2004 BMW 3 Series
Problems, recalls and owner-reported issues
Air bags is the leading concern among 558 owner complaints filed for this model year. This is the 4th highest complaint count among 21 3 Series model years with reports.
Of the 2004 reports, 26 involved a crash and 23 involved a fire. 29 people were injured.
What owners report most often
Recalls and investigations
No safety recalls on file.
Representative owner complaints
558 reports, newest first.
Exterior lighting, Nov 27, 2011
2003 AND 2004 3 SERIES MODELS WITH XENON HEADLAMPS MANUFACTURED BY ZKW HAVE A DEFECT IN WHICH THE HEAT FROM THE XENON HEADLIGHT BULBS ARE MELTING THE PLASTIC PROJECTORS OR REFLECTOR BOWLS. THIS CAUSES A DRASTIC REDUCTION IN PROJECTED LIGHT. THE FIRST SIGN OF THE PROBLEM IS DISCOLORATION OF THE CHROME COATED PLASTIC REFLECTOR BOWL. EVENTUALLY THE REFLECTOR BOWLS SHOW SIGNS OF MELTING. IT SEEMS THE CAUSE IS LIKELY A COMBINATION OF THE XENON BULBS BEING TOO CLOSE TO THE PLASTIC REFLECTORS AND OR THE PLASTIC'S HEAT RESISTANCE IS NOT HIGH ENOUGH. IN 2005 BMW HAD PICKED A NEW MANUFACTURER FOR XENON HEADLAMPS THAT HAVE AN ALUMINUM REFLECTOR BOWL. HOWEVER BMW WILL NOT ADMIT THAT THE ZKW BRAND HEADLAMPS HAVE A DEFECT. THE ONLY SOLUTION BMW HAS OFFERED IS TO HAVE THE HEADLAMPS REPLACED FOR $2400 WITH THE SAME ZKW SEEMINGLY DEFECTIVE LAMPS. THIS IS NOT A SOLUTION AS IT DOESN'T SOLVE THE PROBLEM AND IS ONLY A TEMPORARY AND EXPENSIVE FIX IN MY OPINION. EVEN THE HIGH BEAM MODE IS NOT BRIGHT ENOUGH TO SAFELY DRIVE AT NIGHT. THERE ARE ALSO HALOGEN LAMPS THAT ACT AS RUNNING LIGHTS DURING THE DAY AND ARE INTERMITTENT FLASHERS. IN ORDER TO SEE WHILE DRIVING AT NIGHT, I HAVE HAD TO HOLD DOWN THE FLASHER STICK ON THE LEFT SIDE OF THE STEERING WHEEL IN ORDER TO KEEP THE HALOGEN FLASHERS ON. IT IS TEMPTING TO RE-WIRE THE HALOGEN LAMPS TO THE HIGH BEAM SWITCH SO I DO NOT HAVE TO HOLD THE STICK THE ENTIRE TIME I AM DRIVING. EVEN THOUGH THE HALOGENS ARE NOT INTENDED TO BE DRIVING LIGHTS, IT IS MUCH SAFER IN MY OPINION TO USE THEM AS A SUBSTITUTE EVEN THOUGH IT IS DANGEROUS TO ON-COMING TRAFFIC DUE TO THE BRIGHTNESS AND PROJECTION ANGLE OF THE HALOGEN LIGHTS. IT IS RIDICULOUS TO ME THAT I WOULD HAVE TO GO TO THESE LENGTHS JUST TO HAVE SAFE DRIVING LIGHTS. I THINK BMW SHOULD OFFER A RE-CALL FOR THESE XENON HEADLIGHTS AND SUPPLY A NEW PART THAT IS NOT DEFECTIVE AS THE ZKW LIGHTS SEEM TO BE.
