51 21 090 Removing and installing/replacing door lock in left or right front door

Special tools required:

51 2 190

Necessary preliminary tasks:

Remove FRONT SOUND INSULATION

Driver's side only:

Remove LOCK BARREL LOCK BARREL

Removal:

Side window glass must be opened to dimension (A).

A = 145 mm

Fig 1: Identifying Side Window Glass Opening Dimension

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IMPORTANT: Risk of damage!
Do not bend mounting clips (1) too far.

Carefully unlock power window mounting clips (1) in direction of arrow.

Gently press door window glass (2) upwards to snap retaining lug completely out of door window glass bore hole (2).

Fig 2: Locating Power Window Mounting Clips

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Slide door window glass (1) fully upwards and fix in the window frame with adhesive tape (2).

Fig 3: Identifying Window Frame Adhesive Tape Applying Area

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Release cable from holder in area (1). Release nuts (2) and lay down window lift rail (3) in door.

Fig 4: Identifying Window Lift Rail Nuts

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NOTE: Graphic is similar.

Disconnect Bowden cable at bottom (1) and top (3) from door lock (2).

IMPORTANT: If Bowden cable (1) is routed incorrectly, door can not be opened from the outside.

Fig 5: Disconnecting Door Lock Bowden Cable

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Lever out locking rod (1).

Unfasten plug connection (2) and disconnect.

Release screws (3).

Remove door lock from inside.

Fig 6: Identifying Door Locking Rod And Plug Connection

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Installation:

IMPORTANT: Seal (1) on door lock (2) must not be damaged (water ingress)!

Fig 7: Identifying Seal On Door Lock

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NOTE: Graphic is similar.

Attach Bowden cable at bottom (1) and top (3) from door lock (2).

NOTE: Bowden cable must be correctly engaged in fixture of door lock (2).

Bowden cable must be laid without kinks in bend to door lock (2).

Seal (4) must be correctly fitted on Bowden cable.

Fig 8: Disconnecting Door Lock Bowden Cable

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IMPORTANT: If Bowden cable (1) is routed incorrectly, door can not be opened from the outside.

NOTE: Install door lock (1) and screw in screws (2) but to not tighten.

Slide special tool 51 2 190 into opened rotary striker until striker engages in first stage

Fig 9: Sliding Special Tool (51 2 190)

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NOTE: Pre-tension door lock (1) with knurled screw (2) until special tool 51 2 190 just contacts corner points (3)

IMPORTANT: To tension door lock (1), it is only permitted to tighten knurled screw (2) by a further 1 to 1.5 turns (max.) (risk of damage).
Door lock seal must rest uniformly on inner door panel (water ingress).

Fig 10: Installing Door Lock Using Special Tool (51 2 190)

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Lever in locking rod (1).

Lock plug connection (2).

Tighten screws of door lock (1).

Observe tightening sequence: bottom - top - inner.

Tightening torque 51 21 1AZ .

Fig 11: Identifying Door Locking Rod And Plug Connection

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Clip in cable in area (1).

Feed in window lift rail (3) and secure nuts (2).

Tightening torque 51 33 2AZ .

Fig 12: Identifying Window Lift Rail Nuts

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Gently press window glass (1) into the latch mechanism (2) towards bottom.

NOTE: Make sure the retaining lugs are correctly engaged in the door window glass bore hole.

Fig 13: Identifying Window Glass And Latch Mechanism

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Required follow-up work:

Fit FRONT SOUND INSULATION