51 22 180 Removing and installing/replacing cover on outside handle

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: 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.

Necessary Preliminary Tasks:

Remove outside handle. Refer to 51 21 170 REMOVING AND INSTALLING OR REPLACING OUTSIDE HANDLE FROM LEFT OR RIGHT FRONT DOOR .

Remove trim (2).

Fig 1: Removing Door Trim

G03270919

Courtesy of BMW OF NORTH AMERICA, INC.

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

Release screw (2).

Installation:

Press cover (3) slightly towards rear when screwing down (gap).

Tightening torque, refer to 51 22 8AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 2: Removing Screw Using Special Tool

G03270920

Courtesy of BMW OF NORTH AMERICA, INC.

Remove stop pad (1).

Fig 3: Removing Stop Pad

G03270921

Courtesy of BMW OF NORTH AMERICA, INC.

Loosen screw (1).

Press mounting (2) back, lever out cover (3) at rear and remove in direction of arrow.

Tightening torque, refer to 51 22 7AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 4: Locating Cover Retaining Screw

G03270922

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Following parts of cover on outside handle (5) must not be damaged or missing:

Thread.
Bridges.
Bridges.
Screw surface.

Fig 5: Identifying Outside Handle Cover Components
Courtesy of BMW OF NORTH AMERICA, INC.