51 22 090 Removing and installing/replacing door lock in left or right rear 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:

Remove sound insulation in rear area only. Refer to 51 48 070 REMOVING AND INSTALLING/REPLACING SOUND INSULATION ON LEFT OR RIGHT REAR DOOR .
If necessary, remove crashpad. Refer to 51 22 ... REMOVING AND INSTALLING/REPLACING SIDE IMPACT PROTECTION IN LEFT OR RIGHT REAR 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 .

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: View Of Door Lock Bowden Cable

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Fig 2: Identifying Plug Connections For Door Lock

Courtesy of BMW OF NORTH AMERICA, INC.

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 5 and Fig 6.

Fig 3: Removing Door Lock

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

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

Fig 4: Installing Seal On Door Lock

Courtesy of BMW OF NORTH AMERICA, INC.

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 5: View Of Special Tool 51 2 190

Courtesy of BMW OF NORTH AMERICA, INC.

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 6: Identifying Knurled Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Check function of child lock (1) on door lock (2).

Fig 7: View Of Child Lock On Door Lock

Courtesy of BMW OF NORTH AMERICA, INC.