ZKW Reflector Recall-Open NTHSA Investigation

[edlvrt]

As most of you know, and from what I gather through several internet sites in addition to my limited experience, the low beam reflectors on 2003-2004 ZKW HID headlights were made of some material that degraded when subjected to the heat produced by OEM Xenon bulbs. This results in a significant decrease in light output as the reflector became scorched. I don't know the exact ins and outs, but I would imagine that BMW and ZKW were and are aware of the defect as the newer, redesigned headlights do not suffer from this problem.

I called the National Highway Traffic Safety Administration (NHTSA) out of curiosity to see if the problem had been noted and if there was anything in the works to fix the defective parts. The gentleman that I spoke with said that an investigation of the issue was opened in 2009, closed at one point, and has been reopened. I gave him my information, VIN, and a description of the problem and the affected cars, and he told me their engineering staff would be sending me their ongoing investigation report with a questionnaire of sorts for me to return.

He told me that the more people who report the issue, the greater the chance of some sort of recall. If you suffer from the headlight issue and have a few minutes to spare, please call the NHTSA at 888-327-4236 to report a vehicle defect. If you would rather not call, there is the option to fill out an online form. Go to http://www.nhtsa.gov/ and click the blue banner to the right "Report a Vehicle or Child Seat Defect," then choose to File an Online Form and go from there.

Thanks

[kayger12]

Mount up, boys and girls.

Great info.

[az3579]

Now, for those of us that don't know what the headlights are supposed to look like, how would we test to see if we're affected? I personally have no idea how my car compares to a healthy set of ZKWs...

Sent from my DROIDX using Tapatalk

[PKR]

Let me ask a very basic question .... how does one identify / confirm the manufacturer ?

[edlvrt]

To check the manufacturer, look at the front plastic lens cover. In either the bottom left or right corner, mine say ZKW in small letters. I imagine that the other manufacturer, AL, will say AL, but I can't confirm this. It is also on the sticker on top of the light assembly, but it is likely blocked from view by the car's frame.

Checking to see if your headlights are affected can be done while the assemblies are in the car. Open your hood and remove the square rubber cap that sits behind the bulb. I have attached a picture of what my burnt reflector looks like from behind. It should be fairly obvious if yours is burnt or not.

http://img51.imageshack.us/img51/8471/p6240206o.jpg (http://imageshack.us/photo/my-images/51/p6240206o.jpg/)

http://img17.imageshack.us/img17/7244/p6240207.jpg (http://imageshack.us/photo/my-images/17/p6240207.jpg/)

[Marcus-SanDiego]

Mine says AL. 2005 330ci ZHP.

[danewilson77]

I have sms. I reported this last year and had forgotten about it.

Good lookin out.

HTC Thunderbolt+TT

[KC ZHP]

I have experienced this issue personally - as I understand it, all E46 ZKW zenons will likely have this issue eventually. Certainly a great deal of documentation in the forums and have seen firsthand on other similarly equipped E46s. 2004 330i ZHP sedan at 46K miles - I had LightWerkz perform the TFX retrofit in order to be able to drive the car at night as it was quite literally unsafe to drive. I chose to do the retrofit rather than dropping $1.2K on new OEM zenons with the KPD (known product defect). It's amazing to me that there has not been a recall or corrective action taken on this issue.

Justin

[billschusteriv]

Good stuff.

:like

[Washburn]

Mine says AL. 2005 330ci ZHP.

Mark, where exactly is the spot that says 'AL' on front lens cover?

[Marcus-SanDiego]

I may have a picture of it. Let me check.

[Washburn]

Thanks :) nice of you.

[Marcus-SanDiego]

Wash, on the coupe it will be on each lens (bottom). It will be closest to the grilles. It reads: AL (kind of italicized).

[Washburn]

cool - will check soon - thanks

[Marcus-SanDiego]

Will look like this (but in clear):

http://img.photobucket.com/albums/v125/marcussandiego/al_logo.gif

[spencers]

Never heard of a facelift coupe with ZKWs. If I recall, they're all Bosch/AL

[trancenation]

Good efforts, I'm looking forward for some immediate progress.

[Washburn]

checked mine - They're AL.
Thanks, marcus

[az3579]

It is my understanding that all the coupes had AL lights...

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[GreenFrog]

Reported online.

[edlvrt]

Thanks to all who have called in or reported online. Keep it coming!

[goofiefoot]

Confirmed that I do have the ZKW lamps and noted some discoloration within the assembly. I have submitted a report online. Let's hope this gets resolved!

[PKR]

ZKWs here too. Report submitted.

[danewilson77]

Filed again. Confirmation number is 10411671

[danewilson77]

The email I just recieved, for your reading pleasure.

"Thank you for filing your safety-related complaint via our Web site or our Vehicle Safety Hotline. The ODI Number listed below will be a direct link to your complaint as soon as it is ready to view. Please allow at least two business days for approval and processing before trying to view your complaint online. You will then be able to view it and search any associated documents.
Your Confirmation number (ODI Number) is: 10411671

Your complaint information will be entered into the NHTSA vehicle owner complaint database. NHTSA technical staff review this information to identify potential safety problems. While you may or may not be contacted by a NHTSA investigator to clarify the information submitted, all reports are reviewed and analyzed for potential defects trends. Also, the NHTSA complaint database provides valuable information to other consumers and to manufacturers.
If you have any questions regarding this complaint, please contact ODI:
By phone: 1-888-327-4236 8:00AM to 10:00PM Monday-Friday
TTY: 1-888-424-9153
Have your ODI Number available.
(Spanish-speaking operators available)


By e-mail: http://www-odi.nhtsa.dot.gov/contact.cfm
Indicate your ODI Number in the contact form.
Thank you,
Office of Defects Investigation (ODI)
National Highway Traffic Safety Administration (NHTSA)
U.S. Department of Transportation (DOT)"

[edlvrt]

Thanks to all. I will give them another call this week. I don't know if there will be any updates, but you have to stoke the fire every now and then, right?

[danewilson77]

Thanks to all. I will give them another call this week. I don't know if there will be any updates, but you have to stoke the fire every now and then, right?

Absolutely.

HTC Thunderbolt+TT

[Tampa330i]

Just a note - don't trust what your lens says. My lens says AL, but the label on the top of the headlight says zkw. I suffer from this as well, I can't drive at night without my fogs on.

