The Mini Clubdoor is a cool thing :) Some of the first mini's had problems with faulty routing of the wire, and it caused the wire to get stuck, and sometimes the door switch to break in cold weather.
My dooor got stuck last winter, and I first checked the door switch. This is a mechanical lever that operates the main door lock by wire.
The door switch problem
Pry off the cover and have a look
The Spring (1) should be in the slot (2). In the cold winter the wire got stuck since it is routed wrong. the switch was broken and cant pull the wire to open the lock when the door is open.
The Solution
I went to the dealer and got a new switch, It came with the wire and was not expensive. Less than 30 Euro.
1. Undo the screw at the top cover. Torx 20
2. Pry off the cover with your fingers. It will come straight out from the door and its just snapped in place by clips.
3. Unplug the light wire inside the cover. Make a note of how the cable its routed so you get it back as it should be.
4. Just slide the cover down the seat belt and let it rest on the floor.
5. Now take off the bolt at the top of the door panel. Torx 20.
6. The last bolt is inside this hole at the back of the door panel. Torx 25.
7. Remove the ring around the door handle. Use fingers only and pull it carefully straight out from the door.
8. Pry the door panel strainght out from the door. Use your fingers and be gentle. Its just plastic clip mounts and they don't need much force. Easy does it.. Make a not of how the cables are routed so you can put them back in the right place.
9. The cables are clipped in place several places. Pull straight out and try not to destroy the clip. Unplug and put the panel away.
10. Remove the seat belt mount screws and move away the bracket. Torx 50.
11. Carefully pry away the dust protection cover. Its glued with some elastic "goo" and can be removed and replaced if careful.
12. Remove the 4 screws at the door switch. Torx 20
13. Remove the 4 screws at the Top door lock. Torx 20. At the back of the lock, remove the wire that goes down to the door switch.
14. My cable was routed wrong (a), so when reassembling I put it in the round hole (b). This was installed wrong at the factory on the early models.
Now you just need to reassemble it all. This is a one hour job that anyone can do. The only thing I had to fiddle a little with was to insert the wire and get it routed, but I only used my fingers so its not to difficult. Just put it in from the switch side and route it back to the door lock.
Good luck :)
