Hi guys, first post here - and its about a leaky bimmer
Last Saturday I found a huge (2-3 litres) amount of water sloshing around the driver side footwell of my 2005 120i. I park facing downhill on a relatively steep road, which also has a decent camber, so the car is in a distinct lean to the left also.
I had the fortune of actually seeing a trail of the water coming over the bottom part of the drivers side door seal which isolated the issue to the door (and not the windscreen or firewall). It looked exactly like the photo at the bottom of this page: http://www.z4-forum.com/forum/viewtopic.ph...membrane#p26325, though clearly on a 120 not a Z4.
After taking the door panel off, I found the membrane/vapour barrier to be in good condition (no rips etc), and no sealing issues - this seems to be the number one cause of such leaks according the various forums I have read.
However, with the membrane in place (and the door panel still off) I could easily replicate the leak with a hose trickling water outside the driver door - with the car parked in the same spot as when the leak occurred last weekend. This water flows into the door through the gap between the window and the window seal and also around the exterior door handle (both of which I presume is by design).
The specific downhill/sideways lean of the car seems to make the water that has now made its way into the door fall diagonally inside the door, run along the back of the waterproof membrane to the bottom of the membrane, then back onto the inside of the metal door panel and then straight out the hole for the door panel press fit clips - from there it is a quick trip over the door seal, then into the front footwell. That night it poured down, but even so to see ~2-3 litres of water in your footwell is quite a surprise!!!
I have taken everything out that I can be bothered removing (including drivers side seat; don't worry, I know the precautions about the air bags!) and have the carpet up, force drying. The open cell foam underlay has absorbed 2-3 litres of water itself, and even more annoyingly, the right rear passenger carpet is also wet (I am hoping this is just from water flowing along the chassis, not from a separate leak through the rear right door).
I don't want to go through this drying process again, as it is a huge PITA, as you can imagine, so want to solve this for good. Parking in a garage is not currently an option, but I may be able to find a flatter place to park (though I do feel this shouldn't be necessary on a BM!!!).
Online solutions that I have read mainly centre on fixing the membrane (not an issue in my case). Some also suggest drilling 2mm holes through the top/bottom of the door seal where water first accumulates (see the picture above) so that any water harmlessly drains away, though I don't know what unintended consequences this could create. I also thought that an additional plastic sheet inside the door as a primary water deflector could be good, but it is tight for space and would be a nightmare to fit/attach (and also may have unintended issues). Water has been happily at home in this door it would seem; with the door panel off I did notice some white powdery (galvanic?) corrosion on the electric window actuator - is this normal?.
Any thoughts from the experts on how to avoid this happening again?