[Washburn]

where is this label exactly? any pics?
AFAIK facelift coupes do not have ZKWs, but I would like to double confirm with the label too....

[Tampa330i]

Post #5, look at the silver label, just above the bmw logo. It says zkw in a circle.

[zj96sc]

Submitted mine.

[danewilson77]

Post #5, look at the silver label, just above the bmw logo. It says zkw in a circle.

OK...but where does your's say Al?

[Tampa330i]

OK...but where does your's say Al?

The lenses both say AL.

[danewilson77]

The lenses both say AL.

Ok

HTC Thunderbolt+TT

[edlvrt]

Just got off the phone with a lady with the NHTSA. She was able to tell me that BMW issued a service bulletin to somehow correct the issue at the owner's expense, but the head investigator for this issue was not satisfied with the response. She gave me the investigator's name, and a quick google search provided his contact info, so I shot him an email. I'll let you know where this leads.

[PKR]

Great work edlvrt !
Unless the "owners expense" is reallllly l-o-w, that doesn't sound too good, so let's keep the pressure on.

[edlvrt]

I should have been more specific in my above post, but please note that the BMW SB was issued several years ago, and the investigator was unhappy several years ago, so I don't know if we have accomplished anything recently. I guess we wait and see what the investigator has to say. In the mean time, continue to call the NHTSA and report the defect.

Thanks

Ed

[CERF04ZHP]

ZKW's here... projectors burnt to a crisp. If I'm driving at night when it's raining and don't have my fogs on, I'd be better off aiming a Fisher-Price flashlight down the road. Form submitted.

[danewilson77]

ZKW's here... projectors burnt to a crisp. If I'm driving at night when it's raining and don't have my fogs on, I'd be better off aiming a Fisher-Price flashlight down the road. Form submitted.

+1

HTC Thunderbolt+TT

[danewilson77]

Have we also initiated this thread over at WWW.bmwmafia.com?

HTC Thunderbolt+TT

[Marcus-SanDiego]

I don't think we have, DW.

[iZHP]

complaint submitted. I was kinda annoyed the night I got the car, the roads were wet, I couldn't see a thing. It seemed like the fogs were the headlights and the xenons did nothing. I even called BMW NA a while ago and they never even mentioned a SB.

[jiggz]

Just submitted my complaint - I'd love for something to come out of this, but I'm not holding my breath. I imagine they'd need hundreds of complaints before even batting an eyelash at this issue. I hope I'm wrong in saying that though....

[Bishop]

Complaint filed.

[(BMW)]

complaint submitted. I was kinda annoyed the night I got the car, the roads were wet, I couldn't see a thing. It seemed like the fogs were the headlights and the xenons did nothing. I even called BMW NA a while ago and they never even mentioned a SB.

+2

[Scorpius]

filed my complaint

[Scorpius]

saw this when searching for recalls on this nhtsa site.

Make: BMW Model: 330IModel Year: 2004Manufacturer: BMW OF NORTH AMERICA, LLCMfr's Report Date: AUG 25, 2011NHTSA CAMPAIGN ID Number: 11V438000 PE09036,EA09019
NHTSA Action Number: 2 Investigations found View (javascript:openRelatedDefectsWindow('11V438000',' Vehicles','VEHICLE');) Component: EXTERIOR LIGHTING:TAIL LIGHTS Summary:
http://www-odi.nhtsa.dot.gov/images/spacer.gif BMW IS RECALLING CERTAIN MODEL YEAR 2002-2005 325I, 325XI, 330I, AND 330XI VEHICLES MANUFACTURED FROM SEPTEMBER 1, 2001, THROUGH MARCH 1, 2005. OVER TIME, RESISTANCE IN THE ELECTRICAL CONTACTS MAY CAUSE ONE OR MORE REAR LAMP FUNCTIONS (TAIL LIGHT, BRAKE LIGHT, AND/OR TURN-SIGNAL), WITHIN THE VEHICLE'S BODY PANEL, TO STOP WORKING.Consequence:
http://www-odi.nhtsa.dot.gov/images/spacer.gif INTERMITTENT LIGHT OPERATION REDUCES THE ABILITY TO WARN OTHER MOTORISTS OF THE DRIVER'S INTENTIONS. THIS COULD CAUSE A VEHICLE CRASH WITHOUT WARNING.Remedy:
http://www-odi.nhtsa.dot.gov/images/spacer.gif BMW WILL NOTIFY OWNERS, AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING OCTOBER 2011. OWNERS MAY CONTACT BMW CUSTOMER RELATIONS AND SERVICES AT 1-800-525-7417.Notes:
http://www-odi.nhtsa.dot.gov/images/spacer.gif OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV (http://www.safercar.gov/) .

[danewilson77]

Yeah...that's the e46 tail light recall, no?

HTC Thunderbolt+TT

[Scorpius]

Yeah...that's the e46 tail light recall, no?

HTC Thunderbolt+TT

yea i think so, but darn...called the number to bmw and they say my vin doesnt show recall on it. 'however' they said they do them in waves, so it may just be soemthing about the first wave.
on another note I complained about the xenons and he said to get a dealer to have a bmw rep come inspect it, they are not hearing this as a complaint. Perhaps we need to call and complain more to bmw and have their reps come checking out our cars.
Very least they will spend time and $$ looking at it.

[danewilson77]

yea i think so, but darn...called the number to bmw and they say my vin doesnt show recall on it. 'however' they said they do them in waves, so it may just be soemthing about the first wave.
on another note I complained about the xenons and he said to get a dealer to have a bmw rep come inspect it, they are not hearing this as a complaint. Perhaps we need to call and complain more to bmw and have their reps come checking out our cars.
Very least they will spend time and $$ looking at it.

Yeah...I'm not expecting a letter. That's why I just fixed it myself.

[iZHP]

The fact that the bowls were made from plastic in the first place just baffles me. Good idea guys, let's put a cheap plastic reflector in to cut costs of my $900+ lights. Let's assume everyone with ZKW xenons reports it; that's still "not enough" to make it a recall.
We need a different approach. I will NOT replace my lights with Depo's. This is clearly a manufacturing flaw and needs to be corrected. A tail light wire gets a recall and majority fixed it themselves because it's a cheap fix.
ZHP Mafia meet @ BMW NA??? Lol

[cakM3]

...
ZHP Mafia meet @ BMW NA??? Lol

Sounds like an awesome idea :thumbsup

It would be good to show these people how bad our projector bowles are...

