2006 BMW 5 Series ELECTRICAL SYSTEM,EXTERIOR LIGHTING

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.

DEGRADATION OF HEADLIGHT WIRING. WIRE INSULATION IS FLAKING, CRACKING, AND INTERNAL CONDUCTOR WIRES ARE EXPOSED. CAUSES INTERMITTENT HEADLIGHT ISSUES AS WIRING SHORTS DURING DRIVING.

HEADLIGHT WIRE INSULATION FLAKING OFF AND WIRES ARE SHORTING CAUSING HEADLIGHT TO GO OFF. WIRES SHORT AND ARCING. THE HEADLIGHT WENT OFF WHILE DRIVING ON HIGHWAY AT NIGHT.

THE WIRING HARNESS INSIDE THE HEADLIGHTS IS CRUMBLING AWAY CAUSING LIGHTS TO INTERMITTENTLY NOT WORK. THE WIRES SPARK WHEN THEY TOUCH TOGETHER. THIS IS A FIRE HAZARD.

HEAD LIGHTS ANGLE LIGHTS WIRES GETTING VERY DRY FROM THE HEAT OF THE LIGHT AND THE INSULATION COMING OFF THE OPTICAL WIRES, LIGHTS GO OUT, POSSIBLE SHORTING AND BECOME VERY UNSAFE.

MAIN HEADLIGHT FAILURE DURING NIGHT DRIVING CAUSE BY ELECTRICAL SHORT CIRCUIT, DUE TO HEADLIGHT INTERNAL ELECTRICAL WIRING INSULATION FAILURE. INTERNAL ELECTRICAL WIRING INSULATION SEEMS NOT TO MEET SAE, NEC, ASME, ETC. CODES AND STANDARD FOR THE USES, LIKE ENGINE ELECTRICAL WIRING, SUBJECT TO HEAT EXPOSURE FROM HEADLIGHT BULB GENERATION. MAJOR SAFETY ISSUES CAN RESULT FROM SUDDEN HEADLIGHT FAILURE WITHOUT PREVIOUS NOTICE, WHICH CAN CAUSE ACCIDENT AT DARK ROADS. HEADLIGHT FAILURE OCCURS WHILE DRIVING IN A DARK ROAD AT NIGHT.

A MESSAGE ON THE VEHICLE DISPLAY SCREEN INDICATED THAT THE RIGHT-SIDE LOW BEAM HEADLIGHT WAS MALFUNCTIONING. I REMOVED THE HEADLIGHT ASSEMBLY TO REPLACE THE BULB AND FOUND THE WIRING INSULATION IS CRUMBLING TO THE TOUCH, RESULTING IN A SHORT CIRCUIT. THE HEADLIGHT BULB IS NOT ACTUALLY BURNED OUT. THERE ARE MANY COMPLAINTS ABOUT THIS ON THE BMW FORUMS BUT BMW AND THE HEADLIGHT MANUFACTURER, HELLA, REFUSES TO ACKNOWLEDGE THE PROBLEM OR DO ANYTHING ABOUT IT. *TR

THE WIRING INSULATION IS PEELING AROUND ALL OF THE WIRES IN THE HEADLIGHT ASSEMBLY. THIS IS NOT A SERVICEABLE PART, BUT THE LIGHT BULBS ARE SERVICEABLE. THIS SEEMS TO POSE A FIRE RISK BECAUSE BARE CONDUCTORS OF OPPOSITE POLARITY ARE EXPOSED TO ONE ANOTHER. *TR

HAVE A PROBLEM WITH THE RIGHT HEADLIGHT IN MY 530I 2006 BMW. THE ANGEL LIGHT BULB BURNED OUT AND WHEN I WENT TO REPLACE IT, THE WIRE COVERS STARTED TO COME OFF EXPOSING THE WIRES COMPLETELY. AFTER REPLACING THE BULB (WHICH WAS A BIT DIFFICULT TO DO), MOST OF THE WIRES IN THE HEADLIGHT HAD NO PROTECTION AND WERE COMPLETELY EXPOSED. I HAD TO COVER THEM WITH ELECTRIC TAPE TO PREVENT SOME SHORTS, BUT MISSED A SECTION I GUESS, SINCE NOW THE COMPUTER IS GIVING ME A ADAPTIVE HEADLIGHT WARNING MESSAGE AND THE LIGHT IS NOT POINTING TO THE PROPER DIRECTION. I HAVE DONE SOME RESEARCH ON LINE AND FOUND THAT IT IS HAPPENING TO A LOT OF PEOPLE. CONTACTED BMW OF NORTH AMERICA, AND THEY SAID SINCE MY CAR IS OUT OF WARRANTY, THEY CANNOT DO ANYTHING ABOUT IT. THE MATERIAL USED TO COVER THESE WIRES IS NOT CORRECT, AS IT WILL BREAK OFF JUST BY LIGHTLY TOUCHING THEM. I FEEL THIS IS A SAFETY CONCERN WHERE THERE MAY BE SHORT CIRCUITS WHILE THE CAR IS RUNNING AND IT WOULD AFFECTS THE CAR'S COMPUTERS. IN MY CASE, THE LIGHT CONTROL MODULE IS ALSO SHORTED AND MUST BE REPLACED. I WOULD LIKE TO KNOW IF THERE IS ANYTHING YOU CAN DO TO FIND OUT IF THIS IS A SAFETY CONCERN OR NOT. I BELIEVE IT IS SPECIALLY ON A CAR STILL NEW. LET ME KNOW IF YOU WOULD NEED ANY FURTHER INFORMATION. THANK YOU. *JB