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Door Handle Replacement
 
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Pelican Technical Article:

Door Handle Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$200

Talent:

**

Tools:

Plastic prying tool, door panel clip tool, T30 Torx

Applicable Models:

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

Parts Required:

Door handle

Hot Tip:

Tape body to avoid scratches

Performance Gain:

Door opens normally

Complementary Modification:

Lubricate and clean door latch

Central locking in BMW Z4 models controls the door locks, the luggage compartment lock and the fuel filler flap lock. The electronic functions of central locking are controlled through the general module and the door switches.

The lock mechanism in each door consists of a latch, an exterior door handle and an inside door lock release handle. Only the driver door (left front in North America) is equipped with a lock cylinder. The exterior door handle releases and unlocks the door latch via a cable inside the door. This will make the handle malfunction, usually feeling like you have to apply excess pressure on the handle. The lock cylinder can wear out over time and become stiff. If you want to replace the door lock or handle it can be done with the door panel installed. If you want to replace the door handle carrier or the latch, you will have to remove the door panel and window regulator.

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. Questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

In this tech article, I will go over how to replace the lock cylinder and door handle on the left side door. To replace the other door handle you can use this procedure, with the main difference being the lack of a lock cylinder.

This tech article covers replacing the door handle (blue arrow) and lock cylinder (red arrow).
Figure 1

This tech article covers replacing the door handle (blue arrow) and lock cylinder (red arrow). First the trim cover will have to be removed.

Working in the doorjamb, remove the small plastic cover (blue arrow).
Figure 2

Working in the doorjamb, remove the small plastic cover (blue arrow). Then working in the opening, push the metal tab (red arrows) toward the vehicle interior. The inset photo shows a good view of the small sheet metal tab. When you push it toward the interior, a metal locking plate slides to release the door handle.

Once the locking plate is unlocked, remove the door handle with the trim cover bottom first.
Figure 3

Once the locking plate is unlocked, remove the door handle with the trim cover bottom first.

Remove the handle from the door.
Figure 4

Remove the handle from the door.

This photo shows the rear of the door handle with tabs (red arrow) and the locking plate and slots (blue arrows).
Figure 5

This photo shows the rear of the door handle with tabs (red arrow) and the locking plate and slots (blue arrows). This should give you a good idea of how the handle releases in case you are struggling.

The lock cylinder remains in the door (red arrow).
Figure 6

The lock cylinder remains in the door (red arrow). To replace it, see the following steps. The collar has to be unbolted (blue arrow) through the same access hole the locking plate was unlocked.

Working through the access hole in the door (red arrow), remove the 4mm Allen fastener (red arrow).
Figure 7

Working through the access hole in the door (red arrow), remove the 4mm Allen fastener (red arrow).

Next, the lock cylinder has to be rotated and pulled out.
Figure 8

Next, the lock cylinder has to be rotated and pulled out. This photo shows the back of the lock cylinder, installed in the door handle carrier. When rotated, the tab on the lock cylinder (red arrow) moves to the slot in the carrier (blue arrow).

Next, the lock cylinder has to be rotated and pulled out.
Figure 9

Next, the lock cylinder has to be rotated and pulled out. Use your key. Push it into the lock halfway. You do not want it to unlock and rotate the lock cylinder. You want to use it as a tool to rotate the lock. Alternatively, you can use a flathead screwdriver. Rotate the lock cylinder 90 degrees and pull it straight out with the retainer (red arrow). Reverse these steps to install a new lock cylinder.

To replace the door handle carrier, start by removing the door latch.
Figure 10

To replace the door handle carrier, start by removing the door latch. See our tech article on door latch replacing. Then, remove the two T25 Torx fasteners (red arrows).

Remove the carrier from the door.
Figure 11

Remove the carrier from the door.

This photo gives another view of the door handle locking plate (red arrow).
Figure 12

This photo gives another view of the door handle locking plate (red arrow). With the carrier removed, you can replace the Bowden cable if needed.

Reverse these steps to install the carrier and door handle.
Figure 13

Reverse these steps to install the carrier and door handle. To engage the locking plate, you have two choices. The easy way (if the door panel has been removed) is to use a flathead screwdriver (red arrow) and press the locking plate (blue arrow) over until it stops.

To engage the locking plate (blue arrow), be sure the small bump (red arrow) rests at the plastic tab for the door handle.
Figure 14

To engage the locking plate (blue arrow), be sure the small bump (red arrow) rests at the plastic tab for the door handle.

If you didn't remove the door panel, go through the access hole using a hook tool (red arrow), and pull the locking plate over until it stops.
Figure 15

If you didn't remove the door panel, go through the access hole using a hook tool (red arrow), and pull the locking plate over until it stops. Reverse these steps to assemble the remaining items.


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Page last updated: Wed 12/7/2016 03:00:08 AM