Why not do it right and just open the hole up a bit and see if it solves the problem. If your going to have to remove the door panel to look inside anyway, while it's off you test it and see if it works better with the panel off. That's what the dealer did. When it worked fine with the panel off he just opened the hole up a little. I was in and out of the shop in 30 minutes including the time it took him to walk to parts to get a clip for the fuse panel cover that was broken on delivery.

 

I have had my HHR for almost two weeks, and I am having this problem. Started Saturday night during a snow storm. My daughter was in a car accident during the storm. I unlocked the doors to get in and could not. The drivers door lock was not coming up all the way. Had to reach across from the pass side, and still would not come up. I hit the unlock button on the remote, while pulling up on the button to get it open. And it did it again this morning. Build date is 01/09 and sale date is 11/27/09, so I am the only owner. I am going to take it to the dealership today. I could fix it myself, but while it is under warranty, I is not fixin notin.