51 21 170 Removing and installing or replacing outside handle from left or right front door

WARNING: This page is about a different car, the 2005 BMW 545i and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

For Special Tool identification, see BODY EQUIPMENT - SPECIAL TOOLS - 5-SERIES (E60) .

Special Tools Required:

51 2 220

NOTE: If replacing version with Comfort Access/CA : In order to avoid Comfort Access malfunction, use only original BMW paints on the outside handle with electrically non-conducting primer. New part (from 09/2005) is provided with electrically non-conducting primer.

Removal:

NOTE: Installation is described separately from removal.

2-door Models:

Remove plate (1).

Fig 1: Removing Trim (2-Door Models)

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4-door Models:

Remove plate (1).

Fig 2: Removing Trim (4-Door Models)

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NOTE: Protect bore (1) against scratching (risk of corrosion).

IMPORTANT: If the screw is not correctly secured, the lock mechanism can jump back and the sound insulation must be removed.

Pull outside handle (2) outwards/upwards until screw (3) is accessible and hold.

Using special tool 51 2 220, turn screw (3) counterclockwise and screw down.

Tightening torque, refer to 51 21 5AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 3: Identifying Special Tool 51 2 220

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Pull off outside handle (1) from rear lock actuator (2).
Pull off outside handle (1) downwards (as shown in illustration) from front lock actuator (3).

Fig 4: Removing Outside Handle
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Installation:

Following parts on outside handle (4) must not be damaged or missing:

Rear mounting.
Front mounting.
Felt strip (if available for refitting/replacement no longer required).

Fig 5: Identifying Outside Handle
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Installation:

Stop pad (1) must be fitted.

Insert outside handle (4) with bore (3) correctly in mounting (2).

Engage mounting (5) of outside handle (4) correctly in lock actuator (6).

Fig 6: Locating Stop Pad

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NOTE: Protect bore (1) against scratching/damaged paintwork (risk of corrosion).

IMPORTANT: If the screw is not correctly secured, the lock mechanism can jump back and the sound insulation must be removed.

Using special tool 51 2 220, turn screw (3) counterclockwise and screw down.

Tightening torque, refer to 51 21 5AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Installation:

Carry out function check only with door open.

Fig 7: View Of Special Tool 51 2 220

Courtesy of BMW OF NORTH AMERICA, INC.