51 21 180 Removing and installing/replacing cover on outside handle

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: 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.

Necessary Preliminary Tasks:

Remove outside handle. Refer to 51 21 170 REMOVING AND INSTALLING OR REPLACING OUTSIDE HANDLE FROM LEFT OR RIGHT FRONT DOOR .

2-door Models:

Remove plate (2).

Fig 1: Removing Plate (2-Door Models)

G03270871

Courtesy of BMW OF NORTH AMERICA, INC.

4-door Models:

Remove plate (2).

Fig 2: Removing Plate (4-Door Models)

G03270872

Courtesy of BMW OF NORTH AMERICA, INC.

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

Unscrew bolt (2).

Installation:

Press cover (3) slightly towards rear when screwing down (gap).

Tightening torque, refer to 51 21 8AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 3: Locating Cover Retaining Bolt

G03270873

Courtesy of BMW OF NORTH AMERICA, INC.

Remove stop pad (1).

Fig 4: View Of Stop Pad

G03270874

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Press mounting (2) back, lever out cover (3) at rear and remove in direction of arrow.

Tightening torque, refer to 51 21 7AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 5: Removing Door Handle Cover

G03270875

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Following parts of cover on outside handle (5) must not be damaged or missing:

Thread.
Bridges.
Bridges.
Screw surface.

Fig 6: Identifying Outside Handle Cover Components
Courtesy of BMW OF NORTH AMERICA, INC.