Exterior lighting, Nov 20, 2011
THE BI-XENON ZKW LIGHTS KEPT GETTING DIMMER AND DIMMER. BULB REPLACEMENT DID NOT CORRECT THE PROBLEM. WHEN LOOKED INTO THE ISSUE FOUND OUT THAT THE ZKW PROJECTOR BOWLS HAVE BURNED UP AND DO NOT PROVIDE ANY REFLECTION FOR THE LIGHT OUTPUT ANYMORE. DRIVING AT NIGHT AT THIS POINT WITH LIGHTS ON IS ALMOST LIKE DRIVING WITH THE LIGHTS TURNED OFF. *TR
Exterior lighting, Nov 15, 2011
PROBLEM BEGAN WITH REAR RIGHT TAIL LIGHT WORKING INTERMITTENTLY. NOW THE PROBLEM IS OCCURRING WITH THE LEFT TAIL LIGHT AND FRONT RIGHT SIGNAL. PROBLEM PREVENTS OTHER DRIVERS FROM KNOWING WHEN I AM BRAKING OR MAKING A RIGHT TURN. I HAVE TRIED REPLACING BULBS BUT PROBLEM STILL PERSIST AND APPEARS TO BE A PROBLEM WITH THE WIRING. I HAVE CALLED BMW NORTH AMERICA TO INQUIRE ABOUT RECALL AND I HAVE NOT RECEIVED ANY SOLID INFORMATION ON HOW TO HAVE MY VEHICLE REPAIRED. *TR
Exterior lighting, Nov 15, 2011
THE REAR TURN SIGNALS REPEATEDLY FAIL. THE WIRING IS MELTED. WHILE THIS ISSUE IS ADDRESSED IN NHTSA CAMPAIGN ID NUMBER: 11V438000, MY CAR IS NOT INCLUDED IN THE RECALL. THE RECALL SHOULD BE EXPANDED TO INCLUDE MORE CARS. I CALLED BMW CUSTOMER SERVICE. THEY ARE INDIFFERENT TO THIS ISSUE AND COMPLETELY UNCONCERNED ABOUT THE SAFETY ISSUES CREATED BY THEIR NEGLIGENT MANUFACTURING. THANKS, *TR
Exterior lighting, Nov 11, 2011, crash
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 EXTREMELY POOR. IN INCLEMENT WEATHER, THIS ISSUE IS COMPOUNDED. 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 TRAVELING 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 EMANATING 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. *TR
Engine and engine cooling, Nov 10, 2011
TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT WAS DRIVING 10 MPH WHEN THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER WHO ADVISED THAT THERE WAS A CRACK IN THE ENGINE AND WATER WAS ENTERING THE ENGINE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE WHO STATED THAT THE DEALER NEEDED TO REPLACE THE ENGINE AT THE OWNERS EXPENSE OF $10,000. THEY OFFERED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS 50,000.
Exterior lighting, Nov 9, 2011
TL* THE CONTACT OWNS A 2004 BMW 330I. WHILE PARKED, THE CONTACT NOTICED THAT THE TAIL LIGHT WARNING LIGHT WAS ILLUMINATED. THE CONTACT INSPECTED THE TAIL LIGHTS AND NOTICED THAT THE PIN IN THE TAIL LIGHT ASSEMBLY WAS CORRODED ON THE PASSENGER AND DRIVER SIDES. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING WHERE THE TECHNICIAN ADVISED THAT THE TAIL LIGHT ASSEMBLY WOULD HAVE TO BE REWIRED. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING:TAIL LIGHTS) BUT WAS ADVISED BY THE MANUFACTURER THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 60,000. UPDATED 11/28/11 *BF THE CONSUMER STATED THE RIGHT SIDE IS STILL AN ISSUE, BUT INTERMITTENT. THE LEFT SIDE IN NOT WORKING AND UNSAFE TO DRIVE, WHEN THE LEFT SIDE TURN SIGNAL IS NOT WORKING. THE CONSUMER STATED IT HAD TO BE RE-WIRED. THE CONSUMER STATED HE BELIEVED THE PROBLEM HE EXPERIENCED, IS RELATED TO RECALL # 11V438000. UPDATED 03/05/12
Exterior lighting, Nov 8, 2011
THE XENON HEADLIGHTS BURN AND DISCOLOR THE REFLECTIVE HOUSING AND THE LENS COVER DISCOLORS. THIS MAKES THE HEADLIGHT VIRTUALLY USELESS WHEN DRIVING AT NIGHT. YOU WOULD BE BETTER OFF MOUNTING TWO FISHER-PRICE TOY FLASHLIGHTS UP FRONT. THIS IS A MAJOR SAFETY HAZARD. IN ORDER TO SEE I MUST TURN ON MY FOG LIGHTS OR DRIVE WITH MY HIGHBEAMS ON. *TR
Exterior lighting, Nov 3, 2011, fire
TL* 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.
