Four problems related to wiring have been reported for the 2004 BMW 325. The most recently reported issues are listed below.
Headlight wiring insulation on standard BMW headlights is brittle and falling off exposing bare copper wires within the headlight assembly. In order to protect the headlights I have had to wrap the wires in electrical tape and shrink wrapping. This issue has existed for several years.
Rear turn-signal indicators began failing to operate, especially in hot, humid conditions. Inspection of wiring harness revealed evidence of wiring-connection degradation by heat or corrosion. The car has not been damaged or flooded in any way. It is kept in a garage. Since both rear blinker assemblies have been affected, I believe that the design or engineering was defective. The intermittent failure of turn signals is a serious safety hazard.
2004 BMW 325i - saftey defect. Rear tail light wiring, missing additional ground wire to avoid burning bulb carrier. BMW service information bulletin issued 2/2007 reveals BMW was aware of this issue and failed to notify consumers. Purchased car cpo in March 2007 and was not told. Replaced several taillight bulbs due to intermittent false indicator lights. Finally in 2011, 1 year after car came out of warranty. . . Removed the wiring harness connector to the bulb carrier and found it to be melting. Contacted dealer and was told it could definitely start a fire if left too long. BMW dealer also stated this is a defect on cars produced from 2001 to 2005. After doing research found that BMW has used faulty wiring and there is a additional ground wired needed to fix. Needless to say , had to pay 300. 00 to have peace of mind and repair.
The contact owns a 2004 BMW 325xi. The wire that plugs into the driver side rear tail light harness burned which makes it impossible for the driver to alert others of his intentions regarding direction of travel and speed. Technical service bulletin # 10020856(exterior lighting:tail lights) summarizes the failure. The failure has not been remedied. The current and failure mileages were 59,770. Updated 12/09/09 the consumer stated the same failure happened on the passenger side. There was insufficient grounding which caused the burnout of the tail light wiring.