[az3579]

It would be good to show these people how bad our projector bowles are...

Well, not ours... but it does baffle me how the coupes have different internals than the sedans. Why couldn't they just all be designed the same so parts could be interchanged? It would have not been an issue if the sedans got the same treatment as the coupes, including the M3.


Of course now I'm just beating a dead horse, but how this hasn't become a recall is beyond me. This is much more dangerous than the tail light issue.

[cakM3]

I totally agree BP....you need to see at night which is why we have "headlights"

[edlvrt]

Update... Don't hold your breath.

Yesterday I received a letter from the NHTSA stating that there is not enough evidence of 2004 330s with defective headlights to warrant a safety investigation. So apparently there never was an investigation....

I am composing a letter in response to the one I received stating that the issue is not limited to 2004 330s but all E46s (1999-2006). I also want to stress to them that me driving 45 on the interstate at night is more of a safety concern than the tail lights, which have received the appropriate attention. If you want the name and mailing address so you can write as well, PM me.

Keep calling in, sending online complaints, and mailing letters. They are listening, but they need to hear from more people. Be sure to make note of any near misses or accidents due to your lack of visibility at night.

Thanks

[danewilson77]

Thanks for spearheading this.

HTC Thunderbolt+TT

[iZHP]

Submitted another complaint.

[cakM3]

Submitted my complaint...

Your Confirmation Number (ODI Number) is: 10439285.

[LivesNearCostco]

I filed a complaint back in June, before joining the ZHP Mafia. Complaint #10407333. Called the 888 number and they said there is no open investigation of the headlights at this time, though he immediately noted that there is a recall on the tail lights.

[quikryptonite]

I guess this might be why my driver's side headlight is weak. I'll check to see if it's burned out and then file. Thanks for the info.

[cakM3]

With ZKWs I wouldn't be surprised.....

[LivesNearCostco]

Picture of my driver side ZKW burnt bowl. Not sure what passenger side is--not even sure passenger side is ZKW, as the plug sockets on the back of the headlight are different from the driver's side. Plus one lens says "ZKW" while the other lens says "AL."
Top of the burnt bowl
2925

Inside of the burnt bowl. Note crack in plastic.
2926

And photos of the light output with the old (probably original) HID bulbs. First, with both Xenons:
2930

Then Passenger side only (seems reasonably bright)
2932

And driver side only (very dim)
2931

Edit: And of driver's side light after adding aluminum foil to top 1/3rd of burnt projector bowl. Some visible improvement.
2947

[tripod06]

now my headlights look like that last picture there but then again my lenses are terrible too so that may have an effect on it too. i need to submit one of these after work tonight but i should look and see if i have that problem as well.

[Go Horns!]

I'm thinking class action lawsuit. Negligent design. Best part is we have the alternative design in the AL headlights.

[zhp43867]

The fact that the bowls were made from plastic in the first place just baffles me. Good idea guys, let's put a cheap plastic reflector in to cut costs of my $900+ lights. Let's assume everyone with ZKW xenons reports it; that's still "not enough" to make it a recall.
We need a different approach. I will NOT replace my lights with Depo's. This is clearly a manufacturing flaw and needs to be corrected. A tail light wire gets a recall and majority fixed it themselves because it's a cheap fix.
ZHP Mafia meet @ BMW NA??? Lol

It's not that simple. I don't think these are the only high end xenons with plastic bowls, but the finish is somehow defective.

That's kind of the equivalent of saying, "Our intake manifolds are plastic, what a POS!". There are reasons for everything.

I think the E46 is too old to have any satisfying reconciliation coming from BMWs end.

If I had to guess, BMWs fix was probably retrofitting the AL projector, which they sell or sold separately according to Realoem.

Another way to tell easily which projector you have specifically is to look at it. If the glass is completely smooth, you have a ZKW projector. If it has a horizontal line in the middle of it, kind of akin to a bifocal, you have an AL projector.

Obviously, the reason for AL headlight lenses on ZKW lights is that the lenses are the same fitment, and ZKW lenses are both more expensive and harder to find than AL lenses.

AL light with line:

http://farm8.staticflickr.com/7004/6578788535_3bf97c558f_b.jpg

ZKW light without line:

http://img684.imageshack.us/img684/9076/screwslineup.jpg

[iZHP]

It's as simple as making a recall to replace defective plastic parts with aluminum reflectors. Or swap for AL headlights.

[cakM3]

That's what I ended up doing. I swapped out the ZKW projector assemblies for the AL projector assemblies and swapped out the lenses to maintain the ZKW lighting but with "improved" projectors. Ones that won't burn out...:)

[LivesNearCostco]

Are the AL projector housings made of aluminum or steel? Maybe I'll know soon, I'm hoping to take apart my passenger side light in the next hour.

[SoarinZHP]

This entire situation is a cluster. I am leery of approaching such a big project where really expensive parts can be damaged... I don't even understand half of what's been written about the modification - cutting this part, drilling holes, etc... I wish there was an easier solution...

[cakM3]

This entire situation is a cluster. I am leery of approaching such a big project where really expensive parts can be damaged... I don't even understand half of what's been written about the modification - cutting this part, drilling holes, etc... I wish there was an easier solution...

I hear you....

When I was forced to change out my ZKW projectors, there was nothing tangible I could follow. Bits and pieces here and there between several different forums. I'm not saying my DIY is perfect but at least you can get a fairly good idea how I retrofitted the AL projectors into my ZKW headlight assemblies :thumbsup

You would think BMW would do a recall on these...

[zhp43867]

BMW won't recall it unless they are forced to, because they are saving money.

[LivesNearCostco]

I will say opening the headlight is much faster and less intimidating the 2nd time around! Though this time I didn't take out the projectors. Confirmed my passenger side has AL, driver's side is ZKW. Must have been either accident repair or warranty replacement. So all I need is one E46 AL left bi-Xenon headlight and one extra XKW HID lens...

