How To Repair Heat Damaged Headlight Wiring. On My E90 BMW. 

They really need to have replacement wiring harnesses for the inside of these headlights, the insides absolutely cook themselves and is entirely the fault of low quality wiring/sheathing.

When the guy making the video is wearing plaid pajamas an flip flops, you know he's a real mechanic.

Thanks for the tutorial!! I just finished doing both the headlights on my 07 e92. Had to heatshrink 90% of the wires and remove the clear cover for access. It took the better part of 2 days. Still better than paying 650.00 each. Use 1/8" 3/16" & 1/4" Heatshrink @ 3 to 1.

A friend's 2005 X3 with HID Xenon Headlights (Driver's Side Low Beam Inop) had similar issues with the Insulation Crumbling exposing bare wires within the Headlight Assemblies. I removed the Headlight Assemblies and essentially Coated the Bare Wires and what Cracked Insulation that still existed with Clear Silicone Sealant (Flowable for Windshield Leaks) with my fingers and keeping the Wires separated. 24 Hours later after the Silicone Sealant had Cured... I was able to Diagnose the Drivers' Side as having a Failed Ballast (by swapping Lamps and Ballasts as needed). Randy AKA randog311 (Retired Professional Wrench). FYI: I have no Idea why the NHTSA hasn't Mandated a Vehicle Safety RECALL for this Obvious Safety Headlight Issue that many Automotive Manufacturers have, BMW is not alone.

Excellent video as always. I was changing out the halo lamps in my 08 E92 and realized that I have the same brittle-wires problem. This helped me tackle the surgery required to fix the issue. Saved me a lot of time trying to figure out the best route. Also saved me a ton of money in replacing the headlamp assemblies. I tried the electrical spray tape, but that didn't coat the wires enough for me to give me confidence it wouldn't cause a short. Thanks again!

Really nice work, my Houston 2006 BMW 330i E90 was shorting on the DRL. I tried liquid electrical tape a few months ago as I really did not want to get into the harness. Thanks for showing me the way and really admire your patience.

This 100% should have been a recall. EVERY single owner I know that has one of these has had this problem. Its pathetic :(

I know imma tad bit late but Yes it does suck. Germany used recycled material is why. Because of all their emmisions. I believe they won an award for it as well.

Thanks for the video. I noticed this issue with my ‘09 335i. Had the headlight assembly out today to fix the right side adaptive headlight which was pointing at the ground. Checked over the wires and avoided touching anything that might flake off insulation. LOL You can now buy “paint on” liquid electrical tape and it comes in various colors. Used it a few months ago to fix bad insulation on wires after change out the day time running lights.

I have the same issue. I live in Medellín, Colombia, which is tropical, but also mountain weather. Temps range from 60F to 85F. What I've heard is that BMW used a biodegradable insulation on every single cable (Including the headlights). Didn't think about using shrinks to fix it. I was actually looking for wire to replace them all. But your idea is waaay better. I'll buy some and give it a shot

Hey great work here! I have same problem and fixed it quickly with some hot glue so the wires are stuck and can not touch. But this fix is for sure better. Regarding the Angel eye still off, probably you have to use the Tool32 for the Short Circuit counter Reset. That fixed the issue 100%, i had the same problem

It's biodegradable plastic mandated in the 1990's by the German Green Party...and I am not making that up. Mercedes has cars with engine wiring harness issues as well. I have two 1990's Benz wagons that I had to replace the engine wiring harnesses on because the wiring insulation deteriorated just like this BMW. I also have a 2006 X5 with a headlight issue like this one. That's how I arrived here.

Thanks so much, You saved me alot of money with this vid. Got my lights back.

I have a e92, and I have the same issue on one of my headlights. My halo lights don't work, and when I looked inside the headlight the wires going to the angel eye bulb socket are flaking. Thanks for making this video. 👍

'06 330i: I tested the working Xenon bulb and ballast from the passenger's side on the driver's side and it did not turn on. Driver's side Xenon and ballast don't work on the passenger's side. About a 1.5" of insulation on the DC wires into the ballast is stripped on both leads. Unfortunately, after giving up and slapping the rear headlight cover back on, now the driver's side angel eyes and DRLs are also out in addition to the Xenon. Do I need to go through this whole process of removing my bumper and entire headlight assembly, inspect the wires and heat shrink the bad ones? Your video was so informative and helpful. Even though you sound depressed. Great video. UPDATE: my driver's side angel eyes just came on. So now only the DRLs and Xenons are out on that side. I expect the angel eyes to stay on go out again soon, and maybe be intermittent.

Keep up the great work, ur sport mode not working video got my sport mode back!

