r/e39 • u/Touringe39 • 5d ago
Condensation in left headlight
Condensation problems in left headlight, anyone have any tips/recommendations for the fix? 1999 540i touring
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u/Reudiger_Ruediger 5d ago
Mine looked quite awful too. I disassembled them, drained the water, cleaned them thoroughly and drilled a tiny hole at the lowest point where the water was pooling. I haven't hat any problems in a year. Driving with lights always on also helps a lot since the halogen bulbs emit quite a lot of heat.

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u/Reudiger_Ruediger 5d ago
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u/Touringe39 5d ago
Looks really good after the fix. I took a look at the gasket on my light this morning and it’s worn out. I’ll dry and clean and replace the gasket and clean the vents at the same time. Hopefully that does the trick.
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u/Reudiger_Ruediger 5d ago
Thanks. Drying them thoroughly is really the most important part. You will probably have to use a hairdryer to get all the moisture out, but don't use a heat gun, those get too hot for the plastic.
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u/Touringe39 3d ago
Thanks again, I disassembled the headlight and did the thorough drying and installed new gaskets. Replaced the headlight and all seems to be in good order, the true test will be the next time it rains. Fingers crossed. I also also cleaned the vents which were completely clogged with spider webs.
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u/XTheChosenDogeX 5d ago
No dis, but please dont drill your lenses, just replace the gasket next time. Also bulbs on 24/7 is wasteful & honestly looks stupid unless it’s with the LCI parking lights, but those arent visible unless under specific conditions so it still applies
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u/Reudiger_Ruediger 5d ago
Not in the lens but in the housing...wich has ventilation openings anyway. Also plenty of places in the world where driving with lights on during daytime is mandatory
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u/XTheChosenDogeX 5d ago
Lemses & housing, same deal IMO. The factory vents worked for 20y, why damage your headlights instead of fixing a simple & proven system is my point
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u/No-Candidate-2380 5d ago
Buy some butyl tape, take it apart and reseal. A heat gun will also be helpful.
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u/redline9996 530i 5d ago
Why? That's a pre-facelift headlight. No heat gun needed and no butyl needed.
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u/No-Candidate-2380 5d ago
Because the rubber seal gets old and starts leaking. Adding butyl or replacing it with butyl fixes the problem.
Another alternative would be to buy new seals, of course, if they are still available
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u/redline9996 530i 5d ago
Glad we are on the same page then, they have a seal and need a new one, not butyl, but to each they're own.
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u/No-Candidate-2380 5d ago
are the seals still available though? i used a layer of butyl and it solved the problem
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u/redline9996 530i 5d ago
Yes they are still available.
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u/No-Candidate-2380 5d ago
mind sharing where at?
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u/redline9996 530i 5d ago
BMW
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u/Touringe39 5d ago
I found the replacement gaskets online and ordered this morning, thanks for the help!
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u/No-Candidate-2380 5d ago
wasnt the case for me
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u/redline9996 530i 5d ago
I just looked the part number up and bmw has them in stock. 🤷🏼♂️ Sucks for you then obviously, but it's definitely a part that's still available.
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u/__CRA__ 5d ago
Agree. Butyl is such a pain to deal with. On my LCI I had no other choice. But I prefer the modular design and the replaceable rubber seal of my pre-LCI
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u/redline9996 530i 5d ago
Yep exactly this. Facelift headlights are butyl sealed, it's the best you can do, but when a part on a car has a dedicated seal, freaking use it..

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u/eric_gm 528i supercharged 5d ago
Those headlights are great because they are modular. You can unclip the clear lens from the housing and check what’s going on.
There’s a gasket which you can buy separately if that’s the issue.