Tool Modification (04 15 04)

Publication date: 2004-04-01
Reference number: 04 15 04

TOOL MODIFICATION

TECHNICAL SERVICE BULLETIN

Reference Number(s): SI B 04 15 04, Date of Issue: April 2004

BMW:	E60, E63, E64, E65, E66, E85
GROUP:	04 - Tools and Equipment

SUBJECT

Tool Modification

SITUATION

Starting January 2004, the above models have been fitted with noise-optimized door locks. This physical change has prompted the modification of the door lock adjustment tool (SI B04 16 02 , 90 88 6 512 190) previously distributed. The modification will prevent damage to the door lock. After the modification is complete, the tool may be used on earlier door locks as well as the new type. Distribution of the following tools will be through the Automatic Tool Shipment Program. Additional tools may be purchased through your PDC.

Fig 1 (A) shows the door lock without the noise optimization. Fig 1 (B) shows the door lock with noise optimization. The key differences are the slots (1).

Fig 1: Door Locks With/Without Noise Optimization

Protective sides

90 88 6 512 196

Mandrel

90 88 6 512 197

Fig 2: Protective Sides

The difference in the tool before (1) and after (2) modification is the protective sides (3) and the mandrel (4).

Fig 3: Differences In Tool Before And After Modification

MODIFICATION INSTRUCTIONS

Unscrew bolts (1 - 3 mm) and remove the protective sides (2) from the tool (3).

Fig 4: Removing Protective Sides From Tool
Unscrew bolt (1 - 2.5 mm) and remove it with the washer (2).
Turn knurled knob (3) in direction of arrow and remove it from the tool (4).

Fig 5: Removing Knurled Knob
Strike the locking pin (1) out of locating hole (2) using a suitable drift.
Pull mandrel (512 194) out of tool in the direction of the arrow.

Fig 6: Removing Mandrel
Old mandrel 512 194 is replaced by new mandrel 512 197.
Mandrel 512 197 has been designed so that all locks in the model series listed can be installed using a single tool.

Fig 7: Old Style And New Style Mandrels
Install mandrel 512 197 in special tool (1) until the countersink (3) can be seen through the drift pin opening.
Mandrel must be inserted with the support (2) facing up.
Insert locking pin (4) and drive flush.
The mandrel must move freely. If necessary, lightly oil the sliding surfaces.

Fig 8: Installing Mandrel
Place the knurled knob (2) onto special tool (1)
Turn knurled knob in direction of arrow until it stops.
Replace washer (3) and bolt (4) and tighten.

Fig 9: Placing Knurled Knob Onto Special Tool
Place protective sides 512 196 onto special tool (1) and tighten bolts (2).

Fig 10: Placing Protective Sides Onto Special Tool