As I was taking my door card off anyway I thought I'd post a little how to. There are a few threads that tell you how to do it but none that I know of with pictures so here goes:
- 1, maybe 2 flathead screw drivers
- Torx bit, dunno what size but you'll find it in any normal set
- Big cohunes
You need to remove the insert to access the screws underneath. It's held in with some clips all the way along and comes off fairly easily. I have found the easiest place to start it off is on the bend like in the picture. Today I used 1 screwdriver to start it and then another a little further along to gently prise it out. You may want to use something like a sponge on the trim to prevent any damage to it.
You then need to remove the 3 torx screws that hold the door in place. There are 2 underneath the trim you have removed and one at the bottom of the doorcard.
Using the big cohunes you now need to start to unclip the card from the door starting at the bottom and working around. They're very tight at first and you seem to have to pull very hard but they do come off! I started at the bottom by the speaker:
Once the clips are all undone, pull the card away from the door slightly and then working from the outside edge lift the card off of the top of the door. It may be a bit stuck at first but give it some side to side wiggles and it'll come away.
The card will still be attached to the door by the electrical cable and the door release cable.
To disconnect the cable press the little button under the pink lever, pull the lever down and the connector will pop out:
To undo the door release cable pop it out of the lock and then unhook it:
Once they are off the card will be free to remove completely:
The red and yellow circles are the clips that need to be popped. The red one is different from the rest for some reason. The green circles are the holes for the torx screws.
The refitting is the reverse of the removal but make sure you connect the door release cable properly (my misus was stuck in my car once lol) and before putting the insert back in check that the metal retaining holes are seated properly or it can be a bit difficult:
Replacement clip part numbers:
For the yellow clips that are circled in yellow:
8P0 868 243
The other clip is attached to the door card itself and clips into where the red circle is:
8E0 868 243