Each email that is generated by the shop web application is returning: Delivery status notification, invalid header: bad MIME
From looking at the error message it look like it is complaining about the HTML that is in the email although when viewing the source there doesn't look like a problem.
Your message WAS SUCCESSFULLY RELAYED to:
<tim@example.com>
This delivery report was generated by the program amavisd-new at host
example.com. Our internal reference code for your message is
20971-09/NNjaWqvFY5Qg
INVALID HEADER: BAD MIME HEADER SECTION OR BAD MIME STRUCTURE
MIME error: error: couldn't parse head; error near:; Return ID: 1; Return
Date: 11/09/2011
Return-Path: <tim@example.com>
From: =?UTF-8?B?WW91ciBTdG9yZQ==?=<tim@example.com>
Message-ID: <20110911175440.A84BE5E099@example.com>
X-Mailer: PHP/5.3.4
Subject: =?UTF-8?B?WW91ciBTdG9yZSAtIFJldHVybiBVcGRhdGUgMQ==?=
dsn_status
Reporting-MTA: dns; example.com
Received-From-MTA: smtp; example.com ([127.0.0.1])
Arrival-Date: Sun, 11 Sep 2011 18:54:40 +0100 (BST)
Original-Recipient: rfc822;tim@example.com
Final-Recipient: rfc822;tim@example.com
Action: delayed
Status: 2.0.0
Diagnostic-Code: smtp; 250 2.6.0 Bad message, but will be delivered anyway
Last-Attempt-Date: Sun, 11 Sep 2011 18:54:40 +0100 (BST)
Final-Log-ID: 20971-09/NNjaWqvFY5Qg
header
Return-Path: <tim@example.com>
Received: from example.com (cpc10-donc9-2-0-cust122.barn.cable.virginmedia.com [94.171.174.123])
by example.com (iRedMail) with ESMTPSA id A84BE5E099
for <tim@example.com>; Sun, 11 Sep 2011 18:54:40 +0100 (BST)
To: tim@example.com
Subject: =?UTF-8?B?WW91ciBTdG9yZSAtIFJldHVybiBVcGRhdGUgMQ==?=
X-PHP-Originating-Script: 0:mail.php
MIME-Version: 1.0
Date: Sun, 11 Sep 2011 17:54:40 +0000
From: =?UTF-8?B?WW91ciBTdG9yZQ==?=<tim@example.com>
Reply-To: Your Store<tim@example.com>
X-Mailer: PHP/5.3.4
Content-Type: multipart/related; boundary="----=_NextPart_b45f3c386576f1955bb5338634f5047f"
Message-Id: <20110911175440.A84BE5E099@example.com>
Email Message source that causes the above error:
Return-Path: <tim@example.com>
Delivered-To: tim@example.com
Received: from localhost (localhost.localdomain [127.0.0.1])
by example.com (iRedMail) with ESMTP id 4C03E5E09C
for <tim@example.com>; Sun, 11 Sep 2011 18:54:41 +0100 (BST)
DKIM-Signature: v=1; a=rsa-sha256; c=relaxed/simple; d=example.com;
h=message-id:content-type:content-type:x-mailer:reply-to:from
:from:date:date:mime-version:subject:subject:to; s=dkim; t=
1315763680; x=1316627680; bh=18GKmsQjF86uG/PbhhDg2FY9o3H6chH8XZo
4VFFN45k=; b=g4TbDzU8pWzeX7CdmCI/Sq8JjtPM6wTQIMqQ7dRclE0XqCVgEZ4
OeQtpR1zApiV31RLu87k9QQF6a4mvCmr1N31auiq4u+AfxFW3DujSvDz5h3lSSf4
vPVgHwzEBQbaue9VeZ0nPmHhrrJWojv5iMlfjUKIdNJkBuP9BF3plVgA=
X-Quarantine-ID: <NNjaWqvFY5Qg>
X-Amavis-Modified: Mail body modified (using disclaimer) -
example.com
X-Virus-Scanned: by amavisd at example.com
X-Amavis-Alert: BAD HEADER SECTION, MIME error: error: couldn't parse head;
error near:; Return ID: 1; Return Date: 11/09/2011
X-Spam-Flag: NO
X-Spam-Score: -6.697
X-Spam-Level:
X-Spam-Status: No, score=-6.697 tagged_above=-999 required=6.31
tests=[ALL_TRUSTED=-10, AWL=-1.381, FROM_EXCESS_BASE64=1.984,
HTML_MESSAGE=0.001, MISSING_MIME_HB_SEP=2.699] autolearn=disabled
Received: from example.com ([127.0.0.1])
by localhost (example.com [127.0.0.1]) (amavisd-new, port 10024)
with ESMTP id NNjaWqvFY5Qg for <tim@example.com>;
Sun, 11 Sep 2011 18:54:40 +0100 (BST)
Received: from example.com (cpc10-donc9-2-0-cust122.barn.cable.virginmedia.com [94.171.174.123])
by example.com (iRedMail) with ESMTPSA id A84BE5E099
for <tim@example.com>; Sun, 11 Sep 2011 18:54:40 +0100 (BST)
To: tim@example.com
Subject: =?UTF-8?B?WW91ciBTdG9yZSAtIFJldHVybiBVcGRhdGUgMQ==?=
X-PHP-Originating-Script: 0:mail.php
MIME-Version: 1.0
Date: Sun, 11 Sep 2011 17:54:40 +0000
From: =?UTF-8?B?WW91ciBTdG9yZQ==?=<tim@example.com>
Reply-To: Your Store<tim@example.com>
X-Mailer: PHP/5.3.4
Content-Type: multipart/related; boundary="----=_NextPart_b45f3c386576f1955bb5338634f5047f"
Message-Id: <20110911175440.A84BE5E099@example.com>
------=_NextPart_b45f3c386576f1955bb5338634f5047f
Content-Type: multipart/alternative; boundary="----=_NextPart_b45f3c386576f1955bb5338634f5047f_alt"
------=_NextPart_b45f3c386576f1955bb5338634f5047f_alt
Content-Type: text/plain; charset="utf-8"
Content-Transfer-Encoding: 8bit
Return ID: 1
Return Date: 11/09/2011
Your return has been updated to the following status:
Complete
The comments for your return are:
gsfdgf
g
fdgfdgfdgfd
Please reply to this email if you have any questions.
