Headlights problems of the 2004 BMW 330 - part 2

Dramatically reduced headlight output due to defective factory components.

The contact owns a 2004 BMW 330i. While driving approximately 65 mph, the contact noticed that the visibility of the headlight reflectors was very poor. After inspecting the headlights the contact noticed that the area around the headlight reflectors was burned. The contact replaced the bulb. The failure continued after the replacement of the bulbs. The manufacturer was made aware of the failure and stated that the headlight assembly would have to be replaced. The vehicle was not repaired. The approximate failure mileage was 117,000.

BMW zkw headlight defect. Burnt bowls causing unsafe nightly illumination.

The reflector portion of the vehicle's xenon headlights appear burned/discolored, which significantly reduces their brightness thereby reducing nighttime visibility.

2004 BMW 330i sedan: xenon headlight reflector bowls (zkw brand) are scorched practically eliminating any light output from the headlight.

I own a 2004 BMW 330i m-performance edition. My headlights are manufactured by a company called zkw. I am canadian and my car is a canadian car but the faulty part in question is common to both us-spec and cdn-spec BMW 3-series. My headlight output is extemely poor. In inclement weather, this issue is compunded. I now must always run with my foglights on to aid the headlights. This is not a safe solution to the problem. Foglights are designed to help the driver see your more immediate surroundings. The distance that the light is shone is much shorter than it should be. I am not able to see more that 3-5 meters in front of my vehicle. The 'incident' date noted above is when I had struck a raccoon with my vehicle that I should have seen much much sooner, giving me more time to react or make an evasive maneuver. This is significant because I was not travelling faster than 60-70 kph. The result was a $1,200 repair to my front bumper and bumper trim which sustained damage from the animal. From what I understand, all 3-series purchased in 2003 and 2004 which feature xenon-headlights made by zkw suffer from a design flaw with the reflector bowl. Over time this reflector bowl, which is made of plastic, tends to get fried and discoloured as a result of the heat eminating from the xenon bulb. This causes the reflector bowl to lose it's reflective properties and as result, light output is extremely poor. For model year 2005, BMW went with a different headlight manufacturer which offered headlights which featured and aluminum reflector bowl which is more resilient to the temperatures caused by the xenon bulb. To me, this shows BMW acknowledging the design flaw, especially since model year 2005 was the last year BMW made a 3-series sedan in this chassis.

Headlights have inadequate light output due to manufacturing defect.

The contact owns a 2004 BMW 330i. The contact stated that both front headlights illuminated very dimly. The contact examined the headlights and noticed that the front driver side headlight bulb burned a hole through its housing. The vehicle was not taken to have the failure diagnosed. The contact replaced the bulbs himself, but the failure recurred. The manufacturer was made aware of the failure and offered no assistance. The contact was informed that the entire headlight housing needed to be replaced. The failure mileage was 65,000. The VIN was unavailable.

The head light reflecting bowls on hid headlights are burning out thereby resulting in poor lighting under all conditions.

Xenon reflectors in zkw headlights are burnt, and are cracking. This is significantly reducing light output of the vehicle.

Headlight light output has strongly diminished. In 2003-2004 BMW used zkw headlights in which the reflector bowl behind the light-bulb were prone to the melting due to heat causing poor light output. BMW must have recognized this as they changed headlight suppliers in later models.

Headlights of 2004 BMW 330i with xenons are made by manufacturing company "zkw" and bound to fail. Visibility and light output becomes extremely poor, that you must drive around with extra lights, or high beams on. When you open up the reflective case, you will see that both front headlights driver and passenger side have burnt bowls, which do not allow any light output at all. This is extremely dangerous, I have gotten into an accident due to not being able to see far distance at night. Please address and investigate this matter immediately.

The vehicle headlights include the bi-xenon option. Zkw was the original equipment supplier for these headlights. The reflective housing surrounding the bulb suffers from severe degradation and total light output is significantly reduced. Overall nighttime vehicle visibility and safety is greatly affected. I have learned this is a common problem with the make/model/year and option package of the vehicle.

I recently purchased a 2004 330i zhp, and drove it home. Didn't drive it at night for some time, but when I finally did, found out lighting is very dim, so much, I have no confidence driving at night. I must use foglights on low beam, and high beams when I can. Failure occurs every time I drive at night, and through my research, I feel the reflective material in the bowls is baked off. These light should be better than the halogens I had on my 325i, but they are not. I have not corrected the problem because repairs are too costly. . . . . And do not feel I should pay for the defective headlights.

The zkw brand of high intensity discharge (hid) headlights equipped in the e46 model 3 series BMW sedan have a plastic reflector bowl in the projector that has the tendency to have the chrome reflective plating burnt off rendering the headlights all but useless.

The contact owns a 2004 BMW 330i. While driving 75 mph at night the vehicle head lamps were dim and he was unable to see ahead . The contact stated he replaced the head lamp bulbs himself, but he still finds it difficult to see at night. He had not taken the vehicle to the dealer at the time of the complaint. The failure mileage was 133,000. The current mileage were 134,000. Updated 5/20/2010 updated 07/19/jb.

Bi-xenon headlights gradually grew dimmer after about 100,000 (6 years) the lights were unsafe to use after dark. The lights were repaired by an automotive lighting specialty shop by installing aftermarket headlight projectors. The original reflector bowls on the zkw manufactured projectors were burned and partially melted by the xenon bulbs and was no longer projecting the light ahead of the vehicle.

The zkw-brand xenon headlights that came equipped on the vehicle (a 2004 BMW 330i) have lost their brightness intensity, resulting in nighttime light output that is dangerously low. The problem specifically is that the heat from the projector bulbs melt or discolor the reflective bowls, which decreases the high- and low-beam light output. The heat also discolors the plastic headlight lenses. The bulbs still throw a very low level of light, but without the reflectivity they do little to illuminate the road at night. Service records indicate that BMW noted the problem on my vehicle in the first three months of 2009, but if the parts were replaced they have failed again since then. This is a non-wear item. Many other vehicle owners have also reported this problem.

Low-beam hid headlight reflector bowls on both sides of car have burned and melted causing very low light output and dangerous night driving conditions. The reflector bowls are zkw brand and appear to be made of plastic of some kind.

I have noted that the zkw brand hid headlights on my BMW are less than adequate at providing significant lighting for night driving conditions. I found upon dissasebly of my headlight assembly the reflective base or "bowl" is a coated plastic part that has been significantly discolored from normal use. I am filing a report to have NHTSA look further into the problem and recommend the party responsible offer a reasonable fix. Currently the factory (BMW) recommends replacement of a $1200 (each, two total) headlight assembly. I request a mandate by the NHTSA for replacement of the affected headlight assembly's by BMW, at BMW own cost. I feel the sub standard manufactuing process of this vital part may cause significant safety risks for people who require the proper function of the headlight.