[LivesNearCostco]

Amen. I'm sure when/if the govt. safety agency writes them and says, "Have you had any recurring problems with HID headlight projector bowls getting burnt?" the first BMW NA responses will be:

1) We haven't heard of any significant problems with this
2) It's not affecting very many cars
3) It's not a safety problem; it's normal maintenance or wear-and-tear
4) Nobody died or had a fire from this that we know of
5) It's too expensive for us to recall them all, even though we deny that it's a real problem
6) If it does happen, it must be irresponsible owners who put in aftermarket HID bulbs
7) Customers can fix it easily and inexpensively themselves with something called a Depo P46
8) Don't believe everything you read on the Internet


BMW won't recall it unless they are forced to, because they are saving money.

[SoarinZHP]

This entire situation has me completely pissed off right now. I know bitching about it isn't going to change it. I'm up for taking my headlight housing apart and pulling the projector in hopes the E90 version I picked up will fit. The picture of a projector shown in the Bentley matches what I picked up. I find it disappointing to even have to deal with this. But... This is the price we pay for having the style and class to own and preserve a not-so-special vehicle. I completely get these cars are at least 7 years old (for sedans). Anyways...

This should probably be posted separately...

While I have the housings removed from the car, I am going to add angel eyes.
Anyone have preference for either Umnitza or Aurora or Weisslicht? I myself like the Aurora's but haven't seen them in person. Anyone at the meet see all three? I'm gonna post in the lighting forum separetly, too...

[cakM3]

Soarin,

I feel you here. I have the same frustration....ZKWs supposed to be better than ALs but have plastic projector bowls.....what were they thinking????????

Anyway I had to replace my bowls as they were only putting out 50% of original light output (I went with OEM M3 projector bowls - oh and they are ALs). It was pretty sad that my fogs were putting out more light output than my ZKWs at that point. That's why I put out a DIY to help others since there were no complete DIYs at the time and I was nervous about ruining my headlights...

I would think that BMW would recognize this was a safety-related issue.....understand the business model but this doesn't make it right in my opinion....

[ryankokesh]

As some of your may know, I'm currently attempting to address my "burnt bowl" problem. This has been seen on cars with ZKW Xenon headlights, and basically what happens is the plastic "bowl" that reflects light from the bulb out of the lens burns. This makes it lose it's reflectivity, thereby drastically reducing light output. There are a few solutions, but none are both easy and effective. I eventually went the FX-R route. It's not going to be simple, but I'm sure I'll get it done eventually and will be able to drive (safely) at night!

Anyway, I took my headlight assemblies apart yesterday and assessed the damage. It was much, much worse than I ever imagined. The entire top of the projector bowl was burnt to a crisp. Tiny bubble etchings were in the plastic, and the bowl was literally black in spots. Amazingly, the bowl even got so hot that there is a fairly large hole burnt completely through it.

Before I took the housing apart, I knew the burnt bowl problem makes it very difficult to see at night, posing a substantial safety issue. After seeing the extent of the burning, I'm honestly quite concerned that the bowl may actually catch fire, or even cause another part of the assembly to catch fire (since there's a freakin hole in it now). That said, I took the time this morning to call the NHTSA and document the problem. I'm worried this won't do much, but I figured if it has the potential to stop a car from catching fire, I should probably take 15 mins and just do it. The lady was very nice, and you only need your VIN, milage, and when the problem started.

So, if you have the same problem on your BMW, I think it'd be great if you could help out and give them a call as well. Their number is 1-888-327-4236 and can be found on the SafeCar.gov recall page (http://www-odi.nhtsa.dot.gov/recalls/recallprocess.cfm). It'd probably be even more helpful for people to call who know when the problem started. She asked me this, but since I just got the car I couldn't really give a helpful answer.

Thanks everyone - who knows, maybe we'll make a difference! :caseyshrug

[trancenation]

Soarin,

I feel you here. I have the same frustration....ZKWs supposed to be better than ALs but have plastic projector bowls.....what were they thinking????????

Anyway I had to replace my bowls as they were only putting out 50% of original light output (I went with OEM M3 projector bowls - oh and they are ALs). It was pretty sad that my fogs were putting out more light output than my ZKWs at that point. That's why I put out a DIY to help others since there were no complete DIYs at the time and I was nervous about ruining my headlights...


Same boat here

[danewilson77]

Requesting Jupiter > file a complaint on the ZKW bowls with NTSB and send them pictures. Thank you sir.

[NorCalZman]

ah thanks for the reminder. I need to do my clear corners this weekend and I will look at the lights and see if mine are burnt. If they are even the teeniest way browning I will be filing a complaint too.

[JupiterBMW]

Dane- As requested, I just filed a very detailed complaint. I did not see any place to post or send pictures, but I do have plenty.

[danewilson77]

Dane- As requested, I just filed a very detailed complaint. I did not see any place to post or send pictures, but I do have plenty.

Thanks Jooooopy.

Sent from Williamsburg, VA USA

[cakM3]

Dane- As requested, I just filed a very detailed complaint. I did not see any place to post or send pictures, but I do have plenty.

Jon,

I have pics as well but even better, I have retained my burned reflector bowls in case someone decides they want to see them...(not holding my breath on that though)...

[JupiterBMW]

Good call Charlie. Its too late for that for me. Oh well. Pics tell a thousand words. :)

[cakM3]

Agreed Jon... pics help but then I have the "smoking gun"...:)

[JupiterBMW]

Yeah, in all honesty, I don't see anything coming of the whole NHTSA thing, which is why I've never reported it there until now. But, I suppose now that its in, I'm covered in case anything good does come of it.

[NorCalZman]

I installed my clear corner kit and tried to get a look at my bowls. Obviously there isn't much room in there so I took the back of the bulb case off a bit and stuck my iPhone in there. This is the top of the drivers side bulb. Maybe a little browning on top. not sure if I should file a complaint or not yet. Thoughts?

5270
5271

[JupiterBMW]

I don't think you're quite there yet. Those look great still!

[nike001]

NorCal, If you have to ask if they're burnt.. then they're not.

Trust me, you'd know if they were burnt.

[danewilson77]

NorCal, If you have to ask if they're burnt.. then they're not.

Trust me, you'd know if they were burnt.

+1

Sent from Williamsburg, VA USA

[JupiterBMW]

NorCal, If you have to ask if they're burnt.. then they're not.

Trust me, you'd know if they were burnt.

