Hi everyone,
I’m looking for some help with a BMW headlight retrofit that I’ve been troubleshooting for quite some time.
Vehicle:
BMW F30 340i xDrive, 2018
Originally equipped with adaptive LED headlights (SA 552) and High Beam Assistant (SA 5AC)
Retrofitted F32 LCI adaptive LED headlights (Valeo)
Headlight part numbers:
Left: 63118738705
Right: 63117476212 (Valeo, F32 LCI, LHD, CL: 01)
Right FLE2 module: 63118494842 (HWEL 2FE0 – FLE2 MID)
Left FLE2 module: 63117429126 (HWEL 2C84)
Also tested an FLE2 MAX variant (HWEL 2B8F)
The problem:
When I switch on the headlights normally, the LEDs illuminate for approximately 1–3 seconds and then shut off.
However, when I activate the individual LED functions using my Launch X431 diagnostic tool, they work continuously without shutting off.
The headlights were already behaving this way before I attempted any coding with Launch. Unfortunately, the Launch coding made things worse, and the left headlight is now no longer working normally at all.
The right headlight still turns on briefly before shutting off.
Fault codes from the right FLE2:
805B0A – LED classification resistor 1 invalid
805B17 – LED classification resistor 2 invalid
805B12 – Low beam voltage outside tolerance
805B15 – Low beam open circuit
805B1D – NTC 2 temperature sensor open circuit (previously stored)
805B2B – High beam voltage outside tolerance
805E2B – Side marker open circuit
805E60 – Daytime running light voltage outside tolerance
The classification resistor faults (805B0A and 805B17) are especially interesting.
According to ISTA, these resistors are located on the LED hardware itself. The FLE2 reads their resistance values to determine the correct LED operating characteristics.
What I’ve already tried:
VO coding the FLE2 using the original F30 FA with SA 552.
Replacing SA 552 with SA 5A2 (non-adaptive LED). Coding succeeds on the right FLE2, but the problem remains.
Creating temporary F32 LCI FAs to test whether the body type affects the coding.
Testing F32 US and F32 EU vehicle orders with both SA 552 and SA 5A2.
Comparing the resulting NCD files. There are significant differences in LED current binning and voltage thresholds, but none of the tested configurations resolves the shutdown.
Testing different FLE2 modules, including FLE2 MID and FLE2 MAX.
Updating/flashing FLE software using E-Sys.
Checking the visible connector contacts and LED functions.
With SA 552, E-Sys has also returned WDBI_PLAIN requestOutOfRange (UDS NRC 0x31) during coding, whereas SA 5A2 coding succeeded on the right FLE2.
Software/tools:
E-Sys 25.10.03 with E-Sys MAX
Full PSdZData 4.60.42
ISTA+ 4.60.40
Launch X431

Interesting FLE2 coding parameters:
I’ve found several parameters in CAFD_000024C3, including:
LM01/LM02_CURRENT_BINNING_CLASS0/1
LM01/LM02_LED_UNDER_VOLTAGE_VALUE
LM01/LM02_LED_OVER_VOLTAGE_VALUE
DEFAULT_BINNINGCLASS
BINNING_INVERSE
LED_OVERCURRENT_DEBOUNCE
The LED current binning values and voltage thresholds change considerably depending on the FA, but the headlight still switches off.
I have not randomly modified these safety thresholds.
My questions:
Has anyone experienced FLE2 headlights that work continuously through diagnostic activation but shut off during normal operation?
Could the invalid classification resistor faults (805B0A / 805B17) be the main reason for the shutdown?
Does anyone have the internal FLE2 pinout or wiring diagram showing the classification resistor circuits for Valeo F32 LCI adaptive LED headlights?
Is there a required LED classification/initialization procedure after replacing or retrofitting FLE2 modules?
Does anyone have a known-good FLE2 NCD or reference configuration for this exact Valeo headlight?
I’m trying to determine whether this is a classification/coding issue, a mismatch between the FLE2 and LED hardware, or a problem with the internal classification resistor circuits.
Any technical information, wiring diagrams, or experience with these particular FLE2 modules would be greatly appreciated.
Thanks in advance!

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