51 21 090 Removing and installing/replacing door lock in 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 2 190

Necessary Preliminary Tasks:

Close door windows.
Detach sound insulation in rear area only. Refer to 51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN LEFT OR RIGHT FRONT DOOR .
Only when removing door lock:
Remove Bowden cable for inside door opener. Refer to 51 21 235 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR INSIDE DOOR OPENER ON LEFT OR RIGHT FRONT DOOR .
Security version:
Remove complete sound insulation. Refer to 51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN LEFT OR RIGHT FRONT DOOR .

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

IMPORTANT: Bowden cable must be correctly located in mounts on door lock (2). Seal (4) must be correctly positioned on Bowden cable.

NOTE: The operations for "Removing Bowden cable from door lock" end here.

Fig 1: Disconnecting Bowden Cable From Door Lock

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Unlock plug connection (1) at lugs (2) and detach from door lock (3).

Unclip locking rod (4) from door lock (3).

Fig 2: Locating Plug Connection At Lugs

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IMPORTANT: Do not damage door lock seal during removal.

Release screws (1).

Remove door lock (2) from inside.

IMPORTANT: To avoid leakage and electrical malfunction:

Pull door lock (2) with special tool into corner (3), see Fig 6 and Fig 7.

Fig 3: Removing Door Lock

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Driver's door only:

Installation:

Insert inside door lock (1) correctly into paddle (2) of lock cylinder (3).

Fig 4: Inserting Door Lock Into Paddle Of Lock Cylinder

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Installation:

Seal (1) on door lock (2) must not be damaged.

Fig 5: Identifying Seal On Door Lock

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Installation:

Install door lock and insert screws (1), do not tighten down.
Slide special tool 51 2 190 into opened rotary latch until latch engages in first stage.

Fig 6: Installing Door Lock

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Installation:

Pretension 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 turn knurled screw (2) by a further 1 to 1.5 turns (max.) (risk of damage).

Door lock seal must rest uniformly on inner door plate (water ingress).
Tighten down door lock screws, Tightening torque, refer to 51 21 1AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 7: Pretensioning Door Lock With Knurled Screw
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