Haha, I was thinking the same thing. But you'd have to know Antone (norcal) personally to understand him... :rofl

[NorCalZman]

If any newbies have the ZHP sedan with Xenons you should check out the back of your bowls and consider filing a complaint for it on the NHTSA website. Takes 10 minutes.

[LivesNearCostco]

I filed a NHTSA complaint 12 or 18 months ago. Does it help if I call them again? Or is it only one complaint per owner?

[UdubBadger]

Does filing do anything?


- Goin' H.A.M. Mobile

[BavarianZHP]

Filing does do something. It's their duty to enact recalls:

http://www.edmunds.com/car-safety/how-nhtsa-gets-cars-recalled.html

I believe the tail light recall was from the complaint filings. Although the ZHP is now a decade old, so I doubt any recalls will happen now.

[NorCalZman]

Filing does do something. It's their duty to enact recalls:

http://www.edmunds.com/car-safety/how-nhtsa-gets-cars-recalled.html

I believe the tail light recall was from the complaint filings. Although the ZHP is now a decade old, so I doubt any recalls will happen now.

"There also is a limit on how far back a manufacturer has to go to fix problems without charging the owner. Vehicles eligible for no-cost repair can't be more than 10 years old as of the date the defect was determined. So a recall ordered this year would only reach back to cars sold new from 2003 onward. There is a more complete list of rules on NHTSA's recall process site."

My car is only 7 years old. I have read about recalls for cars as old as 2000 in the news not too long ago too.

[ryankokesh]

I filed about a year ago. The women on the phone instructed me to take it to a BMW dealership and have them take a look at them. Not fix them, just see what they say. Unfortunately Patrick BMW here wouldn't even look at it w/o a $200 fee. WTF.


Sent from my iPhone using Tapatalk

[NorCalZman]

were you supposed to report back to the NHTSA or something? I think that is unreasonable to ask us to go to the dealer just to "see what they say" when they charge 200 just to look at the car. I hope I get a call. I will keep them on the phone for a long time asking them to explain why an investigation has not been opened yet ;)

[midlandtech]

I filed about a year ago. The women on the phone instructed me to take it to a BMW dealership and have them take a look at them. Not fix them, just see what they say. Unfortunately Patrick BMW here wouldn't even look at it w/o a $200 fee. WTF.


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Got the same run around. Told them I had my buddy the shop Forman for the dealership look at them. Finally got a call back from BMW who said that I would have to order new headlights at an astronomical price to correct the issue. I am not a betting man but I would wager my entire savings that no resolution via recall will be reached.

[BavarianZHP]

What ever happened to honor and integrity BMW? Oh, yeah those never ever get you rewarded these days...

[dyintorace]

I have a 2004 ZHP sedan and the headlight output really sucks. I've notice more and more that the headlights of the car behind me at a stoplight illuminate more of the road in front of me than my car. :(

That said, I tried pulling the caps off the back of the projectors but can't get them off far enough to see the tops of the bowels. Can anyone point me to a thread that has DIY pictures for trying to diagnose the situation? I'll readily admit that I'm not much of a wrench in advance.

[danewilson77]

I have a 2004 ZHP sedan and the headlight output really sucks. I've notice more and more that the headlights of the car behind me at a stoplight illuminate more of the road in front of me than my car. :(

That said, I tried pulling the caps off the back of the projectors but can't get them off far enough to see the tops of the bowels. Can anyone point me to a thread that has DIY pictures for trying to diagnose the situation? I'll readily admit that I'm not much of a wrench in advance.

Pull headlights forward a tad by removing 4 headlight housing hold down bolts, then remove the cover. Replace bulbs with Philips 85122+ D2S 4300K bulbs.

Done.

Williamsburg, VA, Droid DNA, Tapatalk

[ejp2fast]

Good to be aware of this- as a newbie to the forum, the previous owner had put in xenon projectors out of a 325i sedan.. so i should be good to go.

[NorCalZman]

I stuck my iPhone into the housings and just snapped pictures.


Sent from my iPad using Tapatalk HD

[aurelius]

Some insight into why this kind of thing takes so long:

http://www.nytimes.com/2013/02/24/automobiles/us-inquiries-over-safety-dragging-on-for-years.html

[ELCID86]

Pull headlights forward a tad by removing 4 headlight housing hold down bolts, then remove the cover. Replace bulbs with Philips 85122+ D2S 4300K bulbs.

Done.

Williamsburg, VA, Droid DNA, Tapatalk
Does this still hold true? Buy this: http://www.amazon.com/Philips-Xenon-Headlight-Bulb-Pack/dp/B00480J4JG/ref=sr_1_1?s=automotive&ie=UTF8&qid=1392390025&sr=1-1&keywords=philips+d2s+85122 ?

[brettbimmer]

Does this still hold true? Buy this: http://www.amazon.com/Philips-Xenon-Headlight-Bulb-Pack/dp/B00480J4JG/ref=sr_1_1?s=automotive&ie=UTF8&qid=1392390025&sr=1-1&keywords=philips+d2s+85122 ?

If you are just asking about replacement bulbs, yes, and the Philips D2S bulbs are OEM.

Usually you have to pull the entire light housing forward to be able to get clear access to the rear of the headlight assembly in order to open the small rear cover for a bulb replacement. I've always ended up removing the entire housing for other work (bowl replacement, etc.), so I ended up removing the section of body-matched plastic trim below the headlight housing also. Unfortunately new bulbs won't help out if you are suffering the dreaded "Burnt Bowls" problem in the ZKW assembly.

Special note - two if the four mounting bolts can be challenging to re-seat on reassembly (the two that are the "hidden" ones), and they love to fall down into the front plastic abyss that takes you the next hour to find. I have set them carefully in place with a long pair of forceps, and that seems to help some. Hopefully that will save you searching for the bolts!

If you have more bowl/headlight questions, please let me know. I ended up following JupiterBMW's E90 custom bowl swap (almost, but with a few other changes), and the difference in light output is phenomenal.

[LivesNearCostco]

It's still true you can slide the headlights forward by loosening those 4 bolts, at least on the sedan and probably on the coupe too. I found it helpful to tape the socket to a 1/4" extension so it wouldn't fall off into the bumper area. New DS2 bulbs will probably increase brightness over old bulbs but will not fix the burnt reflector issue in the ZKW Xenons.

