Wiring problems of the 2008 BMW 5 Series

Just bought a used 2008 528i (e60) w/94k miles, in otherwise perfect condition. Went to change the angel eyes from drab yellow to lux led's. Noticed bare wires on both sides of the bulb connectors, on both sides of the car. Tried to use electrical tape, just made more bare wire. The more I touched the wires, the more insulation flaked off, almost like a powder. I've never seen anything like it. Can't possibly be safe. Definitely a fire hazard. Neighbor brought over a bottle of liquid tape, and I re-coated all the bare wire I could see, making sure each wire was separated so a short would not occur. That is a good temporary fix. Will have to stay on top of this problem, since most, if not all, of the headlight wiring is made with bad, quickly degrading wire insulation. A real disappointment in otherwise good german quality and engineering. I guess the source procurer at the factory saved BMW some big bucks on that wire!! this is definitely a NHTSA safety recall issue. Tort lawyers should have a field day on this one. . Read more...

Electrical wiring insulation/sheathing within the headlight unit/housing is showing signs of and or outright deterioration which in turn exposes bare wires within the headlight housing. At this point, the daytime running lamps have been the only effected lights but the wires for the headlights are also noticeably troubled. The issue is not speed, movement or area dependent. . Read more...

( I am the original owner this vehicle) while replacing a burnt out headlight, I noticed that the insulation in the sealed headlight was missing. When I checked the opposite side, I found the same thing, the insulation was broken and missing. Being that this is a sealed headlight housing, I am unable to remove and repair the problem. BMW parts stated that the wiring harness is not sold for those lights. One has to purchase a completely new headlight assembly at a average cost of $700. 00+.