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Door Panel Replacement
 
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Pelican Technical Article:

Door Panel Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$200

Talent:

**

Tools:

Plastic panel clip tool, flathead screwdriver, T25 Torx

Applicable Models:

BMW Z4 Convertible (2003-06)
BMW Z4 Coupe (2006)

Parts Required:

Door panel, vapor barrier, vapor barrier seal, door panel clips

Hot Tip:

Have door panel trim clips on hand in case they break when

Performance Gain:

Access to interior door components

Complementary Modification:

Replace window regulator

The doors, particularly the driver door, are equipped with a large number of electrical and electronic components. The interior door trim panel has to be removed to access components behind it, such as the door speaker, side airbag, window regulator, door latch and door mirror. In this tech article, I will go over the steps involved in removing the front door panel on your BMW Z4. I suggest having extra door panel clips on hand before removing the panels, as the clips can often break when removing. If you have to remove the vapor barrier, have vapor barrier sealant on hand. Be very careful when removing the vapor barrier. It tears easily. If it is reinstalled with a tear, an interior water leak can develop.

Each inner door trim panel is equipped with an SRS airbag. For safety reasons, be sure to disconnect the vehicle battery before beginning work on the door panel. See our tech article on the battery.

Be sure to use plastic prying tools when working on interior trim panels and other components. Alternatively, wrap the tip of a screwdriver or other metal prying tool with masking or electrical tape to avoid marring trim items.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

To order this part, please call our sales specialists for assistance at 1-888-280-7799

The doors, particularly the driver door, are equipped with a large number of electrical and electronic components.
Figure 1

The interior door trim panel (red arrow) has to be removed to access components behind it, such as the door speaker, side airbag, window regulator, door latch and door mirror. I suggest having extra door panel clips on hand before removing the panels, as the clips can often break when removing. If you have to remove the vapor barrier, have vapor barrier sealant on hand. Be very careful when removing the vapor barrier. It tears easily, and if it is reinstalled with a tear, an interior water leak can develop.

Using a plastic prying tool, gently lever out the tweeter housing (red arrow).
Figure 2

Using a plastic prying tool, gently lever out the tweeter housing (red arrow). There are two plastic clips to detach (blue arrow).

Lower the tweeter housing enough to access the electrical connector, then disconnect the electrical connector by pulling it straight out (red arrow).
Figure 3

Lower the tweeter housing enough to access the electrical connector, then disconnect the electrical connector by pulling it straight out (red arrow).

Then, using a plastic prying tool, lever the door handle trim piece off the door panel (blue arrow).
Figure 4

Then, using a plastic prying tool, lever the door handle trim piece off the door panel (blue arrow). The inset photo and red arrow shows the trim piece removed.

Using a plastic prying tool (red arrow), lever the switch up at the doorjamb side.
Figure 5

Using a plastic prying tool (red arrow), lever the switch up at the doorjamb side. Once the side of the switch closest to the jamb is slightly up, slide it out in the direction of the red arrow. Pull the window switch assembly straight up to remove it. Flip the window switch over. Then disconnect the mirror control connector by pressing the release tab and pulling it straight out. Then disconnect the power window switch electrical connectors by pressing the release tab and opening the lever.

Then, remove the two door panel T25 Torx fasteners (red arrows).
Figure 6

Then, remove the two door panel T25 Torx fasteners (red arrows).

Working inside the door handle, remove the plastic cap (blue arrow).
Figure 7

Working inside the door handle, remove the plastic cap (blue arrow). Then remove the T25 Torx fastener beneath it (red arrow).

Next, use a plastic prying tool to remove the airbag fastener cap (red arrow).
Figure 8

Next, use a plastic prying tool to remove the airbag fastener cap (red arrow). Then remove the T25 Torx fastener beneath it (blue arrow).

Using a door panel clip tool, release the door panel clips (red arrows).
Figure 9

Using a door panel clip tool, release the door panel clips (red arrows). I like to start at the lower corner. Then I work my way around the door panel, releasing all the other clips.

Once the door panel clips have been disconnected, lever the top of the door panel (red arrow) off the door.
Figure 10

Once the door panel clips have been disconnected, lever the top of the door panel (red arrow) off the door. Start at the outer edge of the door and work your way toward the interior.

This photo shows the clips (red arrows) that secure the top of the door panel to the top of the door.
Figure 11

This photo shows the clips (red arrows) that secure the top of the door panel to the top of the door.

Pull door panel back enough to access the speaker electrical connector.
Figure 12

Pull door panel back enough to access the speaker electrical connector. Pull the connector straight out to disconnect it.

Pull the door panel away a little farther to access the door latch Bowden cable.
Figure 13

Pull the door panel away a little farther to access the door latch Bowden cable. Unclip the plastic retainer (red arrow) and lift the cable end off to remove it (blue arrow). You can now service items behind the door panel and repair as needed. When installing, reverse the order of the removal instructions. Be sure to replace any damaged door panel clips. Properly route all wiring as before.

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Page last updated: Wed 12/7/2016 03:00:06 AM