[brettbimmer]

We have a few other good threads going on the burnt bowl replacements, but here is a burnt ZKW bowl and an E90 retrofit bowl. A little difference in output. :D



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[NorCalZman]

Wow. that IS impressive. I wonder if lightwerkz does something like that. when I was looking at umintza a few of their pages that we would loose the bi-xenon functionality of our lights. I am not willing to have my headlights modded to that extent.

[brettbimmer]

Wow. that IS impressive. I wonder if lightwerkz does something like that. when I was looking at umintza a few of their pages that we would loose the bi-xenon functionality of our lights. I am not willing to have my headlights modded to that extent.

I can't speak for Lightwerkz offerings, but I know that we have several family members who have used them and seem happy with the results. Yes, the E90 bowl swap was not super simple as it involves finding donor E90 lights and some custom modifications to the ZKW light structures, but the output is great. A couple of us have this mod here too. If there is a negative (if you want to call it that), my lights seem to have a much, much higher cutoff then the original setup, yet I have only been flashed once by an oncoming driver on a back road. I think it is related to bulb depth in the socket, but the added light is a bonus in my book. If you are able to get the car coded to run Trifecta light mod, you can run Xenons, inner halogens, and fog lights all at once, which makes the ZHP look like an aircraft landing at night, but is really, really bright.

[ELCID86]

If you are just asking about replacement bulbs, yes, and the Philips D2S bulbs are OEM.

Usually you have to pull the entire light housing forward to be able to get clear access to the rear of the headlight assembly in order to open the small rear cover for a bulb replacement. I've always ended up removing the entire housing for other work (bowl replacement, etc.), so I ended up removing the section of body-matched plastic trim below the headlight housing also. Unfortunately new bulbs won't help out if you are suffering the dreaded "Burnt Bowls" problem in the ZKW assembly.

Special note - two if the four mounting bolts can be challenging to re-seat on reassembly (the two that are the "hidden" ones), and they love to fall down into the front plastic abyss that takes you the next hour to find. I have set them carefully in place with a long pair of forceps, and that seems to help some. Hopefully that will save you searching for the bolts!

If you have more bowl/headlight questions, please let me know. I ended up following JupiterBMW's E90 custom bowl swap (almost, but with a few other changes), and the difference in light output is phenomenal.

Thanks for the advice. I learned from the master! Joop actually helped me pull the lights on this car once before. I'm hoping it's only the bulb and not the bowl (as we all do).



Thumbs, iPhone, Tapatalk.

[ELCID86]

It's still true you can slide the headlights forward by loosening those 4 bolts, at least on the sedan and probably on the coupe too. I found it helpful to tape the socket to a 1/4" extension so it wouldn't fall off into the bumper area. New DS2 bulbs will probably increase brightness over old bulbs but will not fix the burnt reflector issue in the ZKW Xenons.

Crap. I now remember I forgot my magnetic claw grabber. Oh well I may not get to it this weekend anyway. Tape may work. Thanks!


Thumbs, iPhone, Tapatalk.

[cakM3]

It's still true you can slide the headlights forward by loosening those 4 bolts, at least on the sedan and probably on the coupe too. I found it helpful to tape the socket to a 1/4" extension so it wouldn't fall off into the bumper area. New DS2 bulbs will probably increase brightness over old bulbs but will not fix the burnt reflector issue in the ZKW Xenons.

From my experience... electrical tape works best here :thumbsup

[brettbimmer]

Thanks for the advice. I learned from the master! Joop actually helped me pull the lights on this car once before. I'm hoping it's only the bulb and not the bowl (as we all do).



Thumbs, iPhone, Tapatalk.

Sure. If one bulb just randomly went out, be sure to check that the problem isn't with the ground wire to the ground plate on the respective side. I had a halogen light go out at 60K and this turned out to be the issue.

[NorCalZman]

And yet another car gets a headlight recall while ours is left out in the cold....

http://www.autoblog.com/2014/03/18/volkswagen-passat-headlight-recall-official/

[04330i]

Just had both my bowls and projectors replaced by a local headlight customization shop for $400 including parts and labor. It was quite scary driving at night with those nasty burnt out bowls!

Sent from my Note 3 using Tapatalk Pro

[NorCalZman]

What did they replace them with? Do your auto levelers still work?

[04330i]

What did they replace them with? Do your auto levelers still work?

They replaced them with an aftermarket unit that has slightly larger bowls made from aluminum instead of plastic and the projectors were slightly larger as well. The auto levelers work normally. He is a very reputable, professional modder that actually does SEMA trucks and cars and only uses reputable vendors so even though I prefer OEM replacement parts, he guaranteed me that these would project better and last much longer. The light output difference was astounding between the new setup and the old. If you like, I can call him and find out where he sourced the replacement parts.

[NorCalZman]

I am looking into another route at the moment, but you should post all that info for any other members who might be interested.

[midlandtech]

Ask him if he knows of someone in the KC area that does similar work

taptalk + Note 3

[04330i]

Here is the link my guy sent me on the kit he used on my headlights:
http://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html#.Uyjdqym9LCQ

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[slater]

nice, that looks like a good kit and a good price.

peter

[aurelius]

Here is the link my guy sent me on the kit he used on my headlights:
http://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html#.Uyjdqym9LCQ


While I'd surely like to solve this issue for $175, the product description mentions it's for E46 models that came with ZKW halogen lights (implication: not for factory xenons). At the same time, the description and tech specs are somewhat contradictory. Some samples:

"Available for a handful of vehicles that come stock with halogen projectors, the kit includes a set of custom designed brackets and hardware to mount up a set of high performance EvoX-R Bi-xenons in their place."

"...they offer excellent low beam performance, a super sharp and attractive cutoff line, and a bi-xenon high beam to work in unison with your factory halogen highs."

"Check compatibility below to find out which projector your kit uses."

Unfortunately there is no such compatibility list or menu. Worse, the compatibility list for the E46-R Projector Shrouds (http://www.theretrofitsource.com/e46-r-shroud.html) does not show any BMW models.

[04330i]

While I'd surely like to solve this issue for $175, the product description mentions it's for E46 models that came with ZKW halogen lights (implication: not for factory xenons). At the same time, the description and tech specs are somewhat contradictory. Some samples:

"Available for a handful of vehicles that come stock with halogen projectors, the kit includes a set of custom designed brackets and hardware to mount up a set of high performance EvoX-R Bi-xenons in their place."

