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Pelican Technical Article:

Door Handle Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$200

Talent:

**

Tools:

Plastic prying tool, door panel clip tool, T30 Torx

Applicable Models:

R56 MINI Cooper Hatchback (2007-11)
R56 MINI Cooper S Hatchback (2007-11)

Parts Required:

Door handle

Hot Tip:

Tape body to avoid scratches

Performance Gain:

Door opens normally

Complementary Modification:

Lubricate and clean door latch

Central locking in MINI R56 models controls door locks, the luggage compartment lock and the fuel filler flap lock. The electronic functions of central locking are spread out over several control modules, with sensors and actuators connected directly to a control module in the vicinity of their installed location. The car access system (CAS) module is the master control module for central locking.

The lock mechanism in each door consists of a latch, an exterior door handle and an inside door lock release handle. Only the driver door (left front in North America) is equipped with a lock cylinder. The exterior door handle releases and unlocks the door latch via a cable inside the door. This will make the handle malfunction, usually feeling like you have to apply excess pressure on the handle button. The lock cylinder can wear out over time and become stiff. If you want to replace the door lock, handle or latch, you will have to remove the window regulator.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

In this tech article, I will go over how to replace the lock cylinder and door handle on the left side door. To replace the other door handle you can use this procedure, with the main difference being the lack of a lock cylinder.

This tech article covers replacing the door handle (red arrow) and lock cylinder (yellow arrow) on a vehicle with comfort access.
Figure 1

This tech article covers replacing the door handle (red arrow) and lock cylinder (yellow arrow) on a vehicle with comfort access. If your vehicle does not have comfort access, there will be less electrical connectors to deal with. Comfort access vehicles can be identified by a button (green arrow) on the door handle. Start by removing the door panel and inner door panel module (IDM). See our tech articles on door panel and window regulator replacing.

With the IDM removed, locate the door handle electrical connector (red arrow).
Figure 2

With the IDM removed, locate the door handle electrical connector (red arrow). Cut the electrical tape holding it to the harness. Then disconnect it by releasing the tab (green arrow) and pulling it apart. Be sure to reattach the connector with tape when reassembling.

Working inside the door panel at the latch, pull the cable (red arrow) up and out of the mount.
Figure 3

Working inside the door panel at the latch, pull the cable (red arrow) up and out of the mount. Then detach the cable end from the stop (green arrow).

Then remove the 5mm Allen at the handle inner mount (red arrow).
Figure 4

Then remove the 5mm Allen at the handle inner mount (red arrow). Remove the plastic mount and feed the comfort access wire through the mount. Note the routing position for reassembly.

Working through the access hole in the door panel (red arrow), remove the 5mm Allen fastener (green arrows).
Figure 5

Working through the access hole in the door panel (red arrow), remove the 5mm Allen fastener (green arrows).

Remove the handle from the door, feeding the wiring through the front hole (green arrow) and the cable out of the rear hole (red arrow).
Figure 6

Remove the handle from the door, feeding the wiring through the front hole (green arrow) and the cable out of the rear hole (red arrow).

The lock cylinder remains in the door (red arrow).
Figure 7

The lock cylinder remains in the door (red arrow). To replace it, see the following steps.

Working at the side of the door, remove the rubber plug covering the lock cylinder fastener (green arrow).
Figure 8

Working at the side of the door, remove the rubber plug covering the lock cylinder fastener (green arrow). There should be a rubber cover here (red arrow). It was missing on my subject vehicle. Remove the T30 Torx fastener (green arrow).

Working inside the door, slide the lock cylinder in and remove it.
Figure 9

Working inside the door, slide the lock cylinder in and remove it. Angle the lock cylinder down to feed the lock rod (red arrow) out of the latch. When installing, be sure that the lock cylinder lip is over (green arrow) the door skin.

Reverse the steps to install the lock cylinder.
Figure 10

Reverse the steps to install the lock cylinder. When installing, be sure that the lock rod (red arrow) is properly engaged with the latch (green arrow). Once the handle has been reinstalled, check the latch operation. Lock and unlock the door. Then latch the door latch using a screwdriver. Confirm that the door latch releases with the inner and outer door handles. Then reassemble the window regulator and door panel.

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Comments and Suggestions:
Perrin Comments: Hi there, I own a cooper S with comfort access handles. Do you have the part number, your catalog does not clearly state.

Also, I was wondering if the 2013 door handle is interchangeable? I find the keyless door button has a better feel and would like to take the opportunity to replace.

If it is interchangeable, can you provide the part number for both the 2008 and 2013 door handle.

Thanks!
November 5, 2016
  Followup from the Pelican Staff: I’m not the best with part numbers.


Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 

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