Door handles and locks — removal and installation (BMW 3 Series E46)

Removal

Interior door handle

1. The interior door handle is part of the trim and cannot be replaced separately.

Front door lock assembly

2 Lower the glass completely, then raise it approximately 140 mm (if you measure along the back edge of the glass). Remove the door trim (see paragraph 12). To access the lock components, carefully remove the sound insulation, then refer to the relevant part of this paragraph. If the sound insulation is damaged during removal, replace it.

3. Loosen the glass clamps (see Fig. 14.5, a, b) and secure the glass with adhesive tape in the raised position. Unscrew the two nuts securing the rear glass support bracket and lower the bracket into the bottom of the door. It is not necessary to remove the glass guide (see fig. 14.8).

4. When removing the lock in the driver's door, remove the lock cylinder (see pp. 13-15).

5. Release the lock assembly wiring harness fasteners and disconnect the wiring harness connector.

6. On models produced since September 2000, remove the cable sheath from the bracket and disconnect the cable from the lock (Fig. 13.6).



7. Remove the lock mounting screws, then slide the lock behind the glass guide and remove the lock assembly together with the lock button rod from the door opening (Fig. 13.7).

Front door outer handle (models produced before September 2000)

8. When removing the driver's door handle, first remove the lock cylinder (see pp. 13-15). When removing the passenger door handle, remove the plug located at the end of the door to access the handle mounting bolt. On the coupe model, carefully bend back the top of the rubber door seal to access the plug. Remove the bolt and remove the rear outer handle cover (fig. 13.8, a, b).





9. Pull the handle outwards and slide it back approximately 2 mm. This will engage the locking mechanism. Push the handle inwards approximately 4 mm, then slide it back and remove it from the door (Fig. 13.9).

Front door outer handle (models produced since September 2000)

10. When removing the driver's door handle, first remove the lock cylinder (see pp. 13-15). When removing the passenger door handle, remove the plug located at the end of the door to access the handle mounting bolt. On the coupe model, carefully bend back the top of the rubber door seal to access the plug. Unscrew the bolt and remove the rear outer handle cover.

11. The lock should remain in place. Pull the handle outward and place a wooden block or rag under it. Turn the actuator screw counterclockwise through the hole in the end of the door until it stops (fig. 13.11). Remove the wooden block (or a rag).



12. Pull the back of the handle outward, then remove the handle from the door.

Front door lock cylinder

13. To access the lock cylinder, remove the plug from the end of the door (fig. 13.13). On the coupe model, carefully bend back the top of the rubber door seal to access the plug.



14. Using a hex key, unscrew the bolt and remove the lock cylinder from the door (fig. 13.14).



15. If necessary, release the two clamps and detach the plastic casing from the cylinder (fig. 13.15).

Rear door lock

16. Remove the door trim and sound insulation (see paragraph 12). Disconnect the electrical connector from the door lock.



17. Remove the lock mounting screws, then remove the lock from the door together with the lock button rod (fig. 13.17).

Rear door outer handle (models produced before September 2000)

18. To access the rear handle cover mounting bolt, remove the plug from the end of the door. Unscrew the bolt and remove the rear cover (fig. 13.18, a, b).





19. Pull the handle outwards and slide it back approximately 2 mm. This will engage the locking mechanism. Push the handle inwards approximately 4 mm, then slide it back and remove it from the door (see fig. 13.9).

Rear door outer handle (models produced since September 2000)

20. To access the rear handle cover mounting bolt, remove the plug from the end of the door. Unscrew the bolt and remove the rear cover.

21. The lock should stay in place. Pull the handle out and place a wooden block or rag underneath it.

22. Turn the actuator screw counterclockwise through the hole in the end of the door until it stops (see fig. 13.11). Remove the wooden block (or a rag).

23. Pull the back of the handle outward, then remove the handle from the door.

Installation

Interior door handle

24. The inner door handle is part of the trim and cannot be replaced separately.

Front door lock assembly

25. Remove traces of old sealant from the lock mounting screws.

26. Before installing the lock, loosen the adjusting screw. In the right door lock, this screw has a left-hand thread, and in the left door, it has a right-hand thread (fig. 13.26, a, b).





27. Install the lock assembly in place. Make sure that the lock button rod fits into the door opening. Make sure that the lock lever is between the door trim and the handle support (fig. 13.27).



28. Apply a little sealant to the lock mounting screws (bMW recommends Loctite 270 sealant), then screw in the screws and tighten them to the required torque.

29. Connect the electrical wiring connector and secure the electrical wiring with the appropriate clamps.

30. Install the lock cylinder in the driver's door (see pp. 43-45).

31. On all models produced since September 2000, connect the cable to the lock lever and secure the cable housing to the bracket (fig. 13.31).



