2006 Xenon Headlight Igniter Plug Wires

[Johnny]

2944029441On my 2006 ZHP 330ci I had a low beam Xenon bulb go out. Upon further examination I found the wire coverings to my igniter plug wires (3 wires, black, green and red) cracked and flaking off exposing bare wires. On the passenger side the green wire was severed.

Attached is two pics, one is not of my car, but of one found on internet (green wire broken), other pic is mine with flaked off wire covers and I too had a severed green wire. Appears to be a common problem, but one folks don't check.

I'm going to try splicing and soldering the green severed wire and electrical tap the other bare wires. From my research it appears a whole new headlight assembly has to be purchased to replace the internal wires within the headlight assembly.

Has anyone else experienced this and what was our solution to repair?

29440

29442

[roadbiker_2]

I had the exact same issue with my sons car. It had several broken wires that someone had put back together with either just electrical tape and or wire nuts. Not a good repair whatsoever. I ended up soldering the wires back together and used 3M 33 electrical tape as I was doing all of this away from my garage with a butane soldering iron that I bought. I would solder the wires and use heat shrink if you can do so.


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[Johnny]

Thanks for sharing. I too did some soldering and 3M taping until I find a new wire solution. I hope a new headlight doesn't have to be purchased in order to get new wiring.

[PdZHP]

Same here. Did some soldering and used liquid electrical tape on the individual wires.

Removed the zip tie as well. Looks like it adds to the problem if you use the adaptive headlight option.

[wstr75]

I had the same issue with the passenger side. Two wires were broken and a third wire was in bad shape. I also found other places where the insulation was cracked. I cut the wires and slid on shrink hose. You have to push the shrink hose well away from the solder joint to keep the hose from prematurely shrinking. My driver side wires did not show any cracking. This tool was my third hand for holding the wires together during soldering: https://www.amazon.com/Lisle-LI55000-Wire-Holder-Assembly/dp/B001C6NJOA/ref=sr_1_1?ie=UTF8&qid=1489968673&sr=8-1&keywords=solder+wire+holder+magnetic

[Johnny]

I agree about the zip ties as a possible contributor to severed wires and removed mine too.

Good tip on soldering wire tool.

[Johnny]

For info. Called Clearwater, Florida BMW dealer for cost to replace two xenon bulbs

For BMW to replace two bulbs $650

One Xenon bulb is
$190 x 2 = $380
One hour labor is
$135 x 2 = $270

I bought two Osram D2S bulbs for $99 and free shipping off Amazon and installed myself.

[Vas]

For info. Called Clearwater, Florida BMW dealer for cost to replace two xenon bulbs

For BMW to replace two bulbs $650

One Xenon bulb is
$190 x 2 = $380
One hour labor is
$135 x 2 = $270

I bought two Osram D2S bulbs for $99 and free shipping off Amazon and installed myself.
How do you like them?