"...they offer excellent low beam performance, a super sharp and attractive cutoff line, and a bi-xenon high beam to work in unison with your factory halogen highs."

"Check compatibility below to find out which projector your kit uses."

Unfortunately there is no such compatibility list or menu. Worse, the compatibility list for the E46-R Projector Shrouds (http://www.theretrofitsource.com/e46-r-shroud.html) does not show any BMW models.

Hmm, well, I have factory Xenon headlights and my headlight installer said it did require a bit of extra work to get in but it does work and also looks and functions fantastically.

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[Sockethead]

I'm sending my ZKWs out to LightWerkz tomorrow for FX-R retrofit. I'll report back on the quality, etc.
I was going to do the e90 bowl conversion using two e90 headlight assemblies that I have but I just don't have the time.
My lights are so bad that I stopped driving it at night this past fall

[NorCalZman]

Don't forget the before and after pics!

[Sockethead]

The headlights are already out of the car....

[Vas]

Let us know how it turns out. I was going to head down that road before this fall.

[jakksfor20]

I am probably going to pull the trigger on getting the kit here this week. Will take photos and post a DIY, maybe.

[Sideshow]

I just filed a complain at you suggested. There are MULTIPLE complaints about this same issue. BMW should do the right thing and recall these and replace them with safe, durable headlights.

[Sideshow]

I have contacted them, how did it work for you?
Sideshow

[Sideshow]

What system did they replace them with? I am in contact with Lightwerkz, but their solution is about $500.

[Vas]

What system did they replace them with? I am in contact with Lightwerkz, but their solution is about $500.

That sounds about right. Projects are about $140 plus labor and return shipping.

[jiggz]

What system did they replace them with? I am in contact with Lightwerkz, but their solution is about $500.

And worth every penny…. My ZKW's weren't even that bad (my passenger side had no visible defects/burnt plastic) and the Lightwerkz upgrade is night and day better than my old stock setup.

[LivesNearCostco]

Thanks for opening a case with the NHTSA. I filed my own complaint 2 years ago. Maybe with the GM ignition switch recall, they will be more active about opening investigations.

Maybe I'll order the kit from TRS. I think I can handle a little cutting and epoxying to fix my light output.

Does anyone know if the RetroQuik kit from TRS can also be used with an AL bi-xenon? TRS just told me know in online chat. Trying to figure out why it doesn't fit there... I realize the frames that hold the bolts have a different bolt pattern.

Edit: I just ordered the E46 ZKW RetroQuik kit with some JB Weld. Ordered for both lights. Even though TRS said it won't work for the AL, I plan to see if there is some way to make it fit with some extra JB Weld and trimming. Otherwise I'll retrofit only the driver's side (ZKW) and sell the other one.


I just filed a complain at you suggested. There are MULTIPLE complaints about this same issue. BMW should do the right thing and recall these and replace them with safe, durable headlights.

[TWong1200]

FWIW, I filed a complaint as well. Doubt anything will come from this, sadly.

[NorCalZman]

It looks like there is something else we can do that would make them look at the issue. It's call petitioning for an investigation. I found it on this page (do a a control F search for petition). Unfortunately they don't say HOW to submit the petition.

"Any person may submit a petition requesting NHTSA to open an investigation into an alleged safety defect. After conducting a technical analysis of such a petition, ODI informs the petitioner whether it has been granted or denied. If the petition is granted, a defect investigation is opened. If the petition is denied, the reasons for the denial are published in the Federal Register. Similarly, a person may submit a petition requesting NHTSA to hold a hearing on whether a manufacturer has reasonably met its obligation to notify and/or remedy a safety defect or noncompliance with a Federal motor vehicle safety standard. If the petition is granted, a hearing is held to assess the matter and decide what corrective action should be taken. If the petition is denied, the reasons for the denial are published in the Federal Register."

http://www-odi.nhtsa.dot.gov/recalls/recallprocess.cfm

[Palindrome]

Here is the link my guy sent me on the kit he used on my headlights:
http://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html#.Uyjdqym9LCQ

Thinking about picking up a set of these unless someone has any better ideas for my burned out ZKW Bi-Xenons...

[az3579]

I still can't believe there's no recall for this...

[Sockethead]

That's because no one has died yet....

[danewilson77]

That's because no one has died yet....

That we know of...

[Palindrome]

Given that I'm having to throw an absolute fit to get my passenger airbag replaced, I can say with certainty that the headlight issue will likely never be resolved by BMW...

[cakM3]

@ Palindrome.....I don't know why you have to throw a fit to get your passenger airbag replaced :scratchinghead

I had no difficulty getting mine replaced on both cars....

[az3579]

@ Palindrome.....I don't know why you have to throw a fit to get your passenger airbag replaced :scratchinghead

I had no difficulty getting mine replaced on both cars....

This. It's a safety recall... they are required by LAW to do it.

[danewilson77]

Given that I'm having to throw an absolute fit to get my passenger airbag replaced, I can say with certainty that the headlight issue will likely never be resolved by BMW...
Please explain. I called them Monday and they were glad to schedule me an appointment.

No flame suit required!

[poke08]

Please explain. I called them Monday and they were glad to schedule me an appointment.

No flame suit required!

BMW is going to repair yours for free? or are they charging you?

[danewilson77]

My air bag homey.

No flame suit required!

[poke08]

My air bag homey.

No flame suit required!

Ahhh, gotcha. I got mine done hassle free as well.

[dyintorace]

Thinking about picking up a set of these unless someone has any better ideas for my burned out ZKW Bi-Xenons...

I wonder about these too. My new-to-me ZHP is going to need the headlights addressed. Does anyone have experience with these?

[jakksfor20]

I wonder about these too. My new-to-me ZHP is going to need the headlights addressed. Does anyone have experience with these?

I've done it on the wife's car. Great improvement. My only suggestion is if they send plastic 1/4" bushings in the kit still, I would upgrade them to aluminum ones. You can find them at Home Depot. If you have any other questions, shoot me a pm. Be glad to help because the burnt bowl problem is crap.


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[Sockethead]

Yea there are a multitude of options out there... all depends on how involved you want to get. I was going to replace my bowls with e90 bowls but then we had twins so I sent them out for FX-R conversion and a few days later, they were back. The difference is unbelievable.

