I had another try last night of the method with the welding rod in the link previously posted. I used a coat hanger instead which is thicker wire than a welding rod.

I think the connection from the outside door handle to the lock mechanism is sound as I can feel the coat hanger wire going up and down when I try to open the door using the external handle. I even tried to hook the coat hanger under neath this latch to try and lift the latch but this did not work either.

I also think the connection from the inside door handle to the lock mechanism is sound as when I operate the inside door handle I can feel the connection between the handle and the lock mechanism moving and hear something moving within the lock mechanism.

I am totally stumped by this?

I dont think it is possible to get the internal door card off from the front passenger door whilst it is closed?

The only solution I can think of is to destroy the internal door card - i.e cut a big hole in it so i can get to the lock mechanism to try and release it. then replace the door card with a second hand one.

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E90 318i 2007 N46 2.0 Manual
E53 X5 2004 M54 3.0 Sport Auto
E83 X3 2004 M54 2.5 Auto