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Old 08-06-2016, 06:00 PM
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Join Date: Dec 2015
Location: Miami
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Headlight wiring falling apart... see pictures...

Hi,
I've had my 2006 X5 3.0 for nearly 10 months. The car has been great, just had to do some minor maintenance. Quite happy until now.

One of those "minor maintenances", was to tape some wiring when maybe 6 months ago I got some "check low beam light" alerts, for my passenger side.
Some of the cables were showing the wiring where the plastic cover had frayed, so I was able to isolate them with some electrical tape (see white taped wires in the first picture below).

Well, a couple of weeks ago I got the alert again. I noticed a few more copper wires showing, so I taped those the best I could, but it still failed sometimes. I.e. some days it would work, others, the low beams wouldn't turn on and I would get the alert.

So today I decided to dedicate some time to this. My findings:
- it's also the passenger high beams and not just the low beams anymore
- I picked inside a little round plug behind the high beams and saw more frayed wires.
- I search for more than one hour for wiring harnesses that could replace the whole thing and got nowhere...
- I found some good information on checking first the voltage coming from the 12 wire connector, to check if the problem isn't in the LCM module.
- The connector has some weird shaped pins, so it wouldn't be easy to use the voltmeter. Anyway, I went for the wiring, as the damaged parts I saw meant that even if it wasn't from them, it would be good to fix it...
- I went ahead and started removing the headlight assembly.
- I then noticed that the front bumper also had to be removed.
- Partially removed the bumper (took all the screws off, but pulling out the passenger bumper side gave me enough space to remove the headlight)
- Removed the headlight plastic back cover
- Did not like what I saw: the complexity of cables and the amount of fraying...

South Florida is rather hot and humid, but never thought cables in a BMW could get like this after 10 years...

Anyway, below are some pictures of what I found.
Has anyone had similar problems? Any recommendations on how to go at it? Is there a part number for this wiring harness?





Zooming in:




Thanks for your help!
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2006 Black BMW X5 3.0
125,000 miles
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