So now I have two complete e90 headlight assemblies if anyone is interested....

[Palindrome]

Please explain. I called them Monday and they were glad to schedule me an appointment.

No flame suit required!


BMW is going to repair yours for free? or are they charging you?

Dealers in my area are OOS of the replacement airbags and there is no ETA on when they will get more. They couldn't even tell me if they will get any more units in 2014 and certainly wouldn't schedule me for an appointment. After 2 days of calling dealers, calling BMW USA customer relations, and posting the attached picture on BMW's facebook page, they finally agreed to loan me a car until my airbag can be replaced. Going tomorrow at 11am to park my car at the dealer and get a dealer paid rental from Enterprise...

yay.... :-/

https://scontent-a-ord.xx.fbcdn.net/hphotos-xpa1/t31.0-8/10669127_10152297731327434_6230368106363659801_o.j pg

[NorCalZman]

Haha very clever picture and idea.

[az3579]

Dealers in my area are OOS of the replacement airbags and there is no ETA on when they will get more. They couldn't even tell me if they will get any more units in 2014 and certainly wouldn't schedule me for an appointment. After 2 days of calling dealers, calling BMW USA customer relations, and posting the attached picture on BMW's facebook page, they finally agreed to loan me a car until my airbag can be replaced. Going tomorrow at 11am to park my car at the dealer and get a dealer paid rental from Enterprise...

yay.... :-/

https://scontent-a-ord.xx.fbcdn.net/hphotos-xpa1/t31.0-8/10669127_10152297731327434_6230368106363659801_o.j pg

Currently, the airbags are on national backorder. Dealers will go through whatever stock they have, but after that who knows when we'll get the replacement airbags. This is not BMW's fault, nor is it the fault of any of the other automakers other than what appears to be Honda. Apparently Honda knew about this years ago, yet never issued a recall for it. If they did, this would have happened years ago for the other manufacturers as well. There have been deaths related to this in the years prior.

I just read about one account where a woman had a minor crash and her airbag exploded, sending shrapnel into her neck and chest. She bled out in front of her 3 kids.

Because these recalls are all happening at the same time to the tune of a few million cars, don't be surprised there is a backorder. You getting a rental paid for by BMW is extremely unusual; consider yourself lucky... assuming the rental car isn't affected by this recall. You should be ok though; I think GM recalls affected the older vehicles, which rental fleets do not have.


Regardless, I do have to agree; it seems that unless someone dies from a defect, an recall won't be issued. That is ridiculous regarding these headlights.

[Palindrome]

Currently, the airbags are on national backorder. Dealers will go through whatever stock they have, but after that who knows when we'll get the replacement airbags. This is not BMW's fault, nor is it the fault of any of the other automakers other than what appears to be Honda. Apparently Honda knew about this years ago, yet never issued a recall for it. If they did, this would have happened years ago for the other manufacturers as well. There have been deaths related to this in the years prior.

I just read about one account where a woman had a minor crash and her airbag exploded, sending shrapnel into her neck and chest. She bled out in front of her 3 kids.

Because these recalls are all happening at the same time to the tune of a few million cars, don't be surprised there is a backorder. You getting a rental paid for by BMW is extremely unusual; consider yourself lucky... assuming the rental car isn't affected by this recall. You should be ok though; I think GM recalls affected the older vehicles, which rental fleets do not have.


Regardless, I do have to agree; it seems that unless someone dies from a defect, an recall won't be issued. That is ridiculous regarding these headlights.

The problem is that my ZHP, unfortunately, is the family car at the moment. My wife's Tribeca is currently in the shop having the engine pulled to do a head gasket and some other work "while they're in there". I have 2 kids in car seats. BMW couldn't and wouldn't advise me it is safe to have a passenger in my front seat and no human could fit between the space left between the two car seats. My insurance company told me that any claim relating to an injury due to a malfunction of the passenger airbag would be denied due to the mandatory recall, advising me that going after BMW in court would be the only recourse. Hence, my actions and the subsequent resolution.

Let's hope they don't stick me in some POS Chevy Aveo or something for the next 3 months or however long this nightmare takes...

[alexandre]

Glad I got mine replaced in time. What a mess.


Because these recalls are all happening at the same time to the tune of a few million cars, don't be surprised there is a backorder. You getting a rental paid for by BMW is extremely unusual; consider yourself lucky... assuming the rental car isn't affected by this recall. You should be ok though; I think GM recalls affected the older vehicles, which rental fleets do not have.

:rofl this really illustrates what is going on here.

[Avetiso]

Good thing I drive alone 95% of the time.

[cakM3]

Hate to say this but it seems that recalls aren't done unless people either get seriously hurt or killed....very unfortunate. Regarding airbag shortage....guess I got lucky getting both of my cars done when I did....

[Palindrome]

Dropped off my car today at the dealer and picked up a 2014 Chrysler Town and Country mini van as my loaner... *facepalm*

At least it's free...

[ELCID86]

Dropped off my car today at the dealer and picked up a 2014 Chrysler Town and Country mini van as my loaner... *facepalm*

At least it's free...

For headlights?


Thumbs, iPhone, Tapatalk.

[Palindrome]

For headlights?

No, got off on a tangent about getting my airbag replaced or rather BMW's inability to replace it.

[TWong1200]

AL headlights for sale. Solve the ZKW issue.
http://www.zhpmafia.com/forums/showthread.php?t=14295

[cakM3]

AL headlights for sale. Solve the ZKW issue.
http://www.zhpmafia.com/forums/showthread.php?t=14295

Luckily, I'm solving my issues thanks to you ;)

[TWong1200]

Luckily, I'm solving my issues thanks to you ;)
[emoji106]

[NorCalZman]

Reading stuff like this really raises my blood pressure. Here is Acura recalling their cars because of back reflective material in their headlights.

http://www.autoblog.com/2014/12/12/acura-rlx-headlight-recall/


Sent from my iPad using Tapatalk HD

[az3579]

Reading stuff like this really raises my blood pressure. Here is Acura recalling their cars because of back reflective material in their headlights.

http://www.autoblog.com/2014/12/12/acura-rlx-headlight-recall/


Sent from my iPad using Tapatalk HD

W
T
F

BMW, get your shit together... smh