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

WARNING: This page is about a different car, the 2010 BMW M3, 2009 BMW M3, and 2008 BMW M3. However, it is still accessible from the selected car via links, so may be relevant.

Necessary preliminary tasks:

Remove front door trim panel

IMPORTANT: Risk of damage!
Only drill down to door trim panel area (2) so as not to damage the contact surface.

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 And 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 Holes And 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 , see 51 41 FRONT DOOR TRIM PANEL WITH ARMRESTS .

Fig 4: Identifying Large Washer And Small Washer

Courtesy of BMW OF NORTH AMERICA, INC.