Introduction
This guide is used to get access to the components of the door. If you need to replace the door panel itself or replace one of the components inside the door, you will need to remove the panel first.
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The first step is to remove the door handle and speaker cover. This is easily done by prying it off the plastic tabs with a flathead screwdriver or possibly even your hands.
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Next you need to remove the four size T30 torx screws that hold the panel in place. Three of these are in the obvious screw holes shown but the last is hidden behind the colored reflector, which you will need to pry off. It is easy to remove with a small flathead screwdriver. Of the four screws, two are 18mm and the other two are 52.5mm long.
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With the screws removed, you will need to pry the panel off of the door using a prybar or flathead screwdriver. I wrapped my screwdriver in electrical tape to keep it from scratching the car.
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The bottom and sides of the panel are held on with one type of clip while the top is held on by another. Because of this, you want to start prying it somewhere along the bottom edge of the panel, I chose the lower outside corner.
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Once you have the bottom and sides of the panel popped off the tabs, you want to to a combination of lifting and pulling along the top edge to remove it from these other types of tabs.
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Once the panel is free from these, you can slide it over the door lock knob and pull the whole thing away.
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That's it. You now have access to the rest of the door. In order to put the panel back on, just follow these directions in reverse order.
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To reassemble your device, follow these instructions in reverse order.
My R53 door handle actually covered the last torx bolt, so I needed to remove it to access the bolt.
I also read that you should disconnect the battery before replacing the actuator; not sure if it's necessary, but I did it just in case.
Sue Cole -
So on my 2005 Cooper S Convertible, the bottom left screw (according to the photo above) is hidden under more dark gray arm rest. Trust me though the screw is there. The arm rest thing slides out away from the screw. You have to stick something flat underneath on the farthest from the screw to get it to slide off. Then when you put it back on just slides back on, right to left if you or working on the door shown above. This issue slowed me down.
Greg Genta -