E39 - headlamp condensation
Discussion
My E39 520 headlamp is constantly misted up, or sometimes has droplets of water inside when the weather is damp. Anyone have any experience of this? I wondered whether its a known issue, and if I need to replace the whole unit (rather not), or perhaps just a seal. I cannot see where the water might be getting in though 
There are two known reasons for this:
- condensation (also common on E60,e8x and E9x)
- water ingress
the latter is most oftenly due to the covers not being closed again properly (ie when changing the bulbs) or the lugs being broken on the covers (and thus the cover not sealing properly). The covers are bloody akward to get to, leave alone taking them off/ back on.
Check that your covers are on and secured properly. If it is just moisture due to condensation, a possible solution is to leave your high beams on for quite a while (with the cover being off).
- condensation (also common on E60,e8x and E9x)
- water ingress
the latter is most oftenly due to the covers not being closed again properly (ie when changing the bulbs) or the lugs being broken on the covers (and thus the cover not sealing properly). The covers are bloody akward to get to, leave alone taking them off/ back on.
Check that your covers are on and secured properly. If it is just moisture due to condensation, a possible solution is to leave your high beams on for quite a while (with the cover being off).
I had the same issue on both near and off-side headlights. I solved the problem by running a bead of silicone sealer along the join between the clear lens and the black plastic headlight body. I took the headlights out of the vehicle to do this - dead easy - just 4 screws and 5 minutes time. Since I did this - no condensation.
Take off the back of the headlamp and clean the seals well with something like a babywipe as they are PH neutral. Let it dry but pop a silica gel bag in there (the sort your mrs gets in her new leather handbag or in your video camera bag or whatever) Soaks up moisture and keeps them clear, worked for me.
King Fisher said:
I had the same issue on both near and off-side headlights. I solved the problem by running a bead of silicone sealer along the join between the clear lens and the black plastic headlight body. I took the headlights out of the vehicle to do this - dead easy - just 4 screws and 5 minutes time. Since I did this - no condensation.
I've decided I need to do something along these lines. Trying to steam it out with the main beam on just isn't working. I looked at removing the headlamp unit earlier today - I can see the obvious 2 screws on top of the unit, but I can't find the other 2? It didn't help I was trying this in the pouring rain...You've found the two on the top of the unit - you'll find the other two at the bottom of the headlight unit, underneath the bulbs etc. Obviously, you'll need to unplug the bulbs to remove the headlight unit but it's easy enough. If you get stuck, drop me a line and I'll take some photo's and mail them to you.
This is more than just condensation - there are several cc's of water inside. Anyhoo, I've got it out now and its drying out on the kitchen boiler. I've got the back off (just a few clips) but can anyone tell me if its possible to separate the clear plastic from the main black structure. All the water is between this clear outer and the glass lenses. Seems worst in the indicator pod - maybe that's where its getting in. I could do with wiping the inside of the clear plastic but I don't want to force it if its not designed to come off.
Hi Skicat
I also had that issue. I dried things out by opening the headlight unit and then removing the two glass lenses. I then used a piece of kitchen roll and a heavy duty cable tie to guide the tissue paper between the black plastic housing and the front lens, but be careful! It's easy to get the tissue stuck! Especially in the area of the indicator where the gap is at its' smallest - make sure that you keep enough of the tissue paper accessible to pull it back out again. I also had a lot of water around the indicator area but once I'd dried things out and I'd run a bead of clear silicone sealer along the join line between the clear plastic front lens and the black plastic housing, the condensation hasn't come back - even with all of the cold damp weather we've been having lately.
I also had that issue. I dried things out by opening the headlight unit and then removing the two glass lenses. I then used a piece of kitchen roll and a heavy duty cable tie to guide the tissue paper between the black plastic housing and the front lens, but be careful! It's easy to get the tissue stuck! Especially in the area of the indicator where the gap is at its' smallest - make sure that you keep enough of the tissue paper accessible to pull it back out again. I also had a lot of water around the indicator area but once I'd dried things out and I'd run a bead of clear silicone sealer along the join line between the clear plastic front lens and the black plastic housing, the condensation hasn't come back - even with all of the cold damp weather we've been having lately.
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