AMOUNTS OF BARE UNPROTECTED WIRES. FURTHER INVESTIGATION SHOWED THE ENTIRE INNER LENS BECAME SO HOT THAT THE PLASTIC WELDS MELTED AND ALSO THE METAL HOUSING CAUSING THE LENS TO FALL AWAY. I CONTACTED BMW NA AND WAS TOLD ON THE PHONE THEY WERE AWARE OF THE PROBLEM BUT COULD NOT COVER THE REPAIR BECAUSE THE CAR IS OUT OF WARRANTY. THIS SITUATION COULD HAVE EASILY LED TO A FULL VEHICLE FIRE HAD I NOT INSPECTED THE PROBLEM AND ATTEMPTED TO REPAIR WITH ELECTRICAL TAPE. I CANNOT GET TO ALL OF THE BARE WIRES BECAUSE THEY ARE INSIDE THE HEAD LIGHT. THE COST OF REPLACING BOTH HEADLIGHT IS ~ $3000.00 PARTS PLUS AROUND 250 IN LABOR CHARGES. SADLY IF THIS IS NOT PROPERLY DISCOVERED IT COULD LEAD TO A TOTAL DESTRUCTION FROM A FIRE IN THE VEHICLE AND EVEN DEATH IF THE DRIVER WAS TO BECOME A ASPHYXIATED FROM THE FUMES WHILE TRAVELING ON THE HIGHWAY. *TR