------=_NextPart_b45f3c386576f1955bb5338634f5047f_alt
Content-Type: text/html; charset="utf-8"
Content-Transfer-Encoding: 8bit
<!DOCTYPE html PUBLIC "-//W3C//DTD XHTML 1.0 Transitional//EN" "http://www.w3.org/TR/xhtml1/DTD/xhtml1-transitional.dtd">
<html xmlns="http://www.w3.org/1999/xhtml">
<head>
<meta http-equiv="Content-Type" content="text/html; charset=utf-8" />
<title>Your Store</title>
<style type="text/css">
v\:* {
behavior: url(#default#VML);
display:inline-block;
}
</style>
</head>
<body bgcolor="#f5f5f5" style="margin:0; padding:0; background-color:#f5f5f5; color:#333333; font-size:12px; font-family:Helvetica, Arial, sans-serif; line-height:18px; width:100% !important;">
<table width="100%" border="0" cellspacing="0" cellpadding="0">
<tr>
<td align="center">
<table width="660" border="0" cellspacing="0" cellpadding="0">
<td id="main-bg" align="center" valign="middle" background="http://www.example.com/default/image/mail/body-repeat-white.gif" style="margin:0 auto; background-image:url('http://www.example.com/default/image/mail/body-repeat-white.gif'); background-repeat:repeat-y; width:660px; postion:relative;">
<!--[if gte mso 9]>
<v:background xmlns:v="urn:schemas-microsoft-com:vml">
<v:fill type="solid" src="http://www.example.com/default/image/mail/body-repeat-white.gif" />
</v:background>
<![endif]-->
<table width="580" border="0" cellspacing="0" cellpadding="0" style="overflow:hidden; table-layout:fixed; width:580px; word-wrap:break-word;">
<tr>
<td id="header-bg" bgcolor="#515151" background="http://www.example.com/default/image/mail/head-bg.jpg" style="background-image:url("http://www.example.com/default/image/mail/head-bg.jpg"); background-repeat:no-repeat; background-color:#434343; font-size:30px; color:#ffffff;">
<table border="0" cellspacing="0" cellpadding="20">
<tr>
<td>
<a href="http://localhost/opencart-1.5/" title="Your Store" style="display:block;padding-left:10px;">
<img src="http://localhost/opencart-1.5/image/data/logo.png" alt="Your Store" style="display:block; border:none;" />
</a>
</td>
</tr>
</table>
</td>
</tr>
<tr>
<td bgcolor="#ffffff" style="background-color:#ffffff; padding:5px 25px 0; font-size:12px; font-family:Helvetica, Arial, sans-serif; line-height:18px;text-align:left;">
<h1 style="color:#333333; font-size:18px; font-weight:bold; line-height:28px; margin:10px 0;">Your Store</h1>
<p>
<strong>Return ID:</strong> 1<br />
<strong>Return Date:</strong> 11/09/2011 </p>
<p>Your return has been updated to the following status: <strong>Complete</strong></p>
<p><strong>The comments for your return are:</strong>gsfdgf<br /><br /><br />g<br />fdgfdgfdgfd</p>
<p>Please reply to this email if you have any questions.</p>
</td>
</tr>
</table>
</td>
</tr>
</table>
</td>
</tr>
</table>
<style type="text/css">
p {
font-size:12px;
font-family:Helvetica, Arial, sans-serif;
line-height:18px;
margin:4px 0 12px;
}
strong {
font-weight:bold;
}
a {
color:#28b0ec;
text-decoration:none;
border:none;
}
a:hover {
color:#28b0ec;
text-decoration:underline;
cursor:pointer;
}
a:visited {
text-decoration:underline;
}
</style>
</body>
</html>
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------=_NextPart_b45f3c386576f1955bb5338634f5047f--