51 22 170 Removing and installing/replacing outside handle on left or right back 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 2 220

NOTE: If replacing version with Comfort Access/CA : In order to avoid Comfort Access malfunction, use only original BMW paints on the outside handle with electrically non-conducting primer. New part (from 09/2005) is provided with electrically non-conducting primer.

Removal:

NOTE: Installation is described separately from removal.

Unclip seal (1) in direction of arrow.

Fig 1: Removing Seal On Door

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Protect bore (1) against scratching (risk of corrosion).

IMPORTANT: If the screw is not correctly secured, the lock mechanism can jump back and the sound insulation must be removed.

Pull outside handle (2) outwards/upwards until screw (3) is accessible and hold.

Using special tool 51 2 220, turn screw (3) counterclockwise and screw down.

Tightening torque, refer to 51 22 5AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 2: Identifying Special Tool 51 2 220

Courtesy of BMW OF NORTH AMERICA, INC.

Pull off outside handle (1) from rear lock actuator (2).
Pull off outside handle (1) downwards (as shown in illustration) from front lock actuator (3).

Fig 3: View Of Outside Handle
Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Following parts on outside handle (4) must not be damaged or missing:

Rear mounting.
Front mounting.
Felt strip (if available for refitting/replacement no longer required).

Fig 4: Identifying Outside Handle Components
Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Stop pad (1) must be fitted.

Insert outside handle (4) with bore (3) correctly in mounting (2).

Engage mounting (5) of outside handle (4) correctly in lock actuator (6).

Fig 5: Installing Stop Pad

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Protect bore (1) against scratching/damaged paintwork (risk of corrosion).

IMPORTANT: If the screw is not correctly secured, the lock mechanism can jump back and the sound insulation must be removed.

Using special tool 51 2 220, turn screw (3) counterclockwise and screw down.

Tightening torque, refer to 51 22 5AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Installation:

Carry out function check only with door open.

Fig 6: Securing Screw Using Special Tool 51 2 220

Courtesy of BMW OF NORTH AMERICA, INC.