Headlights problems of the 2006 Mercedes Benz E320

The insulation covering the electrical wiring that powers the low beam headlights on both passenger and driver sides has failed and crumbled away exposing the bare copper wire. This circuit powers two halogen 55 watt bulbs (110 watts total or ~10 amps) at 12 volts. The insulation failure will present an immediate vehicle fire hazard if the electrical protection fuse fails to actuate as a result of the short circuit created by potential bare wire contact. If the electrical protection fuse does actuate properly the car will lose forward illumination which is essential for safe vehicle operation at night. In either instance a property and personal hazard can result from this defect. This defect can be traced directly to the wire Mercedes Benz selected for the manufacture of this circuitry. Either the gauge of the wire selected is insufficient to dissipate the heat generated by the current flow the circuit demands or the insulation of the wire selected is inherently defective as evidenced by its crumbling deterioration for a component that should be expected to last the life of the vehicle. In either case this wiring failure constitutes a manufacturing defect which should be subject to recall and correction by the manufacturer at his expense. The defect was discovered while attempting to replace a failed low beam headlight bulb, a maintenance activity that can reasonably be expected to be performed a number of times during the vehicle's lifespan. The defective insulation was immediately evident by visual and tactile observation. It was immediately clear an immediate hazard was present and that the lighting could not be used rendering the vehicle unsafe to operate under condition when the lighting circuit might be operated.

I changed the low beam halogen bulbs in my headlights when I discovered that the wire leads to the bulb had lost nearly all of their insulation, exposing bare wire. The insulation flakes were sitting in the bottom of the capsule that contains the light assembly, which is normally closed, accessed by a removable "door". Both headlights had this same issue. This is an obvious sparking/fire danger, so I applied electrical tape over the wires. Had I not changed the bulbs [they lose brightness over the years], I would have been unaware of this danger. I am concerned that this same wire insulation has been used throughout the vehicle. I am amazed that mercedes has not issued a recall on this. I purchased this car new in 2007.

In my opinion, the NHTSA dropped the ball when they approved the hid automobile headlight system on some newer model cars. The glare these headlights produce is very disturbing and in my opinion,this standard should be revisited again by the NHTSA, and revised with new anti-glare parameters.