Get the CREE angel eyes with small balasts, but don't get cheap ones. I put some of those in my E60 and i'm in Dubai where there is lot of heat during the year and they work perfectly. Thanks for the video !

Great job boss I really like way how you work on it and Gentle works!!!!!

I have an '11 E93 and I have a right and left stepper motor box failure DTC. All of the lights blink about 9 times at startup, the headlamps sweep up and down while driving straight and side to side in turns. The FRM has been checked and is fine and the headlamp bulbs are OEM. Do you think this could be my problem or do I need to contact an Exorcist?

My '04 e46 330ci has this same issue. Just found it out and a noticiable thing is I don't use it a lot, and when i do, i do it during daytime (no drl) so i dont use headligthts. it has only 50K miles so i think its age and heat related (not only heat)

What a great video. Thanks a lot for this. And you also have a great diction. Well done.

i had the same problem with my angle eye. the problem was that there is a mirror that sits in a bracket on the inside of the housing that reflects the light into one of the angle eyes (one bulb lights up both angel eyes). i carefully popped the mirror back into the bracket and works perfect now. headlight does have to be removed so it can easily be worked on

man...i need to tackle this job soon...but on an e60...what a PITA. great job though.

You are a HUGE HELP! plan to do the same unpin and heat shrink tubing on my flaking 06 e86 Z4. I purchased 1/8" and 3/32" tubing is that the right Size ?? Thanks! Dan

So, I had this exact problem on my e92, and this video btw, was amazing.. best one I found for removing the headlight. Anyhow, I pulled the headlight out, and honestly- my wires look fantastic. Do you think anything else could cause the same issue? Symptoms: Nothing works in the housing, except for the turn signal & running light bulb. Angel eyes, low & high beams do NOT work at all. Other side works fine (passenger). Could something as simple as the ballast be the issue?

Quick question I have an E92 2008 328 I if i unplugged the The headlight assembly to clean it up do they need to be reprogrammed When I reinstall them I'm not looking to change anything electric or change out anything that the car didn't come with I just want to make sure when I plug it back in it'll work I don't have anything but nice thing but a Fox well NT530 Scanner.

I just went through this problem with my 06 e90 talk about pain in the a**!

My high beam solenoid on the driver's side doesn't work. I'm assuming it looks like your frayed wire to your DRL. Nice video, thanks.

Would it be possible to replace the wiring itself? After you de-pin everything? If all else fails, I guess you could hard wire a D1S using a adapter and find power for the angel eyes themselves. You would lose active steering though. I feel like all used units are going to have this issue. It should be recalled.

Excellent efforts, but the heat shrink means nothing if all the cables are the old ones

Thank you so much for going in depth and talking us through everything. I'm debating doing this for my e93 M3, wanted to see if anybody has done this for that headlight assembly?

My Angel eyes and The actual Light won’t turn on, only the blinker works on my passenger side, any advice on what could be?! I live in Houston as well… thanks!!!

Thanks for the video man!

Thanks. Your video helped me out!!!

Another very informative tutorial. Cheers.

Do you rebuild the 04 BMW E60 Adaptive headlights for customers?

Thanks good job

Great video

Cool video 👍🏻👍🏻

Do you think the E92 headlights would have the same issues? Thanks for the video!

Take entire front end of the car off to replace a headlight wire. F'ing ridiculous.

May i know the heat shrinks size for the headlamp unit ?

Thank you. I have the same problem with my E60, DRL on passenger side went out first I thought it was the lighting bulb, but it wasn't, the drl on the driver side went out yesterday it turned out all the wires were exposed, and i use black tap to wrap it up, it works. but the passenger side is still not working, there no voltage coming out from the harness, or the connector. Do you figure out what is the problem?

i've same issue, with the condition. HID D1S on left side i switch to right side, and there was normal. but when i try to relocated on original position (left) it off, thats the same issue like this vid?

Hey man. Really need some help on mine. Is there any way I could get in contact with you? Email? Text? Anything? I can’t get power to my high or low beams or my DRL or my turn signals on my driver side. I bought the car with a severed harness and i bought a new one and I can’t find where 3 wires go. Really need some help and can’t find a wiring diagram anywhere. Thanks man

What tools do you use to separate the lines in the connector?

You should have attempted to reset foot module. windows xp Impa program....

Heat shrink… a lighter works it in seconds

At 9m53s....thats what she said 😋

This looks very tedious...

Ads every 2 min. Man you're a grifter

I have similar issue if u could help ... I replaced the bulb and ballast and bulb wont turn on I see a slight flicker when I turn on the headlights the halos work ... only having the issue on the passenger side please help always following ur videos