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Old 04-19-2015, 04:59 PM   #1
325CiBrett
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Headlight wire harness

Been having issues with my passenger side bi xenon adaptive headlight. Thought it could be the ballast or wiring. Sure enough, I pop the cap off the xenon cover and find this.
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Does anyone know if it's possible to get a new harness? Or do I need to splice the wires together and call it good?
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Old 04-19-2015, 05:20 PM   #2
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You can get every part for your car. Realoem.com But, if it's just the black wire (the green wasn't hooked up, I think?), then sure, just cut out the bad section and redo it. I would solder it and cover it with shrink tube (remember to have the tube on the wire first, a distance from the soldering). If you don't know how to solder, search youtube--how to solder wires. You could just use a crimp coupling too, but most I know believe those to be inferior. You do not need a new harness...I'm sure you've got enough play in the wire to lose an inch of it.

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Old 04-19-2015, 05:38 PM   #3
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The green wire is actually fully severed, the black wire is partially severed, and the red wire is starting to break at the harness.
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Old 04-19-2015, 06:09 PM   #4
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If you have enough wire coming out of the connector to splice, that's fine. Otherwise, you can just get the connector...and a decent parts guy will get you the wires (with plugs) to go into it...and you'll splice that into what you have. You could find the connector in realoem yourself, but a dealer parts guy will do it quicker...and it won't cost that much.
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Old 04-24-2015, 11:47 PM   #5
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Just an FYI, the dealer near me says they don't have any wiring for the inside of the headlight housing. So my options at this point are:

1. Look for another identical used headlight and swap out the internal wires.

2. Splice the existing wires back together. (Almost impossible at this point, due to the red wire coming apart AT the connector)

3. Buy a new OEM headlight assembly at $875. (Adaptive Bi Xenon)
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Old 07-08-2015, 10:07 PM   #6
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I have the same issue on a 04 330Ci.

There is a wiring harness for this; ask for 61126936975. I learned of it while talking to the Parts Manager at Atlanta BMW, who only knew about it because it's usually used by Auto/Body folks. I'm having one shipped to my Dealer to ensure it's correct.

Here's a Google Search Link and JPG.
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Old 07-08-2015, 11:05 PM   #7
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So those are the internal wires for Bi-Xenon Adaptive headlights?

I've resorted to splicing the wires back together, but I get the feeling that it's just going to happen again at some point due to the small wiring and crappy insulation.

My only question is, are you supposed to plug the wires back into the connectors, or do you also have to order new connectors? As in the one that plugs into the igniter.

And this is just another reason to avoid Baron BMW in Kansas City. Every time I go in there with part numbers in hand, they say they don't carry the part. Even though they're still using the same part on brand new BMWs. I get the same lazy half-assed attitude every time, no matter who is working that day.
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Old 07-09-2015, 08:54 AM   #8
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I've spiced mine to the point I have no more room. According to the guys at Atlanta BMW, it should work. The Parts Manager used to do the Body Work. He suspects it's a plug/play back to the controller and recommended looking at it with the car there to figure it out...nothing better than having a Pro who still thinks like an Owner!
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Old 10-29-2015, 09:36 AM   #9
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Talking

I have the same issue on a 2006 330ci w/ Adaptive Bi Xenon headlights.
It looks almost identical to the photo in this thread. It's sad that they make something like this, that literally just falls apart with no explanation.

I was wondering if the part number that you ordered actually fit and fixed the issue?

If so, I'll order the part and fix mine since it is too frayed to splice.
TIA
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Old 10-30-2015, 08:15 AM   #10
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Wanted to share some insight after further investigation. The part number for a 2003-2006 330Ci with the adaptive bi xenon headlights is 61126939279 from Realoem.com



This part, however, is EXTERNAL to the headlight housing and does NOT repair the ignitor wiring issue. It will repair the external wiring from the headlight housing back to the main underhood wiring loom, including the connectors on the back of the headlight housing, as seen in the attached picture. But it will not replace the internal wiring of the ignitor connection. For this, I have not yet found a solution.

Any previous part numbers listed by the OP might fit other models but are for the M3 only.
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Old 11-02-2015, 11:07 AM   #11
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What did it set you back?
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Old 11-02-2015, 12:11 PM   #12
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I did not buy it because it does not fix my issue. I just wanted others to know that it doesn't actually fix the issue of the broken wiring INSIDE the headlight housing.
For my repair I used these:

Just insert the two broken ends (instead of the three shown).
I had several of them lying around.

So far, it's working.
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Old 11-06-2015, 08:46 AM   #13
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Can someone explain what ^ piece/ picture is? I had planned to solder mine back together.
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Old 11-06-2015, 09:01 AM   #14
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ScotchLoks

Here ya' go. You can pick these up at your local Radio Shack ( if you still have one) or order online. This is for 100 but you can usually find smaller quantities if you look around online.

http://www.elliottelectronicsupply.c...one-wires.html

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Old 11-06-2015, 09:14 AM   #15
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Thank you! Any idea what gauge wire is used in the event that I need to remove an old section or don't have enough room?
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Old 11-06-2015, 10:25 AM   #16
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Sorry, but I would guess maybe 22-24??
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Old 11-06-2015, 10:48 AM   #17
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I've used the liquid electrical tape to repair the wires. Gardner Bender brand on amazon works great and is cheap
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Old 11-06-2015, 03:10 PM   #18
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So I've been subscribed to this thread, (seeing how I created it) and I haven't been getting updated on new posts.

Anyhow, 7 months later and my wiring is still good after splicing them back together.
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Old 11-06-2015, 10:45 PM   #19
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I've repaired my wiring in mine before. If you go to a junk yard for a e46 you can take the connector from the interior motion sensor and cut the wiring back as far as you can. You have to trim one part of the connector a hair but it works perfectly and puts new wiring in where the headlight bends the wiring
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Old 11-07-2015, 02:53 AM   #20
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Mine are the same way. First I had the green totally disconnected and then the black and red were peeling the plastic.

What I did, soldered mine back together. I checked into this maybe a year ago and there is no harness. I even wrote to Hella and asked if they could sell me the internal harness. Never heard back.

So I bought some wire from the wirebarn.com

They sell automotive grade wire, there is a gxl and txl, the txl is a extra thin plastic coating. From my research you need the TXL to work with the fittings and there were both 14 and 20 or 22 GA. in there. So I bought like one roll of 14 GA and a 10 pack of different color in 20 GA.

This stuff is supposedly better than the existing wire in there which from my research I heard it was a biodegradable wire in there. Something about following landfill rules and what not. Anyway, this I feel is a safety issue as the headlights can turn off on you if the wiring breaks or shorts.

So I have not changed the wiring yet. The solder job is still working, but I have the wire on hand. Also I was looking for new connections so I didn't have to use the old ones. I did a lot of searching on line and I even emailed a few places and I have never found the connections I needed, so unless someone does, you may have to try and pull the pins out to get the wires out of the old plugs and re-use the pins with the new wire. If I had an old light I would pull it apart and use that one to make a new harness out of it and have it ready to go.

It is just ridiculous to have to pitch the headlights and drop 600-800 each for new headlights over a wire harness inside of the housings that go bad.
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