51 41 019 Removing and installing/replacing door handle on door trim panel at front (passenger side) left or right

Necessary preliminary tasks 

• Remove front DOOR TRIM PANEL 

Drill out welding spots (1) on door trim panel (2) with 8 mm dia. welding spot drill bit.

Remove welding residue from door trim panel (2) and door handle with a scalpel (for heavy-duty applications) if these components are to be reused.

Fig 1: Identifying Welding Spots On Door Trim Panel

Courtesy of BMW OF NORTH AMERICA, INC.

Replacement 

Drill out holes (1) in door handle (2) to 3.0 mm dia.

Fig 2: Identifying Door Handle

Courtesy of BMW OF NORTH AMERICA, INC.

Slide door handle (1) into door trim panel (2).

Fig 3: Identifying Door Handle And Door Trim Panel

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

• Turn door trim panel over and lay with door handle on clean surface
• Lay large washer (1) on welding pin (2) and mark
• Remove door handle and saw off all welding pins (2) slightly below marking
• Insert door handle
• Fit large washer (1) and small washer (3)
• Secure with screw (4)
• Tighten down all 4 screws

Tightening torque 51 41 3AZ .

Fig 4: Identifying Large Washer On Welding Pin And Mark

Courtesy of BMW OF NORTH AMERICA, INC.