32. Install the glass and rear guide, screw on the nuts and tighten them securely. Lower the glass and insert it into the clamps (see paragraph 14).

33. Do not close the door until you have adjusted and checked the operation of the lock as follows.

• a) To access the adjusting screw, remove the plastic cap located opposite the upper lock mounting screw (see Fig. 13.26, a, b).
• b) In the left door, turn the adjusting screw clockwise until it stops. In the driver's door, turn the adjusting screw counterclockwise until it stops.
• c) Using a screwdriver, "close" the door by pressing the lock lever (fig. 13.33).
• d) Use the key to open the lock.
• d) Using the outside handle, "open" the door.
• e) If the lock does not open, loosen the adjusting screw, then tighten it again. Check the operation of the lock.
• g) Do not close the door until the lock has been adjusted. If you accidentally close the door, you may need to cut the outer door trim to open it.
• c) Replace the plastic cap.

34. Install soundproofing on the door. Install door trim (see paragraph 12).

External door handle (models produced before September 2000)

35. Make sure the lock lever is positioned correctly (see fig. 13.27). If the lever is not positioned correctly, use a screwdriver to turn the lock lever outward.

36. Insert the front part of the handle into the door, then the back part. Press the handle against the door and slide it forward until it "clicks".

37. When installing the handle on the driver's door, install the lock cylinder first (see pp. 43-45). When installing the handle on the passenger door, first install the rear handle cover, and tighten the mounting bolt securely. Install the plug into the door hole.

38. Do not close the door until you have checked the operation of the lock (see item 33). Install sound insulation on the door. Install the door trim (see paragraph 12).

Front door outer handle (models produced since 2000)

39. Before installing the handle, the door lock must be in place. The distance between the support of the actuator of the lock and the outer door trim must not exceed 8 mm (fig. 13.39). If this distance is greater than the specified one, use your finger to move the support outward.



40. Insert the front part of the handle into the door opening, then insert the back part of the handle into the door. Make sure that the seal between the handle and the door trim has not moved. Turn the lock adjusting screw clockwise until it stops.

41. When installing the handle on the driver's door, install the lock cylinder (see pp. 43-45). When installing the handle on the passenger door, first install the rear handle cover, and tighten the mounting bolt securely. Install the plug into the door hole.

42. Do not close the door until you have checked the operation of the lock (see item 33). Install sound insulation on the door. Install the door trim (see paragraph 12).

Front door lock cylinder

43. Install the plastic cover on the lock cylinder (if it was removed).

44. Lubricate the outer surface of the lock cylinder.

45. Insert the cylinder into the lock and tighten the mounting screw securely. Insert the plastic plug into the door. Check the operation of the lock before closing the door (see paragraph 33).

Rear door lock

46. Remove traces of old sealant from the lock mounting screws.

47. Before installing the lock, loosen the adjusting screw. In the right door lock, this screw has a left-hand thread, and in the left door, it has a right-hand thread (fig. 13.47).



48. Install the lock assembly in place. Make sure that the lock button rod fits into the door opening. Make sure that the lock rod is between the door trim and the handle support.

49. Apply a little sealant to the lock mounting screws (bMW recommends Loctite 270 sealant), then screw in the screws and tighten them to the required torque. Connect the wiring connector and secure the wiring with the appropriate clamps.

50. On all models produced since September 2000, connect the cable to the lock lever and secure the cable housing to the bracket.

51. Check the operation of the lock (see item 33).

52. Install soundproofing on the door. Install door trim (see paragraph 12).

Rear door outer handle (models produced before September 2000)

53. Make sure the lock lever is positioned correctly (fig. 13.53). If the lever is not positioned correctly, use a screwdriver to turn the lock lever outward.



54. Insert the front part of the handle into the door, then the back part. Press the handle against the door and slide it forward until it "clicks".

55. Install the rear handle cover and tighten the mounting bolt securely. Install the plug into the door hole.

56. Do not close the door until you have checked the operation of the lock (see item 33).

57. Install soundproofing on the door. Install door trim (see paragraph 12).

Rear door outer handle (models produced since September 200D)

58. Before installing the handle, the door lock must be in place. The distance between the support of the actuator of the lock and the outer door trim must not exceed 8 mm (fig. 13.39). If this distance is greater than the specified one, use your finger to move the support outward.

59. Insert the front part of the handle into the door opening, then insert the back part of the handle into the door. Make sure that the seal between the handle and the door trim has not moved.

60. Install the rear handle cover and tighten the mounting bolt securely. Install the plug into the door hole.

61. Do not close the door until you have checked the operation of the lock (see item 33).

62. Install soundproofing on the door. Install door trim (see paragraph 12).