Exterior Door Handle Problem - Fixed one problem, created another - Bimmerfest - BMW Forums

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E46 (1999 - 2006)
The fourth generation 3 Series (E46 chassis) was introduced in 1999 and set the standard for engineering and performance during it's years of production including being named to Car & Driver's 10 best list every one of those years! ! -- View the E46 Wiki

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Old 11-25-2012, 11:26 AM
JoshBosh JoshBosh is offline
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Location: Arlingotn, VA
Join Date: Jul 2007
Posts: 28
Mein Auto: 1994 BM
Exterior Door Handle Problem - Fixed one problem, created another

My E46 fell victim to the seemingly very common issue of a broken exterior door handle. After coming across a post, I set out to do a DIY fix. I managed to squeeze my hands into the very tight space and get the zip tie in place to hold the cable and keep it taught. This got the actuator action on the cable working correctly but seems to have created another issue.

The cable seems to be too long and it fails to pull on the opening mechanism at the end of the cable. The pictures show that the cable is so far above the mechanism that it doesn't engage it and open the door. I tried a zip tie linking the end of the cable to the mechanism but it didn't activate properly.

I uploaded some pictures. The first shows the end of the cable without the exterior handle pulled. The second one, the handle is pulled. You can see that the cable pulls about an inch or so but it's so long that it doesn't activate the mechanism.

The last picture is my zip tie fix near the top of the cable.

Any suggestions? Has anyone else had this problem?
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