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Door Handle and Lock Cylinder Replacement
 
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Pelican Technical Article:

Door Handle and Lock Cylinder Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$200

Talent:

**

Tools:

Plastic prying tool, Door panel clip tool, flathead & Phillips screwdriver, T20, T25, T30 Torx drivers

Applicable Models:

Mercedes-Benz E320 (2003-09)
Mercedes-Benz E500 (2003-06)
Mercedes-Benz E55 AMG (2003-06)

Parts Required:

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

Hot Tip:

Tape body to avoid scratches

Performance Gain:

Door opens normally

Complementary Modification:

Lubricate and clean door latch

Central locking in Mercedes-Benz W211 models controls door locks, trunk lid or luggage compartment lock and fuel filler flap lock. The electronic functions of central locking are spread out over several door control modules, with sensors and actuators connected directly to a control module in the vicinity of their installed location. The rear electronic (SAM) module is the master control module for central locking.

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 latch is responsible for locking, unlocking and latching the door shut. The latch itself is pretty reliable. However, having the electronic lock solenoid integrated in the latch creates some problems. The lock solenoids fail over time, leaving you with a malfunctioning lock. If it is the driver lock, you can still lock and unlock with the key. With other kinds of doors, you may not be so lucky. If you are having a problem with the lock, try cleaning and lubricating the latch. I find this will restore function of the lock from time to time. If I can successfully restore function this way, I still replace the latch to avoid future problems. It is a good test to see if the problem is electrical or mechanical.

The issue with your lock could also be the door handle or handle release bracket. When you pull the outer door handle, it relays a lever that opens the door latch. If the lever on the bracket fails you will not be able to open the door from the outside, but the door will open from the inside.

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.

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

Working at the outer edge of the door, in line with the outer door handle, pull the seal away from the door (red arrow).
Figure 1

Working at the outer edge of the door, in line with the outer door handle, pull the seal away from the door (red arrow). This will expose the door lock cylinder fastener (red arrow). Loosen the T20 Torx door lock cylinder fastener.

As you loosen the T20 Torx (blue arrow shows Torx as viewed from outside the door), the lock cylinder will move away from the door (red arrow).
Figure 2

As you loosen the T20 Torx (blue arrow shows Torx as viewed from outside the door), the lock cylinder will move away from the door (red arrow).

Pull the door handle out (blue arrow).
Figure 3

Pull the door handle out (blue arrow). Then pull the lock cylinder out of the door. Disconnect the electrical connector by lifting the retaining pin (red arrow) while pulling the connector straight out.

Next, you have to remove the outer door handle.
Figure 4

Next, you have to remove the outer door handle. Do that by pulling the handle toward the outer edge of the door (red arrow). Then pull it out at an angle (blue arrow). The lock cylinder seal will come off with the handle. The handle seal will remain on the door for now.

If you want to replace the handle bracket, use the following steps.
Figure 5

If you want to replace the handle bracket, use the following steps. If you are only replacing the outer handle or lock cylinder, see the few last steps for reinstalling notes. To remove the door handle bracket, start by removing the door panel and door latch. See our tech articles on front door panel and door latch removing. Working at the door handle seal (red arrow), pull it off the door by unclipping the rubber retainer. Then loosen the T20 Torx fastener for the inner bracket. Loosen the fastener about six turns.

Once the fastener is loose, push the bracket toward the doorjamb (red arrow).
Figure 6

Once the fastener is loose, push the bracket toward the doorjamb (red arrow).

Remove the door handle bracket from the door cavity.
Figure 7

Remove the door handle bracket from the door cavity. To install the new bracket, reverse the steps. Be sure that the bracket is properly seated in the door. Then tighten the T20 fastener. Install the rubber seal.

When installing the handle into the door, start by feeding the handle in.
Figure 8

When installing the handle into the door, start by feeding the handle in. Then sliding it toward the jamb to engage the pivot and bracket release lever. If you look into the door toward the jamb side of the bracket, you can confirm that the handle pivot (red arrow) is engaged to the bar on the bracket (blue arrow).

Looking into the door toward the outer portion of the handle, confirm that the pull tab on the handle (blue arrow) is engaged on the release lever (red arrow).
Figure 9

Looking into the door toward the outer portion of the handle, confirm that the pull tab on the handle (blue arrow) is engaged on the release lever (red arrow). When installing the door handle, listen for an audible click to indicate it is properly engaged with the bracket. Then install the door latch, and then the lock cylinder.

Once the handle has been reinstalled, check the latch operation.
Figure 10

Once the handle has been reinstalled, check the latch operation. Lock and unlock the door. Then latch the door latch using a screwdriver. Confirm that the door latch releases with the inner and outer door handles. Then reassemble the window regulator and door panel



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Comments and Suggestions:
Deanna R. Jones Comments: Thanks for the tips! The lock on my car has been pretty stubborn lately. I was wondering why my lock wasn't working like it used to until I finished reading the information. My car needed a few repairs, so it must be because a few parts could have been replaced with different size fasteners. I should check to see if the nuts and bolts in my car are any different, so that I can try to fix my lock using the right size sockets and wrenches.
June 30, 2015
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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