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Old 05-03-2010, 08:01 PM   #1 (permalink)
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2003 540i leaking door seal/windshield seal

Hello to all,

I am the original owner of a 2003 540i that is experiencing some water leakage issues. Due to a tougher than usual winter here in Maryland, the car sat idle in the driveway with a cover on it for several months. I first noticed that condensation could be seen during cold weather or immediately after a rain or snow storm. Also, the rear passenger seat's footwell would become very wet after a steady rain. I checked everywhere in the car and that was the only wet spot to be found. I recently cleaned it up and was getting ready to break it out for the nicer weather. I jumped the battery, as it had been sitting for the time mentioned. The first jump was fine, the car started, and all seemed fine....all lights functioned properly, the radio was fine, and the car ran fine. Unfortunately, the battery did not hold the charge and went dead again. I jumped it again a day or so later, only this time the front headlight washers and windshield washers came alive and sprayed the car as soon as I connected the positive connection. The car started fine once again, all lights turning on and seeming normal, minus the overactive washer streams. Just last week, after a few rain showers, I went out to soak up the wet spot in the back and noticed a water streak coming from the glove compartment. I opened it up to find it full of water. This had never happened before. After cleaning that mess up I jumped the car again and everything started and worked like the other times that I jumped it. Obviously the battery needs to be replaced. I took the car into my local dealership and they indicated that the windshield seal has a leak and that they would need to remove the dashboard to figure out where the leak was coming from and to determine any internal damage. They seemed to be concerned about an electrical fault, etc. despite the fact that everything in the car turns(ed) on when jumped and running. I should hear more tomorrow about what they find under the dash. The service rep that I spoke with seemed unsure as to what the issue is and how to correct it. I am nervous that the water damage may be severe and don't really know what to expect. The car seems to run and "act" perfectly and just seems to need a new battery. Has anyone had a similar issue? If so, how did everything turn out? If anyone can shed some light on these issues or has any suggestions, any help would be greatly appreciated. I love this car and want it back safe and sound.

Thanks,

-Jason
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Old 05-03-2010, 11:39 PM   #2 (permalink)
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Jason, i had the same problem with my car. Its the seal around the windshield. to test it take a hose and run water over the passenger side of the windshield. Us a low amount of water.place hose on top of car,let it run down the windshield seem and then go inside the car (drivers side) and watch the water come in just below the glove box. it a real simple fix unfortunately glass insurance does not cover this
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Old 05-04-2010, 03:01 PM   #3 (permalink)
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Originally Posted by dcuse32 View Post
Jason, i had the same problem with my car. Its the seal around the windshield. to test it take a hose and run water over the passenger side of the windshield. Us a low amount of water.place hose on top of car,let it run down the windshield seem and then go inside the car (drivers side) and watch the water come in just below the glove box. it a real simple fix unfortunately glass insurance does not cover this
I appreciate the information. I spoke with the dealership today and the windshield seal is indeed in bad shape and will be replaced. It sounds like all of my door seals are needing to be replaced as well. There does not seem/appear to be any significant electrical damage inside the dash area, but there is still standing water on the bottom floor panels (where the persistant wet spot is) and a fuse box on the floor will most likely be replaced. If all goes well, I will have the 540i back by the end of the week. I am keeping my fingers crossed that all will go smoothly.

Thanks,

-Jason
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