Exterior lighting, Oct 31, 2011
TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT STATED THAT WHEN THE BRAKES WERE DEPRESSED, THE BRAKES LIGHT FAILED TO ILLUMINATE. THE LEFT TURN SIGNAL ALSO FAILED TO ILLUMINATE ON THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS CONTACTED AND THEY CONFIRMED THAT THE VIN DID NOT QUALIFY FOR REPAIRS UNDER NHTSA CAMPAIGN ID NUMBER: 11V438000: (EXTERIOR LIGHTING: TURN SIGNAL). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 125,000 AND THE CURRENT MILEAGE WAS 135,000.
Exterior lighting, Oct 28, 2011
TL* THE CONTACT OWNS A 2004 BMW 330I. THE CONTACT STATED THAT THE EXTERIOR LIGHTS WOULD ONLY WORK INTERMITTENTLY WITH THE ILLUMINATION OF AN UNKNOWN WARNING LIGHT. THE DEALER WAS NOTIFIED OF THE FAILURE WHO ADVISED THAT HER VIN WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING: TAIL LIGHTS). THE MANUFACTURER WAS ALSO CONTACTED WHO CONFIRMED THAT HER VIN WAS NOT INCLUDED IN THE RECALL AND OFFERED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS 115,000.
Exterior lighting, Oct 13, 2011
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 DISASSEMBLY 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 MANUFACTURING PROCESS OF THIS VITAL PART MAY CAUSE SIGNIFICANT SAFETY RISKS FOR PEOPLE WHO REQUIRE THE PROPER FUNCTION OF THE HEADLIGHT. *TR
Electrical system, Oct 3, 2011
DURING A MASSIVE RAINSTORM WINDSHIELD WIPERS, RADIO AND CENTRAL LOOKING SYSTEM STOP FUNCTIONING PROPERLY. LOOKS LIKE GENERAL MODULE 5 HAS FAILED. *TR
Exterior lighting, Sep 26, 2011
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. *TR
Exterior lighting, Sep 25, 2011
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. *TR
Exterior lighting, Sep 20, 2011
XENON (ZKW) HEADLAMPS IN THE CAR ARE BURNT, THUS DIMINISHING 80% OF LIGHT THAT IS SUPPOSED TO BE COMING FROM THE LAMP. VERY DANGEROUS FOR NIGHT TRAVEL. *TR
Exterior lighting, Sep 14, 2011
XENON REFLECTORS IN ZKW HEADLIGHTS ARE BURNT, AND ARE CRACKING. THIS IS SIGNIFICANTLY REDUCING LIGHT OUTPUT OF THE VEHICLE. *KB
Electrical system, Exterior lighting, Sep 9, 2011
REAR TURN-SIGNAL INDICATORS BEGAN FAILING TO OPERATE, ESPECIALLY IN HOT, HUMID CONDITIONS. INSPECTION OF WIRING HARNESS REVEALED EVIDENCE OF WIRING-CONNECTION DEGRADATION BY HEAT OR CORROSION. THE CAR HAS NOT BEEN DAMAGED OR FLOODED IN ANY WAY. IT IS KEPT IN A GARAGE. SINCE BOTH REAR BLINKER ASSEMBLIES HAVE BEEN AFFECTED, I BELIEVE THAT THE DESIGN OR ENGINEERING WAS DEFECTIVE. THE INTERMITTENT FAILURE OF TURN SIGNALS IS A SERIOUS SAFETY HAZARD. *TR
Exterior lighting, Sep 9, 2011
TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE BRAKE LIGHTS WOULD NOT ILLUMINATE WHEN THE BRAKES WERE APPLIED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THE GROUND WIRE IN THE ELECTRICAL PANEL HAD SHORTED DUE TO CORROSION. THE VEHICLE WAS REPAIRED AND THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT THEY WERE UNABLE TO INFORMED THE CONTACT IF THE VEHICLE WAS INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER: 11V438000 (EXTERIOR LIGHTING:TAIL LIGHTS). THE FAILURE MILEAGE WAS 65,000. UPDATED 10/04/11 *BF UPDATED 3/30/12 *CN
Exterior lighting, Sep 8, 2011
THE HEAD LIGHT REFLECTING BOWLS ON HID HEADLIGHTS ARE BURNING OUT THEREBY RESULTING IN POOR LIGHTING UNDER ALL CONDITIONS. *TR
Air bags, Sep 2, 2011
TL* THE CONTACT OWNS A 2004 BMW 325I. THE CONTACT STATED THAT THE PASSENGER SIDE AIR BAG WARNING LIGHT CONTINUED TO ILLUMINATE WHETHER THE SEAT WAS OCCUPIED OR NOT. THE CONTACT CALLED THE MANUFACTURER REGARDING THE PASSENGER SIDE AIR BAG AND THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INVOLVED IN ANY RECALLS. THE CONTACT STATED THAT THE MANUFACTURER WOULD NOT OFFER ANY ASSISTANCE ON REMEDYING THE ISSUE. THE CONTACT WAS CONCERNED THAT THE AIR BAG WOULD NOT DEPLOY PROPERLY IN THE EVENT OF A CRASH. THE FAILURE MILEAGE WAS 95,000.
Exterior lighting, Interior lighting, Aug 25, 2011
THE XENON HEADLAMPS ON MY 2004 BMW 330I COMPLETELY FAILED. THE HEADLAMP REAR PROJECTOR BOWL ON THIS MODEL IS PRONE TO OVERHEATING WHICH LEADS TO THE DELAMINATION OF THE PROJECTOR REFLECTIVE MATERIALS RESULTING IN COMPLETE HEADLAMP ASSEMBLY FAILURE. REPLACEMENT ASSEMBLIES FROM THE DEALER LIST AT ~ $600 FOR EACH SIDE OF THE CAR. THIS A COMMONLY KNOWN ISSUE IN THE BMW ENTHUSIAST COMMUNITY - I HAVE ALSO WITNESSED THE PROBLEM FIRSTHAND ON TWO OTHER BMW 330IS OF THE SAME MODEL YEAR. WHEN THE ISSUE HAPPENED TO ME, I WAS UNABLE TO DRIVE THE CAR SAFELY AT NIGHT AS THE ONLY ILLUMINATION AVAILABLE WAS FROM THE PARKING LIGHTS. THIS IS CLEARLY A SAFETY ISSUE AND A PRODUCT DEFECT. *TR
Exterior lighting, Aug 8, 2011
BOTH TAILLIGHTS HAVE BEEN OUT DUE TO CORROSION IN THE 8 PIN CONNECTOR. THIS HAS PREVENTED THE SIGNAL AND OCCASIONALLY THE BRAKE LIGHT TO WORK. WHILE MAKING HIGHWAY TURNS I HAVE COME CLOSE TO ACCIDENTS NUMEROUS TIMES. I CANNOT MAKE A TURN WITHOUT TAKING MY EYES OFF THE ROAD. THE BULB WARNING IS ALSO ON DISPLAY ON THE DASH. *TR
Latches/locks/linkages, Aug 4, 2011
2004 BMW 325XI ELECTRONIC DOOR LOCKS FAIL TO UNLOCK INTERMITTENTLY WHETHER I AM OUTSIDE THE CAR OR INSIDE THE CAR. THE KEY FOB WILL INTERMITTENTLY NOT UNLOCK THE DOORS. THE INTERNAL MECHANISMS WILL NOT UNLOCK THE DOOR INCLUDING THE DOOR HANDLES THEMSELVES ONCE THE LOCK IS ENGAGED. THE FAILURE IS AN ELECTRONIC ISSUE AND IS A SIGNIFICANT SAFETY ISSUE IF I CANNOT GET OUT OF THE CAR. *TR
Exterior lighting, Jul 28, 2011
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. *TR