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At the dealer we would replace the sunroof cassette, but that costs a heck of a lot... What I would do myself in this case would be to thoroughly clean and dry the area of the leak, and apply a good sealer to the area of the leak, taking care not to get excess sealer anywhere else. The spot in question might be accessible from the top with the glass back, but you may have to remove the whole sunroof to get to it...
To do that, you would need to fully remove the headliner. (tight fit, but slides out of the back once taken down) Then remove the whole sunroof cassette. To remove it you would first remove the glass by carefully removing the rubber flaps on each side of the glass on the interior to access the 3 T25 screws on each side ,then the glass lifts right out. (when reinstalling, you have to hold the glass at the correct height when tightening these for adjustment purposes, or else wind noise) The outer edge of the sunroof assembly has some 10mm bolts holding it up, 13 of them if I remember right. Unplug the motor at the front center and unhook the drain hoses you ironically just put on, and the whole thing comes right out. (note that this job is easier with a second set of hands around) Then it can be put on the ground, saw horses, etc. and you have full access to everything.
I would definitely try the easier way through the top first, saves a few hours of labor. Just use a fine tip on your adhesive/sealer of choice. I personally use windshield urethane, but that can be hard to come by for an individual, and is quite hard to squeeze out with a standard caulk gun. I would recommend a good automotive sealer like RTV to squeeze down into the crevice.
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X5 pics
RIP 4.6is.....
2003 4.6is
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