I am sure that the door fits just fine otherwise it would have uneven gaps around it or it would not be flush to the surrounding panels, etc. If it looks OK cosmetically then it is OK.
Due to the manufacturing tolerances that are used to make this type of component the door will be fitted and adjusted to suit the door opening and bolted tightly. The window will then be adjusted to suit the door seals and the position of the door itself if it comes to the assembly station in a preset position that is not up to spec at assembly.
It is this final adjustment that was missed and it needs to be corrected to stop the leaks.

I am assuming that the car has been made from an average set of components and not from a set of components that come from the extreme ends and even out of the tolerance spec's. These are what lemons are made of, quite rare but are nearly impossible to adjust as body gaps could be too tight and/or too loose.

Body panels are made with liberal tolerances, other components would have much tighter tolerances for acceptance, thou's and tenth's of thou's. It would be practically impossible to have really tight tolerances on body panels, therefore the need for adjustment at assembly.

 

Has anyone tried this fix successfully...and does it work for wind-noise also? Also...is this problem limited to the passanger side door only?

Thanks...Ben

 

I took a piece of paper today and rolled it up real tight. I stuck it in the hollow part of the passenger side molding. It helped press the rubber up against the inside of the glass. It stopped the water leak from rolling down my window.... at least I think so. I sprayed it real good on the window and I didn't see a drop. Usually I would see the water right away.

I noticed the rubber seal is ripped on the inside causing the weatherstrip to be more flexible and loose around the area that is leaking. Strange that the rip is right in the spot where the window is leaking. My guess is the guy who did my headliner was careless... or it was like that when I bought the car new and it just got worse. Combine the bad weatherseal with a window that needs an angle adjustment and you have a water leak. I think the gap is very small.... so a simple window pitch alignment may do the trick. If the weatherstrip is covered under the max care warranty then I will have them replace it too. If not I will try putting someting in there and patching the problem myself. I would assume this would also help with the wind noise (but I don't think I hear any wind noise).